This is a strange problem. I think what you need to do is isolate the node that is producing the error. The idea is to open the bad subVI and put several error indicators on the front panel and connect them in critical points in your code. This way you can look at the front panel of the executable and see where the error occured.
Now you have to make the executable show the bad subVIs panel when it runs. First goto the VI property page of the bad subVI >> Window Appearance >> customize >> show front panel when called. Now when the main VI calls the subVI, the bad subVI's front panel will open. The next step is to edit how you build the main VI. In application builder go to the VI settings tab. Click on the bad subVI and choose to edit build settings. Make sure the front panel is left on the subVI . Your executable should now be cooking for isolating the problem. Good luck.
