Hello,
I have almost the exact problem, and I did find a solution, but do not like it, and have no answer for why I have the problem.
I have a nested tab control as well, SOMETIMES I can run the VI and the parent tab control will be off the screen. Occasionally restarting the software will fix it, but usually not.
I put a bounds indicator on the child control and found that it was larger than the screen. If I move that tab control out, I can resize the parent. Leave it inside and you can forget it.
If I simply move the controls around inside the child tab control WHILE it is still outside, the bounds will drop to a normal size, and once this happens, I can put the child back inside the parent and all is well until next time.
I think it has something to do with
Labview incorrectly calculating the bounds of a control somewhere inside the child tab control.
I'm open to anyone with a reason I have the problem in the first place, or can offer a solution. I feel your pain as well.