I have had a similar problem that I have pinned down to
something bad happening while the final TOC is being compiled,
after all the conversions of the FM files have been done.
I blew nearly a day troubleshooting, and I can find nothing
wrong or unusual with my FM files, including the TOC. In fact,
earlier, I successfully performed force updates several times.
Fix:
I finally gave up troubleshooting, and started a new RoboHelp
project from scratch, using the same setup, and the same edited
fmstyles.css. The new project worked fine, and I was able to
produce a .chm file, no problem.
Here are my notes:
Symptom: final .chm file won't open
Background: made edits to FM files of project that updated
successfully many times,
Forced update again, that seems to work fine, generated
layout, that seemed to work fine,
But when I clicked View files, nothing happened, the dialog
box silently closed.
When I clicked on the .chm file directly, MS messages says:
Cannot open the file: path/file name
and nothing more. the .chm file looks to be of the correct
file size.
Trys:
Updated FM files, re-imported formats for TOC, re applied
conditions, turned off computer, turned it on
Fix: Threw out RoboHelp project and started a new one
New project works fine.