[etherlab-users] Alternating working count 0/24 (zero and complete)

[J. van der Wulp]

Hello Florian,

We are attempting to do migrate from Linux 2.6.29 to linux 3.4 both with
preempt-rt patchset. In addition we also want to move from version 1.4
of the IGH EtherCAT master to version 1.5.2 (stable-1.5 branch).

To this end we first tested the 1.5.2 version on the Linux 2.6.29 kernel
with good results. However the same version of the master 1.5.2 on the
Linux 3.4.91 kernel on some slave configurations keeps reporting
alternating zero and complete working count changes. We primarily use
the default dc synchronisation pattern:

- call ecrt_master_application_time()
- call ecrt_master_sync_reference_clock()
- call ecrt_master_sync_slave_clocks()

Interestingly the following slave configuration seems to work fine on
both kernels and with both master versions on a configuration with four
Beckhoff slaves:
0  0:0  OP  +  EK1100 EtherCAT-Koppler (2A E-Bus)
1  0:1  OP  +  EL2004 4K. Dig. Ausgang 24V, 0.5A
2  0:2  OP  +  EX260-SEC1 EtherCAT SI Unit (32DO_PNP) Rev1.2
3  0:3  OP  +  EX260-SEC1 EtherCAT SI Unit (32DO_PNP) Rev1.2

However with a configuration of (even only one) of our own slaves (with
both read/write data) we get the alternating working count problems (see
attached log file). The application timing (calling send() and receive()
cyclically has never been better than before with this kernel/kernel
configuration. So I am at a loss, I do not know what to look for.

We are using the ec_r8169 kernel module and with the new master want to
use the ec_e1000e module besides the master. We also tried the generic
module but it gave the same symptoms.

Most important questions:
 - what are the most likely causes, what to check and what experiments
can be performed to get closer to a working situation.
 - what is the status of the ec_r8169 module on Linux 3.4 that is
distributed with the master version 1.5.2 (I have noticed that this
kernel is no longer supported in the development version.

Thanks in advance.

Best,

Jeroen
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[ 1014.239868] EtherCAT DEBUG: dropped 95 bytes
[ 1014.239870] EtherCAT DEBUG: 00 
[ 1014.239872] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.239880] EtherCAT DEBUG: 00 00 FF FF 03 08 01 00 00 00 00 00 00 00 00 00 
[ 1014.239887] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.239895] EtherCAT DEBUG: 00 00 00 00 00 00 00 E1 FF 7F FF 7F 62 1A 3B 1A 
[ 1014.239903] EtherCAT DEBUG: 9C 4A 52 18 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.239910] EtherCAT DEBUG: 00 00 FF FF 00 08 B8 01 00 00 2E 02 00 00 8E FF 
[ 1014.239918] EtherCAT DEBUG: FF FF 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.239926] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 2F 00 FF 18 00 
[ 1014.240287] EtherCAT DEBUG 0: Datagram ffff88003500c7f8 already queued (skipping).
[ 1014.240290] EtherCAT DEBUG 0: Datagram ffff880037b0a498 already queued (skipping).
[ 1014.240386] EtherCAT DEBUG 0: UNMATCHED datagram:
[ 1014.240388] EtherCAT DEBUG: 0E 0C 01 00 10 09 04 80 00 00 7D 8F 6B 25 08 00 
[ 1014.240397] EtherCAT DEBUG 0: UNMATCHED datagram:
[ 1014.240398] EtherCAT DEBUG: 0C 0D 00 00 00 00 52 81 00 00 00 00 00 00 00 00 
[ 1014.240406] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 FF FF 04 09 EA CD 00 00 
[ 1014.240414] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 F3 BD 00 00 00 00 00 00 
[ 1014.240422] EtherCAT DEBUG: 00 00 00 00 FF FF FF FF FF FF 00 00 00 00 00 DA 
[ 1014.240430] EtherCAT DEBUG: 07 92 0C 00 00 D6 FF 7F 78 45 C2 10 B5 10 E6 1F 
[ 1014.240437] EtherCAT DEBUG: E0 1F 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.240445] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.240453] EtherCAT DEBUG: 00 00 00 00 00 00 00 FF FF 00 08 34 C2 F3 FF E8 
[ 1014.240461] EtherCAT DEBUG: dropped 95 bytes
[ 1014.240462] EtherCAT DEBUG: 00 
[ 1014.240464] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.240472] EtherCAT DEBUG: 00 00 FF FF 03 08 01 00 00 00 00 00 00 00 00 00 
[ 1014.240480] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.240488] EtherCAT DEBUG: 00 00 00 00 00 00 00 E3 FF 7F FF 7F 62 1A 3B 1A 
[ 1014.240496] EtherCAT DEBUG: 9B 4A 52 18 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.240503] EtherCAT DEBUG: 00 00 FF FF 00 08 B9 01 00 00 2E 02 00 00 8E FF 
[ 1014.240511] EtherCAT DEBUG: FF FF 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.240519] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 31 00 FF 18 00 
[ 1014.240885] EtherCAT DEBUG 0: Datagram ffff88003500c7f8 already queued (skipping).
[ 1014.240888] EtherCAT DEBUG 0: Datagram ffff880037b0a498 already queued (skipping).
[ 1014.240986] EtherCAT DEBUG 0: UNMATCHED datagram:
[ 1014.240988] EtherCAT DEBUG: 0E 11 01 00 10 09 04 80 00 00 B3 B0 74 25 08 00 
[ 1014.240996] EtherCAT DEBUG 0: UNMATCHED datagram:
[ 1014.240997] EtherCAT DEBUG: 0C 12 00 00 00 00 52 01 00 00 00 00 00 00 00 00 
[ 1014.241021] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 FF FF 04 09 EA CD 00 00 
[ 1014.241029] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 F3 BD 00 00 00 00 00 00 
[ 1014.241037] EtherCAT DEBUG: 00 00 00 00 FF FF FF FF FF FF 00 00 00 00 00 D9 
[ 1014.241045] EtherCAT DEBUG: 07 90 0C 00 00 D8 FF 7F 78 45 C2 10 B5 10 E6 1F 
[ 1014.241053] EtherCAT DEBUG: E0 1F 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.241061] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.241069] EtherCAT DEBUG: 00 00 00 00 00 00 00 FF FF 00 08 34 C2 F3 FF E9 
[ 1014.241077] EtherCAT DEBUG: dropped 95 bytes
[ 1014.241079] EtherCAT DEBUG: 00 
[ 1014.241081] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.241088] EtherCAT DEBUG: 00 00 FF FF 03 08 01 00 00 00 00 00 00 00 00 00 
[ 1014.241096] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.241104] EtherCAT DEBUG: 00 00 00 00 00 00 00 E5 FF 7F FF 7F 62 1A 3B 1A 
[ 1014.241112] EtherCAT DEBUG: 9B 4A 52 18 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.241120] EtherCAT DEBUG: 00 00 FF FF 00 08 B9 01 00 00 2E 02 00 00 8F FF 
[ 1014.241128] EtherCAT DEBUG: FF FF 00 00 00 00 00 00 00 00 00 00 00 00 00 00 
[ 1014.241136] EtherCAT DEBUG: 00 00 00 00 00 00 00 00 00 33 00 FF 18 00