EnergyPlus V 9.0 Vertex size mismatch

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"Surface 427" and "Surface 539" together define an internal surface as they reference each other as the Outside Boundary Condition Object. Since they represent an internal surface, they should have identical vertices, but they have different vertices in your IDF file. If you replace the "Surface 427" vertices with the "Surface 539" vertices or vice versa, the simulation is successful. I suggest you figure out which set of vertices is correct and then use this set of vertices for both surfaces.

I was suffered by the Vertex size mismatch problem as well and I developed a two steps approach to fix it: 1. identify the mismatched surface pair. 2. split the mismatched surface pair to smaller convex surface pairs. you can use projection function cast the slice line to both surfaces. Usually, your mismatched surfaces are non-convex surfaces. when you slice your surfaces, mismatched surfaces will be downsizing to one pair of the sliced surfaces. keep cutting your surfaces until the mismatched "Sub" surfaces become a quadrangle or even triangle. The problem should be solved. This process seems somewhat cumbersome. However, it is effortless when you actually try it.

I had the same issues with my recent building models after the update. And I noticed it always appeared in or around the corridor, when I draw the corridors in specific way (in figure 1), and also when there is a surface shaped in the form of "T" with similar outside boundary condition object. The highlighted or selected surfaces is the corridor.

So, I decided not to draw the geometry in the "T" shape and also simplify the corridor into small rectangular surfaces (in figure 2). Hope this is helpful.