Continuing with the simulation could result in a Program crash when processing the output data

Warning message: continuing with the simulation could result in a Program crash when processing the output data

This warning message is caused by selecting too much hourly or sub-hourly data. In cases with too much data DesignBuilder will often crash following the message. The cause is usually an annual simulation with hourly or sub-hourly results requested in a medium to large-sized model. In this case, the only solution is to reduce the amount of data generated or the simulation period.

Fitting extra physical memory will not help as there are limits to the amount of simulation data that can be read into DesignBuilder.

If you really need hourly or sub-hourly results for the whole year then you should restrict the results to be only for certain zones, surfaces etc. This can be done using the Options model data tab.

Alternatively, use the Results Viewer application for viewing large amounts of hourly/sub-hourly data as this does not suffer from the same problems. You can ensure that DesignBuilder doesn't read simulation results (and run the risk of crashing) by unchecking the “Auto load ESO” option on the EnergyPlus tab of  Program Options - EnergyPlus

See also: Working with large models and speeding up simulations