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Although not an EnergyPlus error, here's the process I went through to track down and fix the problem using Eppy and OpenStudio/Sketchup.

1.Try and open the IDF in OpenStudio SketchUp plugin, thanks to @macumber's comment, and find it looked like this:

image description

2.Realise that points are not being drawn in the right sequence.

3.Run some tests using Eppy to create minimal zone models in the form of 3-, 4- and 5-sided zones, opening each in OpenStudio to see the result. You can make an empty IDF really quickly as shown here and then run geometry and zone generation code.

4.Find the first error is on the 5-sided zone which led to the error where I was using % 4 rather than % len(footprint) when creating floors and ceilings/roofs, in some reused code for rectangular buildings

5.Fix the bug and then... image description

Happy ending, time for bed!

Still no idea why EnergyPlus read that mess of a model as having a huge volume, but not others generated with the same buggy code. If anyone has any thoughts I'd love to know.

Although not an EnergyPlus error, here's the process I went through to track down and fix the problem using Eppy and OpenStudio/Sketchup.

1.Try and open the IDF in OpenStudio SketchUp plugin, thanks to @macumber's comment, and find it looked like this:

image description

2.Realise that points are not being drawn in the right sequence.

3.Run some tests using Eppy to create minimal zone models in the form of 3-, 4- and 5-sided zones, opening each in OpenStudio to see the result. You can make an empty IDF really quickly as shown here and then run geometry and zone generation code.

4.Find the first error is on the 5-sided zone which led to the error where error. I was using % 4 rather than % len(footprint) when creating floors and ceilings/roofs, in based on some reused code for rectangular buildingsbuildings.

5.Fix the bug and then... image description

Happy ending, time for bed!

Still no idea why EnergyPlus read that mess of a model as having a huge volume, but not others generated with the same buggy code. If anyone has any thoughts I'd love to know.