Duet 3 Mini5 Wifi crashes after 1-2 min on PSU

[TimTom]

Hi,

I setup my Duet 3 Mini 5 Wifi with Duet 3 Expansion Mini 2+ yesterday evening for my Voron 2.4 build. I could successfully configure X-,Y-, Z-Axis successfully (only steppers and Mini12864 Panel with ST7564 connected but not yet configured). Software is 3.3 release.m122output.txt config.g

At this point all axis were moving correctly.

Suddenly the Duet board contiuesly started to crash, softreboot (via button) was not working. Hard reboot (killing power) helped for around a minute, until the Duet crashed again.

In that case all LED except LED V Fused and LED 12 V stay on, turn off.
Webinterface is not reachable anymore in that case.

When connecting via USB (PSU power off), the Duet does not crash and stays active (Webinterface reachable and USB/Serial works).

Of course I read documentation and forum, but didn't came along something similar. Things I tried so far.

• Check SD-Card for errors with chkdsk on windows
• Wait for a longer time (over night)
• disconnect everything (except Expansion Mini)
• Checked PSU (Meanwell LRS-200-24) with Multimeter, Voltage is OK
• Screws are "loose" so the board is held but not crushed to the holder

What I noticed was, that leaving the board off for several minutes it turns on OK for a couple of seconds and then crashed again.
Waiting only a couple of seconds after switching it on again, it does not but, but runs directly into the issue again.
It also seems that the time (once recovered) has massivly decreased (yesterday I could get a couple of minutes running before it crashes today it's only seconds).

Attached my config.g and the M122 report.

[dc42]

@timtom the M122 report you attached indicates that the most recent uncommanded reset occurred when running M122, and occurred because the pointer to the CAN device structure was unexpectedly null.

As the board works for a short while, the fault may be related to temperature. Is anything on the board getting hot when VIN power is applied but the board is otherwise idle? In particular: stepper driver chips, the microcontroller, the two small square voltage regulator ICs, and any other ICs on the board?

[TimTom]

@dc42
Hey thanks for the super fast feedback! Really apreciated!

I just switched it on VIN and waited a couple of minutes.
Then I scanned the board with my infrared thermometer (ambient room temperature ~20°C).
Most temperatures are below 30 °C, with a tendency of around 32°C on the top right of the board (driver 0 and driver 1). On the lower end of the board (driver 4) I measured ~24°C.

CPU is between ~26~28 °C

No real "hot spots" (of course I only measured the top of the board).
So temperatures seem to be OK.

I can access the board when connected to USB (Wifi works).

[dc42]

@timtom did you use a FLIR camera, or a IR thermometer? If you used a FLIR camera that's fine; but IR thermometers generally measure over quite a large area, and so are not good for identifying hot spots.

[TimTom]

@dc42
IR thermometer, I'm aware that they spread with distance, that's why I minimized measurment distance to less then a centimeter and passed the thermometer over the whole board surface. (Sorry FLIR camera not yet available .

Also the chips/IC's heat up slowly over time.
There is also no "hot" chip (30°C not considered as hot).

Somehow I doubt that it's a heat issue, just had the system off for ~20 min everthying cooled down to ambiant temperatures (measured before switching on) and it did not boot up this time.

Seems like things are getting worse.
You mentioned something about the pointer to CAN, sounds weired to me as there is nothing connected to CAN?

[fcwilt]

@timtom

Hi,

I've re-posted your config.g file using the </> tag - it makes it easier for all to view.

; Configuration file for Duet WiFi (firmware version 3.3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.5 on Fri Nov 05 2021 19:53:20 GMT+0000 (Coordinated Universal Time)

; General preferences
G90                                                                 ; send absolute coordinates...
M83                                                                 ; ...but relative extruder moves
M550 P"Voron"                                                       ; set printer name
M669 K1                                                             ; select CoreXY mode

; Network
M552 S1                                                             ; enable network
M586 P0 S1                                                          ; enable HTTP
M586 P1 S0                                                          ; disable FTP
M586 P2 S0                                                          ; disable Telnet

