Check for any recursive calls in your code.
Do you have MVCOUNT set in the config.fpw?

>I have a program, that has the following code at the top:
>

 PRIVATE plValue, pcMessage, pcZipFile, pcDestDir, plZipIniExists,  pcCurDir, pcTmpFiles, pcLogFile, pcDrive, plOK, crlf 
> LOCAL lcError, lcSys16, lcProgram 
> lcError=ON('ERROR') 
> plOK=.T. 
>*- Trap all errors - will exit proram on any error 
> ON ERROR DO ErrorLog WITH ERROR(), MESSAGE(), PROGRAM(), LINENO()

>
> Program continues on from here. The above are the only variables used in this program. In the only subroutine ErrorLog, it has 5 more. That is way less than 65,000, which the help file is the max number of variables.
>
> A little more details...
>The program runs fine, no errors in the development environment, the "Too many variables" error occurs only in the exe. In the ErrorLog subroutine, I write out the details of the error to a text file, but the file does not get created, so the above error is not being trapped??
>
>There are no loops in the program... all it does is remove a couple of directories, and then unzips an archive into the removed directories.
>
> Any ideas out there?
>
>TIA,
> Mike