Hi!

>> It has worked well since.  I now moved the HDD to new hardware.  If I
>> select boot 1 or 2, fdconfig.sys gets about to the end and cannot find
>> command.com.  However, the floppy with the same fdconfig.sys boots OK.
>> Screen echo and files are below.

...
>> LBAcache.....
>> Detecting HDDs
...
>> XMS allocated....
>> Bad or missing Command....
...

I would usually guess that you took a menu item with JEMM386
and some of your hardware uses memory in the UMB area without
JEMM386 being able to detect it. Modern PCs do not care much
about DOS sometimes. Try if it helps to boot without JEMM386:
If yes, JEMM386 should work again after you add an extra
X=from-to option to the JEMM386 line to manually exclude the
affected UMB area. Try for example X=c800-cfff X=d000-d7ff
X=d800-dfff X=e000-e7ff or X=e800-efff, or combinations...

> Had this the other day - removing TUNS from LBACACHE
> should fix it and,no, I dont know why

Then the problem might be related to the limited size of
stack for the TUNS option. Try if updating LBACACHE helps:

www.ibiblio.org/pub/micro/pc-stuff/freedos/files/dos/lbacache/2008/

Eric

PS: Please tell which type of new controller and disk you use.




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