Hello Richard, I feel your pain. I have similar, intermittent Com Error problems. I have gotten lots of suggestions over the years, and think my problem is solved, and then it locks up again. I frankly don't trust my machine to run long jobs.
As it has been explained/or as I understand it, packets of data are transferred from you old XP machine over the USB cable to your machine. And those packets/transmissions get corrupted by ESD events, creating the Com Errors and all of your/our woes.
What I don't understand, is with all of the low cost, tiny PCs, why on earth isn't there a simple retrofit of a little PC into the Shopbot's control box. Then once the file gets loaded into the control box, it can run without being corrupted by ESD.
Well, no doubt that is simplistic. But at this rate, I feel like you and I are stuck............. Chuck
Chuck Keysor (circa 1956)
PRT Alpha 60" x 144" (circa 2004)
Columbo 5HP spindle
Aspire 9.0, Rhino 5