I just got more info from the customer, and apparently something went wrong with the version 8.3 installation and it turns out they were using some older version of the NI-DAQ software (I do not know what version)... our software automatically drops down to using Traditional NI-DAQ if NI-DAQmx doesn't load. So the 100% CPU usage is suspect, because they may be using one of the versions that has that issue. This was on an old E series card, but isn't worth worrying about until they can get 8.3 installed (probably by uninstalling all NI stuff first).
However, I did see the 40-60% usage on a 2.4GHz Pentium IV (non HT) CPU using the PCI-6251 card. On version 7.5 of the drivers with the same PC and the same software the CPU usage hovers around 0-10%. It's probably not a show stopper, everything still runs with enough headroom on our newer PC's, but it worries me when it comes to older PC's that we have out in the field if they want to upgrade. The PC is doing 8 channels of data acquisition at 50k/s each.
Thanks for the help.