Problems with iPod Shuffle: nobody sees it after format

I have a 2nd generation iPod Shuffle, and it worked alright for a month.
However, I noticed an empty 0 bytes mp3 file I could not delete with either Windows or iTunes, and decided to format the device. Being foolish enough to do so, I formatted it via Windows to FAT, and then it synchronized with iTunes library OK (I did not reset or restore it with iTunes) But after I copied some music (about 600Mb) there and disconnected it from my PC, it wouldn't work.
The green light near the on/off button is on, but the light on the other side is not glowing.
I tried to connect it to my PC again, but neither iTunes (version 7.0.2, however I doubt it matters) nor Windows XP sees it. I downloaded the iPod Reset Utility, but it doesnt see the iPod either.
I don't know what to do to bring it to life again.

I have similar problems. I formatted mine under FAT32 with Windows' disk management mmc. Then i restored it with ipod shuffle's restore utility. after that I plugged it back in, itunes recognized a new ipod, prompted me for a new name with an option for "autofill".
I first unchecked autofill, and tried to manually drag files over to my shuffle, but it fails to complete the sync process. then I tried changing its options under itune's Settings panel for my shuffle, it fails to sync too.
so then i reformatted it in FAT32, restored it with the utility program. i opened itunes, typed in a new ipod name and CHECKED autofill. this time it completes the autofill on its first recognition phase, i could even listen to the song after i disconnected it from my PC. but when i reconnect it again, itunes can't sync with my ipod just as the previous try.
I also tried enabling Disc Mode, but unfortunately my itunes is unable to sync with ipod, so the option was never enabled...
Please Help!

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