Data collection was switched from an AI Config task writing to an hsdl file to synchronized DAQmx tasks logging to TDMS files. Why are different readings produced for the same test?

A software application was developed to collect and process readings from capacitance sensors and a tachometer in a running spin rig. The sensors were connected to an Aerogate Model HP-04 H1 Band Preamp connected to an NI PXI-6115. The sensors were read using AI Config and AI Start VIs. The data was saved to a file using hsdlConfig and hsdlFileWriter VIs. In order to add the capability of collecting synchronized data from two Eddy Current Position sensors in addition to the existing sensors, which will be connected to a BNC-2144 connected to an NI PXI-4495, the AI and HSDL VIs were replaced with DAQmx VIs logging to TDMS. When running identical tests, the new file format (TDMS) produces reads that are higher and inconsistent with the readings from the older file format (HSDL).
The main VIs are SpinLab 2.4 and SpinLab 3.8 in folders "SpinLab old format" and "Spinlab 3.8" respectfully. SpinLab 3.8 requires the Sound and Vibration suite to run correctly, but it is used after the part that is causing the problem. The problem is occuring during data collection in the Logger segment of code or during processing in the Reader/Converter segment of code. I could send the readings from the identical tests if they would be helpful, but the data takes up approximately 500 MB.
Attachments:
SpinLab 3.8.zip ‏1509 KB
SpinLab 2.4.zip ‏3753 KB
SpinLab Screenshots.doc ‏795 KB

First of all, how different is the data? You say that the reads are higher and inconsistent. How much higher? Is every point inconsistent, or is it just parts of your file? If it's just in parts of the file, does there seem to be a consistent pattern as to when the data is different?
Secondly, here are a couple things to try:
Currently, you are not calling DAQmx Stop Task outside of the loop; you're just calling DAQmx Clear Task. This means that if there were any errors that occured in the logging thread, you might not be getting them (as DAQmx Clear Task clears outstanding errors within the task). Add a DAQmx Stop Task before DAQmx Clear Task to make sure that you're not missing an error.
Try "Log and Read" mode. "Log and Read" is probably going to be fast enough for your application (as it's pretty fast), so you might just try it and see if you get any different result. All that you would need to do is change the enum to "Log and Read", then add a DAQmx Read in the loop (you can just use Raw format since you don't care about the output). I'd recommend that you read in even multiples of the sector size (normally 512) for optimal performance. For example, your rate is 1MHz, perhaps read in sizes of 122880 samples per channel (something like 1/8 of the buffer size rounded down to the nearest multiple of 4096). Note: This is a troubleshooting step to try and narrow down the problem.
Finally, how confident are you in the results from the previous HSDL test? Which readings make more sense? I look forward to hearing more detail about how the data is inconsistent (all data, how different, any patterns). As well, I'll be looking forward to hearing the result of test #2 above.
Thanks,
Andy McRorie
NI R&D

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