Actually, it doesn't sound that inexplicable - it's probably caused by an exception occurring as the DataModule (or some form with db-aware components connected to it via properties) is being loaded into the IDE (see below). Have you tried checking that wherever your ZEOS .BPL files are located is on your system Path? Likewise any .BPLs they depend upon - see the "requires" clause in the .DPK file(s) for Zeos.
This sort of problem arises fairly frequently with flaky DB components, maybe more so than other types of component because db components more frequently involve linkages between datamodules and forms, e.g. when db-aware components on the forms are connected to others on the datamodule.
So, sometimes, whether this sort of problem shows up or not depends on the order in which the IDE will re-open them - try closing the project with only the dm open and then re-opening it. A bit of experimenting with which datamodules and forms are open in the IDE and in which order may help you pin down the problem. If/when you have a reproducible sequence of steps to provoke the problem, report it to the authors.
A fairly reliable way to determine whether the problem is being caused by an exception as a project loads is to run one instance of the IDE inside another. As long as the first ("outer") instance of the IDE has the debugger set to "Break on Language exceptions" it should be able to take you straight to the source of the exception (assuming it occurs, of course) when the project is loaded by the second instance. It may take a few goes to "catch it in the act" of course, but it is hugely satisfying when you manage to. Good luck!