How to fix Automation Studio 6 crash on Windows 11

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1

Subject: Technical Support Request: Automation Studio 6.5.1.7 Crash on Startup (pg.exe - System.Xml.XmlException on Windows 11)

Dear B&R Technical Support Team,

I am experiencing a critical issue where Automation Studio 6 crashes immediately upon startup.

My environment setup is as follows:

OS: Windows 11

Software Version: Automation Studio 6.5.1.7

During the initial installation process, I noticed multiple “Copy failed” errors in the installer log, specifically when copying localized help and release information files (Help-de, Help-en, RevInfos). Although the installer finally marked the process as “Completed,” the software fails to launch.

When I attempt to run Automation Studio 6.5.1.7, it crashes instantly. I checked the Windows Event Viewer and found two related error logs (.NET Runtime and Application Error).

According to the logs, pg.exe terminates due to an unhandled System.Xml.XmlException inside BR.AS.UpgradeCore.UpgradeDataProvider.LoadData. It appears that some configuration or upgrade-related XML files were corrupted or incompletely written during the faulty installation.

I have attached the detailed Windows Event Logs below for your reference:

[Event Log 1: .NET Runtime]

Application: pg.exe

Framework Version: v4.0.30319

Exception Info: System.Xml.XmlException

Stack Trace:
at System.Xml.XmlTextReaderImpl.Throw(System.Exception)
at System.Xml.XmlTextReaderImpl.ParseDocumentContent()
at System.Xml.XmlTextReaderImpl.Read()
at BR.AS.UpgradeCore.UpgradeDataProvider.LoadData(System.String)
at BR.AS.UpgradeCore.UpgradeDataProvider.Init()

[Event Log 2: Application Error]

Faulting Application Name: pg.exe, Version: 0.0.0.0

Faulting Module Name: KERNELBASE.dll, Version: 10.0.22621.6133

Exception Code: 0xe0434352

Faulting Application Path: C:\Program Files (x86)\BRAutomation\AS6\bin-en\pg.exe

Could you please guide me on how to completely clear the corrupted cache/XML configuration or resolve this installer-induced crash on Windows 11?

Thank you for your time and assistance. I look forward to your urgent response.

Best regards,

“Please note that I have already tried completely reinstalling the software 7 times, but the exact same crash persists every single time.”

2

Hello,

Have you run the installation as Administrator? Is .NET Framework 3.5 enabled on your PC?

3

Another tip:

The “Copy failed” errors during installation of help/RevInfo files are typically caused by:

  • Antivirus interference — Temporarily disable your AV/EDR solution before reinstalling
  • Insufficient permissions — Run the installer as Administrator with UAC fully elevated
  • Windows Defender blocking — Add C:\Program Files (x86)\BRAutomation\ and the installer executable to Windows Defender exclusions before installing

Please take into consideration that problem you are describing are very likely your local PC depended. Reinstall 7x makes not sense if you do not change something, your local IT team can help you there :wink:

4

Hi, in my experience when you have this type of crash you have two options only:
-reinstall Automation Studio when windows started in minimal mode;
-formatting and reinstalling windows, this because uninstallation not delete path and keyVar of B&R installation.

and this is why I prefer to install AS on virtual machine.

5

Thanks Jaroslav, totally agreed with you!

6

Hi @cesma2000 , I hope we don’t have to install VM for all versions of AS…hehe
I started my first AS prj with AS 2.5 (and Windows XP), now I’m using AS 6.5.3 (in 10 days 6.7, Windows 11) where in the between I have changed my laptop every 4 years,
but only last year I have installed VM because I converted one prj from AS 2.6 to 4.12 and I was not able to install AS 2.6 on Windows 10.

Ciao
Valerio

7

This is a very drastic solution that I would consider only as a last last option. I have installed many version of AS in my professinal life, starting from version AS2.x and I have never needed to reinstall complete OS just because something was not running properly. Testing installations in a virtual environment is generally a good practice for any software, not just Automation Studio. So if author of this post need quick solution, I would start there..and then I would return back to their local IT and ask for help.

8

Ciao,
I started working with 2.0-2-5-2.7 which I still use occasionally. I have VMs with AS installations ranging from 2.0 to 6.7.

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I don’t know what you do but I’ve been working in this sector for almost 25 years now, using not only B&R products. If for every platform I use I had to dedicate a notebook and update it when the operating system changes (microsoft) or update the pcks for hw or something else (linux) now I would do another job. Unless you’re a solution provider and then that would be another matter. Without VMs, platform management would be impossible.

I still remember the early days of AS 2.x when I spent my days on the phone with B&R technicians (the boss at the time was Dario Rovelli) and they were looking for the best possible HW-config-sw figure of AS for the type of machine.

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I absolutelly agree with you. Especially if you are using tools from different manufacturers, virtual machines are a good solution. I remember conflicts in OS resources between AS and TIA Portal, or e.g. port conflicts from different services, etc. An image for a virtual machine can be stored, so if you need to support old series of machines, you can have a dedicated image for them.

11

Hi @leehsm what is status of your issue, can you update us?