Troubleshooting PI System Explorer Installation Errors: Return Value 3 and Error Code 1603

Installing PI System Explorer should be a straightforward process, but occasionally users encounter errors that can be hard to decipher. One such example is running into a failure during installation, accompanied by messages like "return value 3" and error code 1603 related to a custom action, such as InstallPinetmgrCounters.

In this blog post, we’ll break down what these common errors mean, possible causes, and steps you can take to resolve them when working with the PI Server 2018 SP3 installation kit or other versions.

Understanding the Error Messages

Errors like the following often appear in the installation logs:

CustomAction InstallPinetmgrCounters returned actual error code 1603 (note this may not be 100% accurate if translation happened inside sandbox)
WixQuietExec64: Error 0xc0000135: Command line returned an error.
WixQuietExec64: Error 0xc0000135: QuietExec64 Failed

Error Code 1603 is a generic Windows Installer error that means a fatal error occurred during installation. "Return value 3" also indicates a failure, but isn’t descriptive by itself. The real clues are typically found in the lines just above this message in your MSI (Windows Installer) log file.

Common Root Causes

There are several factors that can contribute to these installation failures:

1. Insufficient User Permissions

Installing PI System Explorer (or most PI components) requires local administrator rights. Without proper permissions, certain actions—like registering services or libraries—may fail.

2. Disk Space Issues

Make sure the target machine has sufficient free disk space. Out-of-space errors sometimes surface as vague installation failures.

3. Missing Dependencies (.NET Framework, Visual C++ Redistributables, etc.)

PI System Explorer and its components depend on various prerequisites. Error 0xc0000135, for example, indicates a missing DLL or, frequently, the required .NET Framework version (often .NET Framework 4.6.1 or later).

4. Incomplete or Corrupt Installation Media

Corrupted installation files can lead to failures during unattended or custom actions. Always validate the integrity of your installer.

5. Background Processes or Antivirus

Occasionally, antivirus or system protection tools can block installation scripts or custom actions. Temporarily disable them—if your IT policies allow—during installation.

Troubleshooting Steps

Here’s a step-by-step guide to diagnose and resolve the problem:

1. Check Log Files

   • Locate the MSI installation log (enable logging with /L*v install.log).
   • Review lines above the "return value 3" for clues.

2. Verify User Permissions

   • Run the installer as a local administrator.

3. Check Disk Space

   • Ensure ample free space on system and target installation drives.

4. Install Prerequisites

   • Ensure required .NET Framework versions and Visual C++ Redistributables are present. For PI System Explorer 2018+, .NET 4.6.1 is usually required.

5. Validate Installation Media

   • If possible, re-download or use a different copy of the installer.

6. Consult OSIsoft Tech Support

   • If problems persist, provide the installer log and detailed error messages when opening a support case with OSIsoft (now AVEVA).

Conclusion

Installation issues like error code 1603 and return value 3 can be frustrating, but with careful log analysis and systematic troubleshooting, most problems can be resolved. Always verify permissions, prerequisites, and log details. When in doubt, OSIsoft Support is there to help.

Have you encountered similar installer errors? Share your experiences or tips in the comments section below!