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Hey @Gilbro4422 ,
Would you be able to share a little more on why you're needing to run the workflow three times? Are you making some changes with each run to create new results to append, or using new inputs?
A screenshot of the workflow may help for a little context as well.
@Gilbro4422 - Interesting, as there shouldn't be any limitations on the records coming into Designer. Looks like you've posted the .xlsx, are you able to share the workflow .yxmd file as well?
My thought here is that because you have many output tools writing to the same excel file, they're competing to write at the same time and that's causing errors generating some sheets until it's run enough times that they're all created.
Whats typically done here is to use the block until done tool - you'll probably want one or a series of them at the beginning of your workflow to branch out from, but with a Block tool in place your workflow will run, create the first sheet, run the next process and create this sheet, and so on.
Check out this article for reference: