How do I get a replacement Rotating Magnet sensor?

clegg78

So I have verified that its not cable, its not the port on the board, I have one of my 2 rotating filament sensors errors out with a "Sensor not working" error. I've had to disable the sensor on all prints just to ensure it doesnt error out the print.

@dc42 @T3P3Tony I've posted about some of the errors here, and haven't seen any responses... So I just want to return/replace this one bad sensor for one that works. I am guessing I need your blessing to get Filastruder to do the return/replace.

dc42

I'm sorry, I appear to have missed the original posts you made on 18 January.

Please update to firmware version 2.05 unless you are already running either that version or 3.0 or a 3.01 beta version
Please send M591 D0 with no further parameters (assuming it is extruder 0 giving the problems) and report the response, in particular the agc value. Same for M591 D1.

clegg78

Here is the readout immediately after a "sensor is not working" error just now:

M591 D0
Duet3D magnetic filament monitor on input 11, enabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 40.0mm, version 3, mag 130 agc 82, measured sensitivity 25.00mm/rev, min 100% max 100% over 80.1mm

M122:

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.05 running on Duet Ethernet 1.02 or later + DueX5
Board ID: 08DGM-917NK-F23T0-6J1F6-3SD6T-1GBWD
Used output buffers: 3 of 24 (22 max)
=== RTOS ===
Static ram: 25712
Dynamic ram: 95048 of which 0 recycled
Exception stack ram used: 520
Never used ram: 9792
Tasks: NETWORK(ready,628) HEAT(blocked,1232) DUEX(suspended,160) MAIN(running,3736) IDLE(ready,160)
Owned mutexes:
=== Platform ===
Last reset 03:35:18 ago, cause: software
Last software reset at 2020-01-31 11:57, reason: User, spinning module GCodes, available RAM 9832 bytes (slot 2)
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0441f000 BFAR 0xe000ed38 SP 0xffffffff Task 0x4e49414d
Error status: 10
Free file entries: 8
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 309.0ms, max retries 0
MCU temperature: min 41.2, current 42.6, max 44.6
Supply voltage: min 23.8, current 23.9, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
Driver 0: standstill, SG min/max 23/1023
Driver 1: standstill, SG min/max 130/1023
Driver 2: standstill, SG min/max 137/1023
Driver 3: standstill, SG min/max 0/1023
Driver 4: standstill, SG min/max 0/1023
Driver 5: standstill, SG min/max 122/1023
Driver 6: standstill, SG min/max 14/1023
Driver 7: standstill, SG min/max 16/1023
Driver 8: standstill, SG min/max not available
Driver 9: standstill, SG min/max not available
Date/time: 2020-01-31 15:32:24
Cache data hit count 4294967295
Slowest loop: 209.79ms; fastest: 0.07ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Move ===
Hiccups: 0, FreeDm: 160, MinFreeDm: 103, MaxWait: 448804ms
Bed compensation in use: mesh, comp offset 0.000
=== DDARing ===
Scheduled moves: 2456, completed moves: 2456, StepErrors: 0, LaErrors: 0, Underruns: 0, 0
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.1
=== GCodes ===
Segments left: 0
Stack records: 3 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is idle in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Slowest loop: 309.55ms; fastest: 0.05ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8
Interface state 5, link 100Mbps full duplex
=== Filament sensors ===
Extruder 0: pos 0.00, errs: frame 1 parity 0 ovrun 0 pol 1 ovdue 0
Extruder 1: pos 124.10, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0

and the line in the Error log:
2020-01-31 15:32:15 Extruder 0 reports sensor not working
2020-01-31 15:32:23 Printing paused at X26.2 Y17.2 Z1.8 U201.0
2020-01-31 15:32:50 Printing resumed

The Sensor on E1 seems to work fine, the one on E0 always errors like this now.

dc42

Thanks. Those readings look OK, in particular, the agc value is low enough. Can you swap the cables for filament monitors 0 and 1 over? If the fault remains on extruder 0, that indicates a problem with the filament monitor. Or if it's easier, leave the cables in place and swap the filament monitor units over; then if the fault moves to extruder 1 that will indicate a problem with the filament monitor.

clegg78

@dc42 i swapped the cables last week and the errors stayed with sensor 0. I even moved sensor 0 to a different endstop on the duet and it still had issues.

dc42

Thanks, in that case I approve a replacement under warranty. Please contact your supplier.

clegg78

Thanks @dc42 I received the replacement in hand. So far none of the "sensor not working" errors I was seeing before.

I am seeing the error count go up even for the sensor thats not being used in a specific print. I am printing with E0 right now and this is the error counts:

Extruder 0: pos 159.26, errs: frame 18 parity 0 ovrun 0 pol 22 ovdue 0
Extruder 1: pos 358.24, errs: frame 0 parity 0 ovrun 0 pol 17 ovdue 0

(this is the M591 report for D0)
Duet3D magnetic filament monitor on input 11, enabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 40.0mm, version 3, mag 129 agc 99, measured sensitivity 25.74mm/rev, min 42% max 109% over 13439.1mm

What is the definition of those error categories (Frame, Parity, Ovrun, Pol) and is there a certain threshold that should be concerning?

clegg78

Hey @dc42 I received and am using the new replacement sensor, and it seemed for a while to be working consistent. I am running 2.05.1 firmware now, and Occasionally I will still get "Extruder 0 reports sensor not working" errors on big prints.

Is the wiring really sensitive for these to EMI? I can try re-routing, but it is very odd its always E0 throwing this error, regardless of what pin/endstop its using, even with a replacement sensor, and swapping the wires between my 2 sensors I have. I've never seen the E1 sensor throw this error, only E0.

Is there any more diagnostics I can do to see where the issue is coming in? Its still FAR better than it was before with the old sensor.

dc42

Your agc 99 value is borderline high, suggesting that the magnet isn't close enough to the sensor chip. Try tightening up the screws holding the PCB to the housing. You could also check for bumps in the housing that stop the PCB from sitting flush. If that doesn't reduce the agc value, then I am happy to approve another replacement. An agc of 90 or below is good, although up to 100 is OK as long as it doesn't go much higher.

dc42

PS - are you getting higher error counts in the M591 reports from E0 than from E1, or about the same?

clegg78

Just about the same, maybe slightly higher on the E0. I will check on some bigger prints coming up on the numbers, I just re-disabled the sensor as I am worried about it pausing again overnight for no reason.