For a SCADA + RT (DCS) project developed using National Instruments hardware and a SCADA HMI interface created with LabVIEW, we are experiencing a rather serious issue involving the restart of the RT application within the PLCs. The entire project was developed using LabVIEW 2020.
Below is the list of software installed on the development and build PC:
- CompactRIO 2022 Q4
- C Series Module Support
- IVI Driver Toolset 1.5
IVI Engine 142.5
LabVIEW 2020 f1
- Control Design and Simulation Module
Database Connectivity Toolkit
Datalogging and Supervisory Control
Datalogging and Supervisory Control Run Time System
EtherNet/IP Toolkit
FPGA
Real-Time
Real-Time Trace Viewer - LabVIEW 2020 Support
Report Generation Toolkit For Microsoft Office
- LabVIEW 2020 f1
- Control Design and Simulation Module
Database Connectivity Toolkit
Datalogging and Supervisory Control
EtherNet/IP Toolkit
FPGA
Real-Time
Real-Time Trace Viewer - LabVIEW 2020 Support
Report Generation Toolkit For Microsoft Office
- LabVIEW 2021
- Advanced Signal Processing Toolkit
Database Connectivity Toolkit
EtherNet/IP Toolkit
FPGA
Real-Time
Real-Time Trace Viewer - LabVIEW 2021 Support
Report Generation Toolkit For Microsoft Office
Unit Test Framework Toolkit
VI Analyzer Toolkit
- LabVIEW 2021
- Advanced Signal Processing Toolkit
Database Connectivity Toolkit
EtherNet/IP Toolkit
FPGA
Real-Time
Real-Time Trace Viewer - LabVIEW 2021 Support
Report Generation Toolkit For Microsoft Office
Unit Test Framework Toolkit
VI Analyzer Toolkit
- LabVIEW 2022 Q3 Patch 1
LabVIEW 2022 Q3 Patch 1
LabVIEW 2022 Q3 Patch 1
- Advanced Signal Processing Toolkit
Database Connectivity Toolkit
Datalogging and Supervisory Control
Datalogging and Supervisory Control Run Time System
Digital Filter Design Toolkit
Real-Time
Real-Time Trace Viewer - LabVIEW 2022 Support
Report Generation Toolkit For Microsoft Office
Unit Test Framework Toolkit
VI Analyzer Toolkit
- LabVIEW Datalogging and Supervisory Control Run Time System 2020
LabVIEW Datalogging and Supervisory Control Run Time System 2022 Q3
LabVIEW Runtime 2018 SP1 f5
LabVIEW Runtime 2019 SP1 f5
LabVIEW Runtime 2020 SP1 f1
LabVIEW Runtime 2021 SP1 f2
LabVIEW Runtime 2022 Q3 Patch 1
LabVIEW Runtime 2022 Q3 Patch 1
LabVIEW Runtime 2022 Q3 Patch 1 (64-bit)
LabVIEW Runtime 2022 Q3 Patch 1 (64-bit)
LabWindows/CVI Runtime 2020 f2
Measurement & Automation Explorer 2022 Q3
Measurement Studio for VS2012
NI I/O Trace 2022 Q3
NI Industrial Controller
- Development Support 2022 Q3
Runtime 2022 Q3
- NI PXI Platform Services Configuration 2022 Q4
NI PXI Platform Services Runtime 2022 Q4
NI System Configuration 2022 Q4
NI-488.2 20.0
NI-488.2 Runtime 21.5
NI-DAQmx ADE Support 2022 Q4
NI-DAQmx Device Driver 2022 Q4
NI-DAQmx MAX Configuration 2022 Q4
NI-Industrial Communications for DeviceNet 22.8
NI-Industrial Communications for EtherCAT 20.0
NI-Industrial Communications for EtherNet/IP 22.5
NI-PAL 22.8
NI-RIO 2022 Q4
NI-Serial Configuration 21.5
NI-Serial Runtime 21.5
NI-Sync 2022 Q4
NI-Sync Runtime 2022 Q4
NI-VISA 22.5
- NiVisaServer.exe
NIvisaic.exe
- NI-VISA Runtime 22.5
Vision Common Resources 2021
- Image Processing and Machine Vision
Image Services
The effect of the issue we are experiencing is a restart of the RT application running on the three PLCs installed in the plant, occurring in a semi-random manner. The error found on the PLCs is the following:
01/16/2026 16:18:20 0 1633 41 [error] LabVIEW: The LabVIEW Real-Time process encountered an unexpected error and restarted automatically. LabVIEW Real-Time process restarted
I do not know a method to accurately determine what might be causing the RT application to restart.On the forum, I found another similar error that seems to indicate a CPU usage issue on the various CompactRIO units.
Attached are the images showing CPU and memory usage on the PLCs.
Could someone help me by suggesting a method to analyze the problem?
