Quote:
the max 2.67ms and audio breaks up. RT CPU does not exceed even 40% in either case.
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I can't give you a specific answer but
CPU utilization doesn't tell the whole story...
All it takes is for some task (writing to the hard drive?) to "hog" the system a few-milliseconds too long. The operating system doesn't get-around to reading the buffer in time, and your buffer overflows.
(With playback/monitoring, the danger is buffer underflow when the buffer doesn't get re-filled in time.)