Thanks Michael, I think you have hit the nail on the head.
I have followed your suggestion to ignore the VI's and concentrate on the test panel.
Starting from my machine turning on with the USB-6251 turned off I turned the USB-6251 on. I chose configure and test this device. The USB-6251 appears in the NI-DAQmx devices correctly (green). I right clicked on that and chose test panels.
Changed the mode to continuous and the Input Configuration to RSE.
Clicked start and the CPU use went to 100%. This is where I thought everything was frozen.
In the past I have shut down the test panel and the CPU usage still was 100%. I discovered that if I turn the USB-6251 off the CPU usage went back to low %use.
This time instead of pressing stop and shutting the test panels down, I happened to wait for a long time and finaly a red ball with a cross in it came up indicating an error.
The error was: Error -200361 occured at Test Pane Possible Reason(s). Onboard device memory overflow. Because of system and/or bus-bandwidth limitations, the driver could not read data from the device fast enough to keep up with the device throughput. Reduce the sample rate, or reduce the number of programs your computer is executing concurrently.
I've done the above things again just now and the test panel still hasn't come back with the error (at least 5 mins) but it is not reading and CPU is stuck on 100%.
Doing the above test and clicking stop and start again I have got it to work once or twice i.e. a line actually appears in the chart and responds to changing input. When it does work the CPU usage is roughly 5% with spike of up to 11%. I notice that when I click on stop when it has been working the CPU% goes up to 100% and it will not run correctly after that until I turn it the USB-6251 off and start the test panel again.
If the device is flakey should I ring the local (across the Tasman Sea in Australia) NI people to arrange a repair?
Thanks again for the reply.