VIN under-voltage event (9.5V)

elvisprestley

@phaedrux @mendenmh thank you. This power supply has been working great and this only just happened after switching out the hotend. Any chance the hot-end created a problem that I would not have noticed (meaning there was no smoke or flame event)?

Phaedrux

If you disconnect everything from the PSU outputs and check it's voltage output again is it still undervoltage?

elvisprestley

@phaedrux So I got another power supply and am getting a good solid 14v. When I fire up the heaters this is what happens:

Error: Heater 1 fault: temperature excursion exceeded 15.0°C (target 195.0°C, actual 213.2°C)

Heater 1 is my hot end heater. Fortunately, I haven't blown this power supply (yet).

So, do I conclude that my brand-new hotend has a short? Or could there still be a problem on the Duet board? How do I diagnose where the issue is?

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 3.3 (2021-06-15 21:44:54) running on Duet WiFi 1.02 or later
Board ID: 0JD0M-9P6B2-NJ4S8-6J9D6-3SD6J-1U7YL
Used output buffers: 3 of 24 (14 max)
=== RTOS ===
Static ram: 23876
Dynamic ram: 74928 of which 0 recycled
Never used RAM 15612, free system stack 116 words
Tasks: NETWORK(ready,14.8%,237) HEAT(delaying,0.0%,208) Move(notifyWait,0.1%,303) MAIN(running,84.8%,153) IDLE(ready,0.3%,29), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:05:02 ago, cause: power up
Last software reset at 2022-02-20 15:31, reason: User, GCodes spinning, available RAM 12388, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0041f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Step timer max interval 0
MCU temperature: min 22.7, current 28.8, max 29.1
Supply voltage: min 14.4, current 14.7, max 15.1, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Driver 0: position 52028, standstill, SG min/max 0/602
Driver 1: position 52028, standstill, SG min/max 0/587
Driver 2: position 52028, standstill, SG min/max 0/580
Driver 3: position 0, standstill, SG min/max not available
Driver 4: position 0, standstill, SG min/max not available
Driver 5: position 0
Driver 6: position 0
Driver 7: position 0
Driver 8: position 0
Driver 9: position 0
Driver 10: position 0
Driver 11: position 0
Date/time: 2022-02-24 18:44:13
Cache data hit count 4294967295
Slowest loop: 6.34ms; fastest: 0.14ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest read time 2.4ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, maxWait 15909ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 59, completed moves 59, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1 -1 -1
Heater 0 is on, I-accum = 0.3
=== GCodes ===
Segments left: 0
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
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger is idle in state(s) 0
Queue is idle in state(s) 0
LCD is idle in state(s) 0
Daemon is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Slowest loop: 15.46ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8

WiFi -
Network state is active
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.26
WiFi MAC address 48:3f:da:a6:e3:25
WiFi Vcc 3.35, reset reason Power up
WiFi flash size 2097152, free heap 26664
WiFi IP address 192.168.164.234
WiFi signal strength -63dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 4 0 0 0 0 0 0 0

Phaedrux

@elvisprestley said in VIN under-voltage event (9.5V):

Supply voltage: min 14.4, current 14.7, max 15.1

If it's a 12v power supply and a 12v heater cartridge you should find the tuning knob on the PSU and dial it down to 12v checking with your multimeter.

droftarts

@elvisprestley

Error: Heater 1 fault: temperature excursion exceeded 15.0°C (target 195.0°C, actual 213.2°C)

That probably means that the heater overshot the target temperature. Most likely you haven’t tuned your heater(s) with M303. This gives the firmware an accurate model of how your heater reacts, so it can spot if something goes wrong. See https://docs.duet3d.com/User_manual/Reference/Gcodes#m303-run-heater-tuning and https://docs.duet3d.com/en/User_manual/Connecting_hardware/Heaters_tuning

Ian

elvisprestley

@droftarts this is brilliant, why is this not a step in the setup configuration?

elvisprestley

what am I supposed to do when my Duet's wifi card fails to initialize? This seems to happen about 10% of the time and it's ridiculously annoying to plug in the USB and re-initialize the wifi module all the time like this.

droftarts

@elvisprestley said in VIN under-voltage event (9.5V):

@droftarts this is brilliant, why is this not a step in the setup configuration?

