It's hard to know exactly what goes wrong in your case, but generally speaking this error arises for 3 reasons:
* The use of the constraint "DensityMatrix" when the system converges to zero charge
* Atoms placed on top of each other
* Converging to very low tolerance, like 1e-16
In general the final NC file produced by a the optimization is indeed a properly converged calculation, so you don't actually need to rerun the calculation, just restore it and perform the analysis tasks. Also take care to extract the optimized geometry from the VNL file!
Perhaps, when I think about it, your problem is a simple matter of removing the checkmark for "Only use initial density" on the self-consistent tab in the NanoLanguage Scripter in VNL?