Cindy,
The motion controller has a command fifo which is 16 elements deep. If commands come down to the board too rapidly any one of a number of errors can occur, this being one of them.
It is very possible that most of the time your application is sending commands at just under the limit of how fast the board can process them and that every once in a while the elements conspire just right, your computer gets a second wind and rams a whole slew of instructions down into the FIFO causing this problem.
The simplest solution is generaly to hold the riens on your computer a little tighter. Use delays in your loops and between commands in order not to overload the board. Depending on the reasons for looping: status checking, monitoring position, graphing position, wai
ting for an event; you should probably use 60ms, 30ms, 10ms, 5ms respectively as the limiter.
If the issue persists please contact NI Support dirrectly by chosing email engineer from ni.com/ask.
Regards,
Amaury
NI Application Engineer