PDF fails to generate correctly -- "malformed topic" error

First, I am not a developer, only an online help writer since 1990.

Secondly, how are third-party software, network issues, insufficient resources, overly aggressive anti-virus software, etc. under the purview of RoboHelp?

Looking at the files you provided, I suspect that the Previous/Title/Next tables at the very top of these topics, particularly if they were converted from Framemaker, might be at the root of your problem.

Try this:

1. Assign the Print conditional tag to that entire table, then add a separate Chapter title (title only) with the Online conditional tag.
2. Add a "NOT Online" conditional build expression to the Print Documentation layout.
3. Add a "NOT Print" conditional build expression to the WebHelp layout.

Good luck,

Leon