To increase the memory to the Config Tool:
1) Start Control Panel
2) Click Settings
3) Increase memory to the Config Tool
4) restart the Control Panel.
Now start the Config Tool & try the export.
I had this happen one time as the size & complexity of my BSV increased. If you have a number of different BSVs in test mode, I also recommend taking some of them out of test mode to decrease the memory requirements of the Config Tool.