FE, I think you may have a problem in your process. A. It seams you are importing incomplete models into RF as you're creating the model. If this is the case you should expect inherent errors.
B. You seam to be using the base model physic setup and leaning on that for your new model. If so you will still encounter errors. I suggest that anyone making a model to have the minimum required parts included on the model before import. These being landing gear and wheels, wings, tail flight surfaces and all control surfaces. I also suggest that all serious attempts should get unique new wire frames in the editor. That way you're not borrowing problems and errors. This makes it easier to troubleshoot your model. As for the exporter throwing an error when NUP values are present. It doesn't make sense that raising the poly limit should affect these parameters.
Absolutely.
A. All minimum parts are normally present in planes initially imported-- as they should be. The two models in question happened to not be so (remembering that I am working on finishing many in process models). The point intended was if the details of missing parts are unknown (such as not if working on the model for awhile, or maybe finishing up a model on the behalf of another modeler), RF7 did not not provide the clues RF6 did as an aid indicating
where to look. Admittedly, that may have changed, as I am behind on getting the latest update. But at the time, the RF7 crashing was fixed with added the missing part names, and work moved on.
B. New models based on existing ones has always worked. The new models contain the bare minimum of required parts, as you mention, and the base model selected is also very basic. Once the import is done, it is immediately saved with it's new name. After that new parts and features are added to "build up" the model towards it's final state. For example, the initial model (and its base model) has no retracts, and then eventually the first NUP is added, such as the nose gear. Make sure that works as intended and then add its gear doors or one of the mains. By increasing the NUP count one at a time, it is clear where to look if the "unknown error" shows up. As there is no mechanism available to us as to what part or setting by name has the problem, we simply have to add items one at a time.
As to the present NUP error on the new model, I'm rather sure I've missed something obvious on its first pass.
The greater mystery is the fairly recent older model. It was initially built and imported on RF6 and the previous kex exporter. When RF7 was installed, the model converted over just fine, so there was no need to re-export the kex. When the kex export problem with the new model is figured out, it will hopefully provide the clues needed to resolve the older one.
Will report on what is found.
We are all in this together, so that info may help someone else!