Thanks Fred,
Glad you mentioned checking the logical drive map; as I did this I noticed PC Doctor was detecting 7 physical hard drives, each over 700 GB, inside the laptop which only has a single HDD. It appears as though PC-Doc isn't getting along well with the Dell E6400; when I retested on our "known-good" system everything was working as expected. (I must have used the wrong key yesteday when testing...)
The Dell laptop has it's own diagnostic partion setup with onboard diags; which when run indicate everything is ok with the laptop. The odd service/diag partitions on the laptop HDD may be throwing PC-Doc for a loop...
Either way, I edited our test scripts to write the diagnostic log to a USB floppy drive and re-ran PC-Doctor. When the log was written to the USB floppy disc (as opposed to a location on the USB key) everything worked as expected. PC-Doctor detected, tested, and passed 4 HDD's on the laptop. Odd that when running the detect physical drive option in PC-Doc it found 7 drives; but when running the tests it only tested 4. I'm not sure why it would see the single hard drive in the laptop as 4; but I guess it could have to do with the sevice/diagnostic partitions that come on the drive from the Dell factory...