JVM is probably out of memory. Try this.
1. Define Excel server at SMP > System > Configuration > Zen Report Excel Servers > Zen Report Excel Server, let's say at port 44444
2. Start it. Copy OS command. Should be something like:
C:\InterSystems\Ensemble\lib\ExcelExporter\runserver.bat -port 44444 -numthreads 5 -loglevel 3 -maxlogfilesize 32000 -logrotationcount 100 -numpingthreads 5 -pingport 44445 2>&1
3. Stop Excel server
4. Execute the command from 2 in OS terminal, but set JVM heap size. See how.
5. In your ZEN report add:
Parameter EXCELSERVER = 44444;
to use your excel server.
6. Recompile report and try to run it again.
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