I upgraded my Z-Wave plugin from 2.0.91 to 2.0.96 two weeks ago and I have noticed that 5-10 of my 50+ devices now suddenly are getting NACK:s and when trying to re-sync them they time out at the assign return route step with the message "Syncing - failed to assign return route".
This happens for many different devices of different brands (Qubino, TBKHome, BeNext) but it seems to only happen for devices that has no direct contact with the controller and therefore is using 1 or more hops.
I have tested with optimizing nodes near the ones failing and I have also tested with excluding them and then re-including them again but still the same problem.
As soon as I keep any of those problematic devices near the controller and exclude them, resync them in again it works fine but as soon as I try to do network wide inclusion (NWI) it wont work and I have to do normal inclusion closer to the controller (up to 10-15 meters seems to work fine in my house). However, as soon as I move the device to its intended location (where it was working previously) and try to re-optimize the node to update the neighbour list or if I try to re-sync the device into Indigo it fails with the time out message.
I can see in the neighbour list of the failing devices that they all have a neighbour close enough that has direct contact with the controller so we are talking about a one hop only.
I also tested with removing the Z-Stick S2 and running it on my Windows machine with Zensys tool and in the network topology map I can see that these nodes has one hop to a slave node that is close enough and then further on to the controller.
It is almost as if 2.0.96 does not handle routing between devices properly?
It could of course be my S2-stick as well that is starting to behave bad. I have tested with both stopping the Z-Wave plugin, removing the stick, inserting it again and then restarting the plugin but still the same problem. I have also tested with a full reboot but no help there either.
I might bite the bullet and start my move from S2 stick to the S5 stick (that is running on my dev machine) during the weekend to see if that helps but my gut feeling is that there is something wrong with the 2.0.96 Z-Wave plugin.
@Matt: Can you provide a link to the 2.0.91 version so that I can try that one again since I did not have any kind of these problems running that version?