; Drives
M569 P0 S1                                                          ; physical drive 0 goes forwards A
M569 P1 S2                                                          ; physical drive 1 goes forwards B
M569 P2 S1                                                          ; physical drive 2 goes forwards Z0
M569 P3 S0                                                          ; physical drive 3 goes forwards Z1
M569 P4 S1                                                          ; physical drive 3 goes forwards Z2
M569 P5 S0                                                          ; physical drive 3 goes forwards Z3
M569 P6 S1                                                          ; physical drive 3 goes forwards E0
M584 X0 Y1 Z2:3:4:5 E6                                              ; set drive mapping
M350 E64:64:64:64 I0                                                ; configure microstepping without interpolation
M350 X16 Y16 Z16 I1                                                 ; configure microstepping with interpolation
M92 X80.00 Y80.00 Z400.00:400.00:400.00:400.00 E420.00              ; set steps per mm
M566 X900.00 Y900.00 Z900.00:900.00:900.00:900.00 E120              ; set maximum instantaneous speed changes (mm/min)
M203 X60000.00 Y60000.00 Z60000.00:6000.00:6000.00:6000.00 E120.00  ; set maximum speeds (mm/min)
M201 X6000.00 Y6000.00 Z4000.00:4000.00:4000.00:4000.00 E250.00     ; set accelerations (mm/s^2)
M906 X1200 Y1200 Z1200:1200:1200:1200 E400 I30                      ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                                             ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z0 S1                                                    ; set axis minima
M208 X350 Y350 Z350 S0                                              ; set axis maxima

; Endstops
M574 X1 S3                                                          ; configure sensorless endstop for low end on X
M574 Y1 S3                                                          ; configure sensorless endstop for low end on Y
M574 Z1 S2                                                          ; configure Z-probe endstop for low end on Z

; Z-Probe
M558 P1 C"zprobe.in" H5 F120 T60000                                 ; set Z probe type to unmodulated and the dive height + speeds
G31 P500 X0 Y0 Z2.5                                                 ; set Z probe trigger value, offset and trigger height
M557 X15:215 Y15:195 S20                                            ; define mesh grid

; Heaters
M308 S0 P"bedtemp" Y"thermistor" T100000 B4138                      ; configure sensor 0 as thermistor on pin bedtemp
M950 H0 C"bedheat" T0                                               ; create bed heater output on bedheat and map it to sensor 0
M307 H0 B1 S1.00                                                    ; enable bang-bang mode for the bed heater and set PWM limit
M140 H0                                                             ; map heated bed to heater 0
M143 H0 S120                                                        ; set temperature limit for heater 0 to 120C
M308 S1 P"e0temp" Y"thermistor" T100000 B4138                       ; configure sensor 1 as thermistor on pin e0temp
M950 H1 C"e0heat" T1                                                ; create nozzle heater output on e0heat and map it to sensor 1
M307 H1 B0 S1.00                                                    ; disable bang-bang mode for heater  and set PWM limit
M143 H1 S280                                                        ; set temperature limit for heater 1 to 280C

; Fans
M950 F0 C"fan0" Q500                                                ; create fan 0 on pin fan0 and set its frequency
M106 P0 S0 H-1                                                      ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"fan1" Q500                                                ; create fan 1 on pin fan1 and set its frequency
M106 P1 S1 H1 T45                                                   ; set fan 1 value. Thermostatic control is turned on

; Tools
M563 P0 D0 H1 F0                                                    ; define tool 0
G10 P0 X0 Y0 Z0                                                     ; set tool 0 axis offsets
G10 P0 R0 S0                                                        ; set initial tool 0 active and standby temperatures to 0C

; Custom settings ;are not defined
; M918 P2 

[dc42]

@timtom if the board is reliable when using USB power, it suggests to me that either the internally-generated 5V power is dropping after a period of time, or something that depends on VIN power is heating up.

Does the board still reset after a while if you disconnect everything from it except VIN power?

Is it reliable if you use both VIN and USB power? Be very careful of USB ground loops (see https://duet3d.dozuki.com/Wiki/USB_ground_loops) and make sure that you have a really solid ground connection between the main PSU and the Duet.

In the minutes leading up to a reset, is the VIN voltage indicated by M122 stable?

[fcwilt]

@timtom

Hi,

I don't think these are related to your specific problem. All of them are benign I think but thought I would bring them to your attention just to be safe.

At line 20 you have M569 P1 S2 - S2 is not listed as a valid parameter.

At line 27 your have settings for 4 extruders but you have only one specified in line 26.

At line 29 through 33 you have multiple values for the Z steppers - that is not valid.

From the docs:

RepRapFirmware does not support individual motor settings where an axis has multiple motors connected to different stepper drivers. The first parameter specified will be used for all motors on the axis. You should use identical motors on any axis that has more than one motor to avoid unexpected behaviour.

