Toro,
Are you exceeding the maximum switching capacity of the module? Page 573 of the 2004 NI Product Catalog gives the maximum and minimum specifications. If you remove whatever you have connected can you switch the relay in Measurement & Automation Explorer (MAX)? Did you try swapping the other FP-RLY-422 with this one and see if it behaves the same? Did you try swapping the terminal base (TB-1) and see if the problem follows the base? Otherwise it sounds like it may be an RMA. You can do an RMA by calling 1-877-493-2406.
Ames
Applications Engineering
National Instruments