MAC36 - Station - Station crash: powering off and on

Quick Diagnostic Guide

If your MAC36 station crashes and only recovers after powering the controller off and on, use this guide to identify and prevent future crashes.

First Step: Check the Logs

Before troubleshooting, always review the error logs:

1. Log in to the platform

2. Go to Platform → Application Director

3. Review the console logs (both recent and historical)

4. Look for error messages or patterns before the crash

Common Causes & Solutions

1. Version Mismatch Issues

Problem A: JAR Modules Don't Match Distribution Files

What this means: The software modules (JAR files like baja-rt) are a different version than the core system files.

How to identify:

• Station crashes unpredictably

• Recently updated Niagara version

• Workbench version is newer than controller supports

Example: Controller supports Niagara 4.11.1.16, but Workbench is 4.11.2.18

Solution:

1. Clean the distribution:

   • Go to Platform → Distribution File Installer

   • Run cleanDist

2. Install correct Workbench version:

   • Check supported versions at: iSMA CONTROLLI Download Center

     • iSMA CONTROLLI Download Center

   • Install the matching version

3. Reload files:

   • Run the BAT script from iSMA_MAC36_files_installer_vX.Y.zip

   • Open Workbench (this loads the files)

4. Re-commission the controller

Problem B: Old Modules Overwritten New Ones

How this happens:

• Upgrading from Niagara 4.9 to 4.11

• Copied ALL modules from old version to new version

• Accidentally overwrote newer modules with older ones

Result: Controller has Niagara 4.11 system but 4.9 modules (including critical baja-rt module)

Solution:

1. Clean the distribution:

   • Go to Platform → Distribution File Installer

   • Run cleanDist

2. Completely remove Workbench:

   • Uninstall Workbench

   • Delete any remaining Workbench files

3. Fresh install:

   • Reinstall Workbench (correct version)

   • Run BAT script from iSMA_MAC36_files_installer_vX.Y.zip

   • Open Workbench fresh

4. Re-commission the controller

5. Move only custom modules (not basic Tridium modules)

2. Schedule Configuration Problems

Symptom: Logs show errors like:

Subordinate schedule not found for supervisor id: slot:/Schedules/Schedule1

How this happens:

• Controller schedules were imported to a Supervisor station via FOX

• Station structure changed after integration (schedules moved or station renamed)

• Links between Supervisor and controller schedules broke

Solution:

1. Remove the schedule import/export configuration on the Supervisor

2. Recreate the schedule integration from scratch

3. Ensure station structure remains stable after integration

3. Email Service Configuration Issues

Symptom: Logs show repeated authentication failures:

AuthenticationFailedException: 535 5.7.8 Error: authentication failed

Followed by:

ENGINE WATCHDOG TIMEOUT STACK DUMP

This is a known Tridium bug - EmailService crashes the station over time when it can't connect.

Possible causes:

• ❌ No internet connection on controller

• ❌ Incorrect email provider settings

• ❌ Email password changed

• ❌ EmailService added but not configured

Solutions:

Check Network Connection:

1. Verify controller has internet access

2. Check Platform → TCP/IP Configuration:

   • IPv4 gateway correct?

   • DNSv4 servers correct?

3. Check with IT department - external connections may be blocked

Fix Email Configuration:

Location: Config/Services/EmailService/IncomingAccount or OutgoingAccount

Verify these settings against your email provider:

• ☑ Hostname

• ☑ Port

• ☑ Account Password (may expire annually)

• ☑ Store (or Transport)

• ☑ Use SSL

• ☑ Use Start TLS

• ☑ Use Authentication

Best Practice - Remove Unused Email Service: If email functionality is not needed or configuration is unavailable, remove the entire EmailService from the station rather than leaving it unconfigured. This prevents crashes.

4. Too Many Program Components

What are Program components? Components that contain Java code interpreted on-the-fly.

The problem: MAC36 controllers have limited processing power compared to PCs. Each Program component:

• Opens a new thread

• Interprets code in real-time

• Consumes significant resources

Recommendation: Use no more than 10 Program components per station

Better alternatives:

Option 1: Create Custom Module (Most Efficient)

• Write logic as a compiled JAR module

• Much more efficient than Program components

• Reusable across projects

Option 2: Use Template Service

• Create logic template using TemplateService

• Reuse throughout the station

• Easy updates - change template once, updates all references

5. Station Crashes When Saving

Symptom: Station crashes every time you try to save, logs show:

INFO [sys] Saving station...
SEVERE [platform] Error connecting to local session
AuthenticationException

Cause: NiagaraNetwork component is missing from Config/Drivers

Solution:

1. Navigate to Config/Drivers in the station

2. Add NiagaraNetwork component

   • From module: niagaraNetwork

   • Drag to Config/Drivers location

3. Save the station

4. Test by making a small change and saving again

Quick Reference Table

Prevention Checklist

✅ Version Management:

• Always use Workbench version supported by your controller

• Check iSMA CONTROLLI Download Center for compatible versions

• When upgrading, move only custom modules (not Tridium base modules)

✅ Email Service:

• Only add EmailService if you will use it

• Keep email credentials current

• Test email connection after configuration

• Remove EmailService if unused

✅ Performance:

• Limit Program components to 10 or fewer

• Use compiled modules for complex recurring logic

• Use TemplateService for reusable logic blocks

✅ Configuration:

• Keep NiagaraNetwork component in Config/Drivers

• Don't rename or move schedules after Supervisor integration

• Document station structure before major changes

✅ Regular Maintenance:

• Review Application Director logs weekly

• Check for repeating errors

• Keep backups before major changes

Checking Supported Niagara Versions

Where to find compatible versions:

1. Visit iSMA CONTROLLI Download Center

2. Check the latest Release Notes for your MAC36 model

3. Note the supported Niagara versions list

4. Use only listed versions

Example compatibility:

• MAC36NL may support: 4.9, 4.10, 4.11.1.16

• Do NOT use: 4.11.2.18 (if not listed)

When to Contact Support

Contact iSMA CONTROLLI or Forest Rock technical support if:

• Crashes continue after following this guide

• Logs show errors not covered here

• Station crashes immediately after any action

• Engine Watchdog timeouts occur without clear cause

• Need help identifying compatible Niagara versions

Product: iSMA-B-MAC36 Series
Category:Troubleshooting - Station Crashes
Difficulty:Intermediate to Advanced

Related Guides:

• MAC36 Software Manager and Module Installation

• MAC36 Niagara Version Compatibility

• MAC36 Email Service Configuration

• MAC36 Station Performance Optimization

• MAC36 Backup and Recovery Procedures

• MAC36 - Station - Station crash: powering off and on | iC Knowledge Base