Mick,
OK, that explains the error message to me -
The MSM profile should be loading a screen set in the file "MachStdMill.set" . This file is supposed to be in the default mach install directory. So with a default install location, you should have C:\mach3\MachStdMill.set
Is that file present?
I suspect the set file is missing - which would also explain why you do not get the MSM screen set loaded at start up by the profile.
I'll tell you how to fix this in a second - first I want to verify what I think probably happened...
I'd bet that to "fix" this, you looked around and found the MachStdMill\set files dir - which tempted you to use the mach menus to load what looked like a good choice: MachStdMill-v3-10x7 - is this a correct supposition on my part?
If my supposition is good, I have to say that what you did probably seems reasonable under the old simple way screen sets operated, but as the saying goes "this is not your father's Oldsmobile"...

There is only one profile name that should be loaded to run MSM - and that is <mach install dir>\MachStdMill.set
For a default location install of mach and MSM this will actually be C:\mach3\MachStdMill.set
With MSM, one should never, ever, attempt to load a different screen set name manually via the mach menus.
(congratulations on being the first to do this - we knew it'd happen sooner or later. I'm sorry to tell you there is no prize for being first

)
The reason for this is that al MSM scripts/macros make use of the the new #expand facilities in mach (I'll not try to explain those in this thread). Mach looks for expand files locations that are keyed off the loaded screenset name. This means that changing a screen set name will change where mach looks for the #expand files that MSM uses.... Therefore the screeenset name for MSM had to be static and not be changing no matter what resolution screen set was dynamically loaded. The constant, static screen set name that MSM uses is MachStdMill.set
When necessary, behind the scenes, MSM looks at configured options, and copies some base set files as MachStdMill.set and then reloads the MachStdMill.set file - this avoids problems from changing screen set names (this is how the system dynamically changes between the 10x7 and 12x0 resolutions for example - a user should not need to know this).
In any case the rule is that the only set file to load with MSM is always c:\mach3\MachStdMill.set
I am not sure how the file became missing - I know that the install package puts it the Mach3 install dir - if it wasn't getting installed everyone would be seeing the problem you have experienced.
If you do not have that file present, that explains what happened. I am assuming this is the case in the instructions below -
So, back to the issue at hand - please do these steps:
1) close mach down so that none of the files we want to fix up are in use.
2) copy c:\mach3\MachStdMill\Set Files\machStdMill-v3_10x7.set to c:\Mach3\MachStdMill.set
That will give you back the MSM set file for mach to find. (The alternative is to reinstall MSM over itself to get the missing file back; copying this single files seemed simpler to get you running).
3) things will still not work the next time you start mach/MSM - you will need to use the mach menus to point the profile back to the correct set file name: using mach menus: view - load screens and load c:\Mach3\MachStdMill.set
4) close mach (this will get the current settings saves into the profile XML)
5) restart mach with the profile - you should now come up running MSM
I've got my fingers crossed for you - let ms know if this fixes you up.
Dave