It is in the new instructions I’m currently writing.

Ian

Phaedrux

@elvisprestley said in VIN under-voltage event (9.5V):

what am I supposed to do when my Duet's wifi card fails to initialize? This seems to happen about 10% of the time and it's ridiculously annoying to plug in the USB and re-initialize the wifi module all the time like this.

What do you mean it fails to initialize?

What does the wifi section of M122 report when it fails to connect?

You can try reflashing the wifi module with M997 S1.

elvisprestley

@phaedrux I had a long conversation with Steve from SeeMeCNC and he suggested I roll back from RipRap version 3.3 to 3.2.2 and follow his service manual guide: https://docs.google.com/document/d/1IQf191FP7EgV8IRpa__jZviF_lfd1jcKVwHD2J7U9pw/edit

He said he's tested this instruction set on over 100 different brands (he might have been exaggerating a little). He cautioned me that there are a few redundant steps, flash the FW, make a change, and flash it again. He said doing that was important. So tomorrow, I'm going to go through his instructions and follow every step.

If/when I hit the issue where the Duet wifi server fails to initialize again, I'll send you the M122 output. With any luck rolling back might address that.

elvisprestley

@phaedrux hey there, thanks for helping me out with this.

It looks like because of the file structure changes between RipRap 3.2.2 -> 3.3 I am no longer able to downgrade. What happens is when I hit M997 S0:1 the system throws the error that the file 0:/firmware/DuetWifiServer.bin is not found. Which of course it isn't since I'm trying to downgrade. Oddly, even if I put the file there, it still is unable to find it. I still get the error that the file is not found.

OK so then it gets weird. M997 S1 does successfully install the old WiFiServer with no errors.
And doing M997 S0 says 0:/firmware/Duet2CombinedFirmware.bin is not found - even when the file is there. I've tried putting the old file there, and the new file there. I've even tried renaming the WifiServer.bin to see if I could spoof it. No joy. Long story short - I am unable to downgrade

Phaedrux

Are you uploading the .bin files in DWC? Does it prompt to install, or are you placing the files on the SD card and sending the command?

I'm not really sure that going to 3.2.2 will have any benefit other than that's what SeeMeCNC supports and has documentation for. But if you want to go back to 3.2.2 you can always use Bossa to flash the board over USB and replace the /www folder with the DWC files from 3.2.2 as well.

The wifi server version shouldn't matter either way. But once you're back on 3.2.2 you shouldn't have any problems since the firmware folder won't be in use.

elvisprestley

@phaedrux I was copying the files to the SD card, and connecting via terminal which is where I was seeing the file not found error.

I gave up, and tried it in the DWC, which happily rolled back the WiFi server and the DWC with no errors but when I try uploading the Duet2CombinedIAP.bin and the Duet2combinedFirmware.bin as a package - it silently fails to do the downgrade.

This leaves me here:

DWC version 2.0.4
RipRapFW version 3.3
Wifi version 1.23

Like you said, I don't think any of this matters. Although I haven't had the Wifi fail to connect so the jury is still out.

elvisprestley

@phaedrux caught the wifi failing to initialize. Here's the M122 output:

=== Network ===
Slowest loop: 14.98ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 0 of 8

WiFi -
Network state is active
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.23
WiFi MAC address 48:3f:da:a6:e3:25
WiFi Vcc 3.35, reset reason Power up
WiFi flash size 2097152, free heap 26936
WiFi IP address 255.255.255.255
WiFi signal strength 31dBm, mode none, reconnections 0, sleep mode modem
Clock register ffffffff
Socket states: 0 0 0 0 0 0 0 0
ok

If I try to inquiry the state of the WiFi Module with a M552 S1 I get no response. But if I set it to S0 and then S1 it will kick back in and start working again.

So strange.

elvisprestley

@phaedrux I am finally printing! I used the SeeMeCNC config files (which were almost identical to my own) and took apart the hotend again reassembling it very carefully.

I've got good power supply, good extrusion, and no heater faults.

The Wifi is still failing to initialize about 10% of the time, annoying, but manageable with a quick USB plugin and resetting the system.

Things are going so well, I'm tempted to start rolling some of this software forward...