[Greg McKaskle]

You indeed have lots of observations, and I can't make sense of all of them either.

I'd start by turning off the error logging -- if using LV. To do so, open ErrorsGlobal.vi, drop the global icon into the diagram of Begin.vi and set it to FALSE. Turning off error logging will not hurt anything, as unhandled errors are still being sent to the DS and logged. This global should have been off all along and was an oversight.

While your cRIO is running your code, open the Tools>>Real Time>>System Manager and observe the memory usage over time and the CPU usage over time.

Another thing to point out is that the VIs tab is another way to selectively terminate VIs. It is likely to be faster to kill the Robot Main and deploy rather than flip the DIP, reboot, deploy, flip, reboot.

Greg McKaskle