crystal report with barcode installed inconsistent

I have 2 similar reports that use idautomation barcode font 128a in a formula field.  The field is mapped to a sql field in the report database.  The reports are embedded in designer in vb6 applications.

Report1 has no issues running on any machine as long as the fonts are installed.  Report2 runs on 2 of 6 machines I've tested.  On the other 2 I am getting the crystal report error "remaining text does not appear to be part of the formula" when it tries to open the report on 2 XP machines, 1 of these a brand new machine.  Both of these machines can run Report1 without error.

The error is tracked to the formula field for the error.  When I remove the formula, there is no error.

I have tried re-registering the CRUFLHD.dll, downloading and installing a new copy of the old version, and downloading and installing the latest version.  No help.

It makes no sense to me why the same machine can one report with the same formula field and barcode font, but not crash on the barcode formula field on the other.

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Delta7428Connect With a Mentor Author Commented:
This is mysteriously working.

Each app that kicked off report1 and report2, retrieved and sent the report paramers in different ways.  The parameter was the string part of the bar code formula.  The report that wouldn't work was looping through selected row(s) on a grid and sending a column value it to the report as a parameter and running the report multiple times, potentially, if more than one row was selected.  I doubt any user is selecting more than 1 row.   After taking the loop out and just sending the column value of the current row as a parm it started working ... BUT after running it a few times, it started getting the error again.

I got the vs2008 version of the crystal report working as a stand alone report in an exe. After I installed it on the machine that was getting the error on the cr8 report, it starting working consistently, as of the last 3 days anyway.

I'll award points for anyone that might have some relevant input or guess as WHY IS IT WORKING NOW?!!
What version of Crystal?

Delta7428Author Commented:
Crystal 8.0
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Delta7428Author Commented:
I've decided to try converting the report to crystal in VS 2008.  I can't get the report to load.  I downloaded IDAutomation.NetAssembly.dll and added a reference to my project.
I'm not sure what to do next.

The text field on the CR8 report is formatted:  IDAutomationFontEncoderCode128a ({table1.field1})
I changed it according to the format I found on idautomation's site:

Any body?
I haven't used the .Net versions so I don't know.

Delta7428Author Commented:
Converting to .Net right now is not my preference.  It's not just a matter of converting the report, I'd have to recode the entire application.  So if you come up with anything ...  I've tried everything imaginable to me, including:
1) Formatting a hardcoded string in place of the field.
2) Creating a new report.
3) Making a copy of the report that will run and modifying it with the different tables required for the report that won't work.
4) Modifying the datatype (the barcode field on working report is varchar, the other is nvarchar)
5) Creating a new project.
6) Saving the .dsr report to an rpt. and replacing the .dsr with the new rpt
7) The dll stuff I mentioned in my original post
8) Creating a blank report with just 1 string formatted to a barcode

There's probably more I could add to the list if I thought real hard.  This seems to be a dead end and might be the first issue I've had to wave the white flag to in the 4 years I've been in my present job.  :( I'm thinking there's some dll conflict somewhere.  We've had glitches pop up on other CR 8 reports due to Microsoft upgrades and loss of support there.  i.e, It's not longer possible on an XP machine to export a CR8 report to an RTF without making registry changes.
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