Wow Chris,
I really appreciate the effort you are going to to help - the issue appears to be the program. It is not able to connect to the server which I start manually (or the production which is a service).
We do not display the status window - we use our own status info in the window of our app. That just happens to be the line the error is occurring on, but I am missing something. I have verified that we don't call the registry directly from the code so that doesn't appear to be it.
The PB code works for XP and Win 7 32-bit, but fails when run from Win 7 64-bit. When we create the database we use the build and sync bat files created in the deploy and they work fine, but when we call if from code for future syncs is when we get the process failure error. That indicates to me the issue is related in some way to it being a 64 bit machine. I just hope it doesn't come down to a setting on the machine itself causing all this - lol.
I will continue looking at the code and settings and, again, I really appreciate the effort you have put in on this.
VR,
jeff