RoboHelp 7 Crash - MS Visual C Runtime Error

I have been using RH7 for many months. Today, I was using Single Source Layout > Printed Documentation > Properties. And it crashes without doing any more than looking at the dialogue; sometimes when setting the location for the output.
I get a Microsoft Visual C++ Runtime Library "Runtime Error" - RoboHTML.exe ... "The app has requested the Runtime to terminate it in an unusual way. Please contact the application's support team for more information."
This has now happened 3 times in a row. On one occasion I was warned of a corrupted $StylePrepFile.htm, which I deleted and tried again.
I have rebooted; I have run Norton SystemWorks diagnostics to repair system errors. But it's still doing it.
I have tried deleting the CPD file, but it still crashes on this project. When I click on the OK button in the error message dialogue, RH disappears instantly. But you cannot re-open RH and then open the project again because it tells me it is locked by another instance of RH. I looked in Task Manager, and RoboHtml.exe is still loaded. I have to delete it here before I can reopen it and load the project.
A thought: I have been trying RH8 in Trial mode, and decided not to upgrade just yet; so I uninstalled it. Would this cause problems with RH7? If so, how do I fix it?
Any ideas anyone?

Thank you for your suggestion, Peter. I tried it and this is what happened.
I had trouble with two separate printed doc layouts. So I loaded a recent backup copy of the project, and tried adding a new Print layout. I used the same conditional build tags. I built the output, which went through its normal slow processing, and then, at the end, I got an error message like this:
The Output View showed a long log of the build:
===========================================
Starting to build Printed Documentation...
Printed Documentation processor 7.00.145
Building D:\!Active clients\Client BP Sunbury\Client BPOSS Shipboard\Copy of Backup copy 90610 BPOSS_SB_Source\!SSL!\Inst_Setup_Upgrade_Restore_Guide_BP_-_PDF\Inst_Setup_Upgrade_Restor e_Guide_BP_-_PDF.doc ...
Preparing to create Printed Documentation...
Clearing output folder...
Preparing files for Print Document...
Copying files...
Updating files...
Finished preparing in 11 seconds.
Preparing environment...
Printed Document Generator Environment: Word 11.0.8307, OS 5.1.2600, RAM 1535 M Bytes
Building Printed Documentation 'Inst Setup Upgrade Restore Guide BP - PDF'...
Building Single Document 'Inst_Setup_Upgrade_Restore_Guide_BP_-_PDF.doc'...
Building 'TitlePage Installation & Setup Guide - BP Ships'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'TitlePage_Installation_&_Setup_Guide_-_BP_Ships.htm'
Failed to build 'TitlePage Installation & Setup Guide - BP Ships'...
Failed to generate section 'TitlePage Installation & Setup Guide - BP Ships'...
Building 'Table of Contents'...
Preparing to build chapters...
Building 'Installation and Setup Guide'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Installation_and_Setup_Guide.htm'
Failed to build 'Installation and Setup Guide'...
Building 'Installing BPOSS Shipboard.'...
Processing 'Minimum System Requirements'...
Processing 'Installation Concepts - BP Ships'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Minimum_System_Requirements.htm'
Processing 'Download BPOSS Shipboard Files'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Installation_Concepts_-_BP_Ships.htm'
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Download_BPOSS_Shipboard_Files.htm'
Failed to process 'Download BPOSS Shipboard Files'...
Fatal Error: Word Document got corrupt. Abort building 'Installing BPOSS Shipboard.'.
Failed to build 'Installing BPOSS Shipboard.'...
Failed to build 'Installing BPOSS Shipboard.'...
Building 'Configure AMOS Mail'...
Processing 'Configure AMOS Mail for BPOSS'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Configure_AMOS_Mail_for_BPOSS.htm'
Failed to build 'Configure AMOS Mail'...
Building 'System Setup - BP Ships'...
Processing 'Initial Setup - Authorisation Codes'...
Warning: style (p.ListBullet) is not defined and will be mapped to 'Normal'.
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Initial_Setup_-_Authorisation.htm'
Failed to process 'Initial Setup - Authorisation Codes'...
Fatal Error: Word Document got corrupt. Abort building 'System Setup - BP Ships'.
Failed to build 'System Setup - BP Ships'...
Failed to build 'System Setup - BP Ships'...
Building 'Restore Data from Backup.'...
Processing 'Primary Restore Data Procedure'...
Processing 'Secondary Restore Data Procedure'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Primary_Restore_Data_Procedure.htm'
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Secondary_Restore_Data_Procedure.htm'
Failed to build 'Restore Data from Backup.'...
Building 'Help Desk'...
Processing 'Technical Support'...
Warning: The Word Document became corrupt when attempting to append a malformed topic: 'Technical_Support.htm'
Failed to process 'Technical Support'...
Fatal Error: Word Document got corrupt. Abort building 'Help Desk'.
Failed to build 'Help Desk'...
Failed to build 'Help Desk'...
Failed to build one or more chapters.
Building 'Glossary'...
Failed to build 'Glossary'...
Building 'Index'...
Updating list paragraphs...
Updating images...
Updating page numbers...
Updating page headers...
Updating Table of Contents...
Updating Index...
Saving 'Inst_Setup_Upgrade_Restore_Guide_BP_-_PDF.doc'...
Generating 'Inst_Setup_Upgrade_Restore_Guide_BP_-_PDF.pdf'...
Failed the generate PDF file 'D:\!Active clients\Client BP Sunbury\Client BPOSS Shipboard\Copy of Backup copy 90610 BPOSS_SB_Source\!SSL!\Inst_Setup_Upgrade_Restore_Guide_BP_-_PDF\Inst_Setup_Upgrade_Restor e_Guide_BP_-_PDF.pdf'...
Failed to save 'Inst_Setup_Upgrade_Restore_Guide_BP_-_PDF.doc'...
Cleaning up temporary files...
Internal error encountered, Failed to generate Printed Documentation.
===========================================
As you see, this is full of Warnings - I think it reports every topic as Malformed.
The final output is a word doc that fails to load when I double-click on the filename.
If I load MS Word 2003 and load the file, it disables Word such that where the document should view, the area is white all over and the scroll bars are disabled. I can switch between Normal View, Print view etc, but all look the same white area.
If I load a "good" word document, the same problem - all white and no text. Something has gone badly wrong. See short movie:
RH7 does not offer the option of a repair, so I would have to uninstall and reinstall.
This is an important Help project, so I've got to fix it somehow...
Any idea, anyone?

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