asterisk users - Sep 2005 - Unable to create ZAP channel - All circuits are busy

Hello,
 
I have *@Home 1.5 installed and all is working fine for incoming calls and
sometimes outgoing calls. Installed in the box is a digium TDM04B (4xFXO
Ports)
setup as ZAP1 to ZAP4.  I have incoming calls coming in on lines 1-4 in that
order and outgoing calls prefering ZAP4 then ZAP3 then ZAP2.
 
When i try to dial out to the PSTN from a SIP phone it sometimes works
(normally after a reboot) and a few calls later i get the voiceprompt "All
circuits are busy....."
I know the PSTN line is on hook and ok to use.  
 
Looking in the log file i can see a line saying unable to create a ZAP
channel. (See extract below)
Sep 16 07:47:46 VERBOSE[2012]: -- Executing SetVar("SIP/200-361a",
"DIAL_NUMBER=850220") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Executing SetVar("SIP/200-361a",
"DIAL_TRUNK=3") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Executing AGI("SIP/200-361a",
"fixlocalprefix") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Launched AGI Script
/var/lib/asterisk/agi-bin/fixlocalprefix
Sep 16 07:47:46 VERBOSE[2012]: fixlocalprefix: Could not parse
/etc/asterisk/localprefixes.conf
Sep 16 07:47:46 VERBOSE[2012]: -- AGI Script fixlocalprefix completed,
returning 0
Sep 16 07:47:46 VERBOSE[2012]: -- Executing SetVar("SIP/200-361a",
"OUTNUM=850220") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Executing Cut("SIP/200-361a",
"custom=OUT_3|:|1") in new stack
Sep 16 07:47:46 DEBUG[2012]: Expression is '0'
Sep 16 07:47:46 VERBOSE[2012]: -- Executing GotoIf("SIP/200-361a",
"0?19")
in new stack
Sep 16 07:47:46 DEBUG[2012]: Not taking any branch
Sep 16 07:47:46 VERBOSE[2012]: -- Executing Dial("SIP/200-361a",
"ZAP/2/850220") in new stack
Sep 16 07:47:46 NOTICE[2012]: Unable to create channel of type 'ZAP'
Sep 16 07:47:46 VERBOSE[2012]: == Everyone is busy/congested at this time
Sep 16 07:47:46 DEBUG[2012]: Exiting with DIALSTATUS=CHANUNAVAIL.
Sep 16 07:47:46 VERBOSE[2012]: -- Executing Goto("SIP/200-361a",
"s-CHANUNAVAIL|1") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Goto (macro-dialout-trunk,s-CHANUNAVAIL,1)
Sep 16 07:47:46 VERBOSE[2012]: -- Executing NoOp("SIP/200-361a",
"Dial
failed due to CHANUNAVAIL") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Executing Macro("SIP/200-361a",
"outisbusy") in new stack
Sep 16 07:47:46 VERBOSE[2012]: -- Executing Playback("SIP/200-361a",
"allison7/all-circuits-busy-now") in new stack
Sep 16 07:47:46 DEBUG[2012]: Ooh, format changed from unknown to ulaw
Sep 16 07:47:46 DEBUG[2012]: Scheduling timer at 160 sample intervals
Sep 16 07:47:46 VERBOSE[2012]: -- Playing
'allison7/all-circuits-busy-now'
(language 'en')
Sep 16 07:47:46 DEBUG[2012]: Stopping retransmission on
'000d28ba-959b001f-1ff0c2e0-67fac805@10.1.1.146' of Response 102: Found
Sep 16 07:47:47 DEBUG[2012]: Setting NAT on RTP to 0
Sep 16 07:47:48 DEBUG[2012]: Scheduling timer at 0 sample intervals
Sep 16 07:47:48 VERBOSE[2012]: == Spawn extension (macro-outisbusy, s, 1)
exited non-zero on 'SIP/200-361a' in macro 'outisbusy'
Sep 16 07:47:48 VERBOSE[2012]: == Spawn extension (from-internal, 9850220,
4) exited non-zero on 'SIP/200-361a'
Sep 16 07:47:48 VERBOSE[2012]: -- Executing Macro("SIP/200-361a",
"hangupcall") in new stack
Sep 16 07:47:48 VERBOSE[2012]: -- Executing ResetCDR("SIP/200-361a",
"w") in
new stack
Sep 16 07:47:48 DEBUG[2012]: cdr_mysql: inserting a CDR record.

Ive tried rebooting, genzaptel, rebuilt zaptel drivers etc....Does anyone
have any suggestions as to what i can do to debug.
 
Any help would be appreciated.
Thanks
 
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