At line 43 you have M574 Z1 S2.

From the docs:

The S2 option of M574 is intended for use only when axes other than Z are using the Z probe for homing. The only printers known that do this using Duet electronics are the RepRapPro Ormerod, Huxley Duo, and Mendel Tricolour machines. When using the Z probe to home Z, M574 Z has no bearing on the probe setup or usage. A Z probe and a Z endstop can both be configured at the same time. G30 calling the probe setup with M558, and G1 H1 Z moves calling the endstop configured with M574 Z.

[TimTom]

@dc42
No currently it does not come back anymore after some time (getting worse).

Are there "active" 5 Volt pins I could easily point my multimeter to? (Would like to avoid actually measuring CPU pins).

Avoided connecting mains and USB as I read some warnings about it. Thanks for the heads up. I'll simply use a USB-powerbank (as I can connect via wifi in this case).

I hooked up USB power bank in parallel to VIN - lights go on, as soon as I disconnect USB, lights go out.

@fcwilt
Will do next time, followed forum instructions to upload files

[TimTom]

@fcwilt
Thanks for the hint, I was still in the process in ironing out configuration until the board showed this weired behavior (stopping me in the process).

Unfortunately the "online" config tool, only allows to assign one stepper to one axis. So I assigned the rest of the steppers to Ex and started modifying configuration.

Also Probes and Bed sensors are not yet configured properly (I'd love to do that as soon as the boars starts working again )

[dc42]

@timtom said in Duet 3 Mini5 Wifi crashes after 1-2 min on PSU:

Are there "active" 5 Volt pins I could easily point my multimeter to?

Yes, there are 3.3V and 5V pins available on the 5-pin IO connectors. They are not the same ones used by the internal circuitry, however if the problem is that the 5V rail is dropping then I would expect that 5V on the IO connectors would drop too.

If the 3.3V rail is dropping then the VIN voltage reported by M122 will read high, because 3.3V is used as the voltage reference when reading the VIN voltage.

[dc42]

@timtom said in Duet 3 Mini5 Wifi crashes after 1-2 min on PSU:

I hooked up USB power bank in parallel to VIN - lights go on, as soon as I disconnect USB, lights go out.

Which lights: the red 5V and green 3.3V LEDs? If those are not lit when using VIN power alone, then that indicates the problem is with power. Is the blue VIN LED lit solidly? What about the amber 12V LED next to the blue one?

[TimTom]

@dc42
Yes that seems to be the trouble 3.3V and 5V are dead.
As soon as USB power is gone no 3.3 Volts on IO pins and 5 Volt slowly drops to zero over time.

Yes that's what I wanted to say in my first post (all LED's switch off)
Only LED V Fused and LED 12V stay on.

Given the analysis so far I assume I'm the lucky winner in the hardware defect draw :), unless you have further suggestions I'd contact my reseller for replacement (or is the board of interest for further analysis?)

[dc42]

@timtom it would be worth trying disconnecting everything (endstops, Z probe etc.) from the IO connectors and also disconnecting any LCD display that you have connected to the Duet, in case anything is drawing excess current. If the problem persists then I agree, you need a replacement under warranty.

[TimTom]

@dc42
Disconnecting everything was the first thing I did.
The only remaining connection is to the Duet 3 Expansion Mini 2+ (as this is really well connected). And nothing on the board was exceptionally hot.

Thanks a lot for your support. Usually I tend to believe I'm to stupid but in this case lucky for me, that did not turn out to be true

Thanks again for your great support on a rainy Saturday afternoon.

[dc42]

@timtom I'm sorry your board has developed a fault. Please email warranty@duet3d.com to start your warranty claim. You will receive a reply with a link to a form to fill in.

[TimTom]

@dc42
Thanks, do you want the board for review? Then I would go that path, if not I would contact my German reseller (Filafarm) easing things with Brexit and Shipping :).

BTW, keep up the great work, beside the HW defect it is a pleasure to work with the board, it boots fast, reacts fast, etc.

So for now I'm going to finish my configuration with VIN and USB-powerbank :). (Wife and kid are with family over the weekend, need to take this chance).

[dc42]

@timtom you will need to fill in the form anyway so that we can contact Filafarm and authorise them to replace your board. Yes Brexit is a horrible mess and makes things difficult, so we will arrange for Filafarm to provide the replacement.