PDW-HD1500 - Final Cut Pro export to Sony XDCAM error

I have a sequence in Final Cut Pro with XDCAM HD422 1080i50. When I try to export going via the "File > Export > Sony XDCAM" menu, choose "XDCAM HD422 1080i50 CBR" and hit the "Export" button.
On a 5 minute clip, I get this error message after 8% of exporting. In the system.log in Mac OS X there is a "write error 138" reported by the XDCAM exporter.
If I set an out point to reduce the in-point to just 5 secons, the export is successful. If I try 1 minute, the export fails. If I check "recompress all frames" and export the 1 minute clip, the export is successful.
Waiting for Final Cut Pro to recompress all frames takes too long on a new MacBook Pro 17-inch. 1 minute takes about 4 minutes to recompress.
I am running Mac OS X 10.5.8, Final Cut Pro 6.0.4, QuickTime 7.6.4, XDCAM Transfer 2.11, and firmware version 1.51 on the PDW-HD1500.
I have set the audio outputs of my sequence to 8 tracks dual mono discrete, and set each audio track to go 1-1, 2-2, 3-3, 4-4 and so on. The video settings are XDCAM HD422 1080i50 50Mb.
I have checked that the settings on the PDW-HD1500 is set to HD422, 50i, 8ch 24-bit. Are there any other settings I might have overlooked?
Any suggestions? I would really appreciate some help.

I've had experience wiith using 7toX and never had that message. Have you tried contacting the developer? My guess is they would be responsive.
Russ

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