I’m not sure that this is your problem but it sounds a little like what I ran into this weekend. I was running a file that I had run a couple of times before but this time I had changed the file name and added a instead of () around part of the name. I wasn’t aware that there were special characters the buildbotics controller doesn’t like. I had to do a few google searches to find the answer.
In any case, it locked up in the processing phase. I hit e-stop, restarted, but got the same message when I tried to load that file. While I didn’t have the memory stick in any more, the controller still had it in it’s memory. So I had to select a file in the memory that I knew was OK. Once that loaded I selected “delete all” so the poorly named file got deleted. That fixed the problem for me.
Below is a post with a different approach.