Opening a PES File in PE Design

I am creating files in Wilcom Hatch 2 and sharing the PES output file with a friend who uses PE Design (version   to open the file and save it to  a card (using a card reader) to use on her Brother single needle machine.  We initially had some issues with her not being able to open the files in her software. That's when we discovered that I needed to export the PES file in a lower version that her software could read.  That worked for a number of files and then one day she was again unable to open any files I sent her.

I checked to ensure that I was outputting the PES file in a lower version her software was able to open in the past; I was. I then proceeded to save the file in all lower versions of PES and sent them to her to test. She was unable to open them. She could still open the files I initially sent her (and that she was able to open) but if I re-exported them to PES and sent them again, she can't open the new file.

Is there a setting that I have inadvertently changed which is causing this?  Any thoughts, ideas or suggestions are gratefully accepted.