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I guess then the first question is if you go back to a version before you started using source control, does that have the same problem?
Then what about the supplied sample projects, same problem there?
You will find the samples at
C:\Program Files\Adobe\Adobe RoboHelp 7\RoboHTML\Samples\en_US
C:\Program Files\Adobe\Adobe Technical Communication Suite 2\Adobe RoboHelp 7\RoboHTML\Samples\en_US
See www.grainge.org for RoboHelp and Authoring tips
I replicated this issue by deleting the rhfontset.apj file from a test project (and deleting the cpd). Theoretically you should just be able to copy the file from one of the sample projects.
Thank you very much Amebr, that fixed it! I did have a rhfontset file, but it was noticeably smaller than the other (~100 bytes vs 5-12 kb), so I replaced it with another project's file, deleted the .cpd and now it's working!
(I had tried to get a previous version of the project, from before source control, but it looks like the file was already broken before we added it.)