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You must understand that it is called “clippings” for a reason. It is meant to imply the extraction of a SMALL part of a family tree 🙂

The sizes you are referring to are well outside the design parameters, unless you have huge server resources, both in terms of the memory required to amass the necessary data to put in the file as well as the file space to save it. Zipping it is only a later option, designed to make the actual downloading over slower internet connections easier.

Clearly your server cannot cope, but that is not unusual. You would be paying a very high price if it could.

Your testing is simply demonstrating the way the code needs to work.
Step one,, work out the connections to all individuals, families, sources, notes, media requested.
Step two, gather all of the GEDCOM data and construct a fully formatted GEDCOM file of it in memory.
Step three, create an empty file in the data directory.
Step four, copy the data into the file
Step five, convert the file into a zip folder.
Step six, copy each linked media item into the zip folder, then close the file.
Step seven, open a browser download window and let it do its thing to transfer the zip file to your desktop.
Step eight, delete the folder.

My (personal) recommendation would be to not worry about the process failing, as that is inevitable unless you want to pay for a massive increase in your server resources. Instead, try to work out why one or more users find it necessary to take away such large quantities of data?
I overcame this simply on my site by removing access to the clippings cart from users below “manager” level. Only three of us out of 100+ have that level of access. They can still request the data, but not take whatever they think they need whenever the want. For my site that would be a privacy concern.

Nigel
My personal kiwitrees site is www.our-families.info