Thanks to all who replied, we have all (finally) found an answer to this
very frustrating question.
Win 9x does indeed, despite it's marketing blurb, have limits with the size
of the EXE and we exceeded this.
The problem occurs when we start the application of just over 11 megs. The
application immediately, without running ANY code whatsoever, halts with a
windows message relating that it has insufficient resources and to close
some programs.
Watching the memory meter shows no change in the memory used.
Running Memory Sleuth over the application on another computer (win2000)
shows that it only takes a few hundred K of memory at the main menu and up
to 3.5 megs at the most memory hungry and largest piece in the program.
This lead us all to believe that Win(lose)dows simply said "oooh - your too
big and thinking that hard hurts me, go away!".
We were then faced with the choice of splitting the the app into smaller
chunks using either several exes or DLLs. In mid season with still a few
million trays to pack in the next few weeks, this seemed a bit drastic.
We finally solved the problem by compiling with runtime packages. This
dropped the exe to about 9.5 megs but left us with the problem of now
ensuring that all users also have the BPL files that we excluded.
An interesting side to this is that, without changing code, we have
decreased the EXE but drastically increased the total size of the
distributables in that there is about 4.5 megs of bpl files needed giving a
total of around 14 megs instead of the original 11.2 megs.
Thanks for everyone's help in this. It was a doozy that had 5 us running in
circles for a couple of days, interrupted only by telephone calls from
pannicky users and trips to the coffee pot.
Steve
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