Here is the error protocol file. I get this when I drag a ps file (size 2.4 Gb) into pdf creator monitor. I would've attached a screen shot of the PDFCreator 1.4.0 Error message window/popup, but insert image did not work on this. I would also attach the ps file but it is quite large and there isn't a mechanism to do that. Smaller ps files (created by the same process), 800 Mb work fine.
By default PDFCreator supports only files < 2GB. But we found a solution for bigger files. We have tested an 11 GB postscript file with 2,000,000 pages which PDFCreator has converted to an 1,5 GB pdf file in 4,5h. (Tested on Win7/64bit)