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1. I would double check that the project properties for this particular project are set properly. Otherwise, that sounds like a question for Support. Here's their link: https://support.smartbear.com/testcomplete/
2. Default project properties are the ones you get when you create a new project. Project properties are the ones for the current project.
3. https://support.smartbear.com/articles/testcomplete/handling-unexpected-windows/