OK I couldn't leave it alone.......not solved but new interesting data........
I ran "process explorer" and "portmon" from the Microsoft sysinternalssuite. They do not show any program or process using the serial port when the error occurs (radio immediately displays "error" after A button pushed to upload when in clone mode). Appears there is not another application capturing the serial port and changing levels.
I even disabled the modem (COM3) just in case......no change....shot in the dark
I connected the USB to Serial cable to one of the Dell USB ports and it assigned COM6. I plugged the serial cable from the radio on the end and everything works great (upload and download). Looks like it is not a system software problem. I am starting to think I have a hardware problem on COM1 serial port. But it downloads fine and the HRD suite of products run fine through it. Wish I had all of the test equipment (scope, etc) I threw out when I downsized and moved after retiring. Wait a minute, I think I have a logic probe out in my toolbox......
Oh, to only go back to the days when I could simply use the system maintenance panels to displays signal levels and logic prints to track down what was happening <sigh>.
Suggestions welcome.......