CRIO application works in interactive mode but broken VIs reported in error log when run built application on target

Question

I have been getting more than my fair share of grey hairs the past few days because of this. Over the past few months this almost never happened. Lately, after a seemingly minor change to some serial communications code, hardly a single build works without throwing errors like this:
#OSVers: 6.3
#OSBuild: Jun 6 2014, 09:14:16
#AppName: /c/ni-rt/system/lvrt.out
#Version: 14.0
#AppKind: AppLib
#AppModDate:
InitExecSystem() call to GetCurrProcessNumProcessors() reports: 1 processors
InitExecSystem() call to GetNumProcessors() reports: 1 processors
InitExecSystem() will use: 1 processors
starting LabVIEW Execution System 306708506 Thread 0 , capacity: 1 at [3507679466.00933790, (19:24:26.009337710 2015:02:24)]
starting LabVIEW Execution System 306708507 Thread 0 , capacity: 1 at [3507679470.59560204, (19:24:30.595601929 2015:02:24)]
starting LabVIEW Execution System 2 Thread 0 , capacity: 24 at [3507679481.25993776, (19:24:41.259937648 2015:02:24)]
starting LabVIEW Execution System 2 Thread 1 , capacity: 24 at [3507679481.25993776, (19:24:41.259937648 2015:02:24)]
starting LabVIEW Execution System 2 Thread 2 , capacity: 24 at [3507679481.25993776, (19:24:41.259937648 2015:02:24)]
starting LabVIEW Execution System 2 Thread 3 , capacity: 24 at [3507679481.25993776, (19:24:41.259937648 2015:02:24)]
Thread consumption suspected: 3 Try starting 4 threads
starting LabVIEW Execution System 2 Thread 4 , capacity: 24 at [3507679515.59324312, (19:25:15.593243004 2015:02:24)]
starting LabVIEW Execution System 2 Thread 5 , capacity: 24 at [3507679515.59324312, (19:25:15.593243004 2015:02:24)]
starting LabVIEW Execution System 2 Thread 6 , capacity: 24 at [3507679515.59324312, (19:25:15.593243004 2015:02:24)]
starting LabVIEW Execution System 2 Thread 7 , capacity: 24 at [3507679515.59324312, (19:25:15.593243004 2015:02:24)]
Thread consumption suspected: 8 Try starting 1 threads
starting LabVIEW Execution System 2 Thread 8 , capacity: 24 at [3507679515.73854351, (19:25:15.738543576 2015:02:24)]
and 
#Date: TUE, FEB 24, 2015 04:47:22 PM
#OSName: VxWorks
#OSVers: 6.3
#OSBuild: Jun 6 2014, 09:14:16
#AppName: /c/ni-rt/system/lvrt.out
#Version: 14.0
#AppKind: AppLib
#AppModDate:
InitExecSystem() call to GetCurrProcessNumProcessors() reports: 1 processors
InitExecSystem() call to GetNumProcessors() reports: 1 processors
InitExecSystem() will use: 1 processors
starting LabVIEW Execution System 306708506 Thread 0 , capacity: 1 at [3507670087.84041262, (16:48:07.840412710 2015:02:24)]
starting LabVIEW Execution System 306708507 Thread 0 , capacity: 1 at [3507670092.45153570, (16:48:12.451535843 2015:02:24)]
starting LabVIEW Execution System 2 Thread 0 , capacity: 24 at [3507670103.11840487, (16:48:23.118404925 2015:02:24)]
starting LabVIEW Execution System 2 Thread 1 , capacity: 24 at [3507670103.11840487, (16:48:23.118404925 2015:02:24)]
starting LabVIEW Execution System 2 Thread 2 , capacity: 24 at [3507670103.11840487, (16:48:23.118404925 2015:02:24)]
starting LabVIEW Execution System 2 Thread 3 , capacity: 24 at [3507670103.11840487, (16:48:23.118404925 2015:02:24)]
VI_BROKEN (0): [VI "NC serial comms protocol.lvlibet Lower Temperature Limit.vi" (0x04667310)]
VirtualInstrument:etOrClearBadVILibrary - now VI is bad on [VI "NC serial comms protocol.lvlibet Lower Temperature Limit.vi" (0x04667310)]
this->flags=33563136, compilerError=6
VI_BROKEN (0): [VI "Heater Control HAL.lvclass:Write Heater Control Active.vi" (0x058c4e98)]
VirtualInstrument:etOrClearBadVILibrary - now VI is bad on [VI "Heater Control HAL.lvclass:Write Heater Control Active.vi" (0x058c4e98)]
this->flags=50340352, compilerError=6
VI_BROKEN (0): [VI "NI_LVConfig.lvlibave Config File.vi" (0x047b7e90)]
VirtualInstrument:etOrClearBadVILibrary - now VI is bad on [VI "NI_LVConfig.lvlibave Config File.vi" (0x047b7e90)]
this->flags=33563136, compilerError=6
and so on.
This is using a cRIO 9074 running CompactRIO recommended software set  14.0.1 .
These errors happen right at startup. Memory use is steady in interactive mode, about 20 MB contiguous memory is unallocated out of 128 MB. I have taken pains to prevent allocation and follow cRIO besta practices non concatenated strings array building in loops etc). CPU is 50-60% when running interactive mode.
Really at my whit's end here, I have tried the various combination of enabling / disabling debugging in the RTEXE, disconnecting typedefs etc. I have not noticed a pattern. 
Regards,
MarkCG

Answer 1

Hello MarkCG,
What minor changes did you make to the serial communication code? Posting the VI or a screenshot of the VI with the modifications which caused the RTEXE to stop functioning could be useful to troubleshoot the issue. 
Regards,
J_Bou