Printer just stopped, can't find the reason

appjaws · 13 Jul 2022, 13:54

Yesterday I left my printer to print a 4hr job. When I came in to check that it had finished I was shocked to find the nozzle above the almost completed print in the middle of the print bed. The nozzle was caked in filament but not stuck to the object, the heater was still on and would not turn off. When I attempted to move the head, nothing happened. I eventually switched off and on so that the print head could cool.
Today I switched the printer on and actioned the homeall button, so the XU, YV and Z all homed correctly but the homeall button is just showing the wait symbol (rotating circle) as is the send button. Eventually the buttons returned to normal.
I then issued G1 X100 Y100 and pressed send button but nothing happened, the button just shows the rotating circle. No commands or macros will work.
This is the M122 outputs
M122-output.txt](/assets/uploads/files/1657720392921-m122-output.txt)

How do I find the fault? It's almost like the processor is on a go slow.

Phaedrux · 13 Jul 2022, 22:02

Your M122 failed to upload. Can you try again?

appjaws · 14 Jul 2022, 08:25

@Phaedrux thanks for any help, I am at a loss.
Hope the file has been uploaded this time.
M122-output.txt

Phaedrux · 14 Jul 2022, 17:06

Is this the M122 from immediately after you rebooted after the crash?

From your M122 report I see you're using a release candidate. The final release is now available.

https://github.com/Duet3D/RepRapFirmware/releases/tag/3.4.1

I also notice your CPU temps are a bit high, but maybe you haven't calibrated the values, so it's showing as artificially high.

MCU temperature: min 43.5, current 51.2, max 51.9

If those are the idle temps and accurate they would be pretty high and I could see them getting pretty high during a long print.

See instructions here for how to calibrate that: https://docs.duet3d.com/en/User_manual/Connecting_hardware/Temperature_configuring_mcu_temp#calibrating-the-mcu-temperature

How is the board cooled?

appjaws · 14 Jul 2022, 19:22

@Phaedrux thanks for any help, I upgraded to the latest full release and will calibrate the MCU temperature in the morning.

I have a fan that runs when the MCU reaches 45 and forces air between the duet and dueX5 boards.

After the update I homed all XU, YV, Z which worked fine but the homeall button just showed a rotating circle. Eventually that stopped and the button label was correct so I tried my macro auto bed levelling, nothing happened except a rotating circle against the maco entry.
I really don't understand this, the processor actions the homeall but doesn't action any macro

How do I check to see if the processor is working correctly?
Could the problem be in the dueX5 board?

this is todays M122
M122-output.txt

deckingman · 14 Jul 2022, 20:01

@appjaws Hi Paul. From what I can gather, homeall.g works but other macros do not. Now homeall.g is a macro so that seems strange and would lead me to suspect something other than the board - i.e. it will run some macros but not others. The difference is that the homing macros are in the /sys folder, whereas other macros are in the /macros folder. Your initial failed print was running a gcode file that exists inside the /gcodes folder. So I'm wondering if your problems are stemming from a corrupt or failing SD card. Do you have another that you can try?

appjaws · 14 Jul 2022, 20:18

@deckingman thanks, I thought it could have been the SD card so I opened a new 32GB card and copied all the directories and files from the original card to it.
This didn't make any difference.
I even tried to enter G1 X10 but nothing happened except the rotation circle busy sign again.

I have an awful feeling that the processor is damaged , how I don't know, unless it overheated because of the hot weather. I don't want to buy another duet2 untill I am sure that it is damaged and that the dueX5 is OK.

Phaedrux · 14 Jul 2022, 21:16

Are you able to safely test individual motor movement commands using G1 H2 for each axis?

At this point it would help if you gave some more information about the machine and configuration. I see you have a U and V axis, so your homing files and config.g would be helpful.

@appjaws said in Printer just stopped, can't find the reason:

I then issued G1 X100 Y100 and pressed send button but nothing happened, the button just shows the rotating circle.

This makes me think that there is something preventing the motors from actually moving. Where are the motors physically connected? The Duet or the Duex?

deckingman · 14 Jul 2022, 21:31

@appjaws I have the original Duet Ethernet from my machine that I could lend you. It'll cost you the postage and I'd want it back. Pm or email me if that's any use.

Edit. I also have the Duex 5 so I could lend them both

jay_s_uk · 15 Jul 2022, 05:11

@appjaws I also have some refirb duet 2s I'll be selling if you're interested

appjaws · 15 Jul 2022, 15:22

@deckingman Thank you so much for the offer, I am pretty convinced that it is a processor fault, so I will be buying a used Duet2. In the unlikely event that the replacement board doesn't solve the problem, I'll ask you for a loan of your dueX5 so I can confirm the state of mine.

@deckingman @Phaedrux
I don't think it is the dueX5 board because I have 3 Z motors connected and they are working as well as the XU, YV and E motors.

It's almost as if the processor is only handling the first instructions and not releasing for the next set. As an example I ran my auto start macro, the macro started and the first thing it does is the set the bed temperature to 60C, when that is reached it then sets to 65C and the nozzle to 195C. What happened is that the bed reached 60C and then nothing else... very strange. This macro is used daily and is included at the end of this entry FYI.

I have calibrated the MCU temperature and it now reads about 36 degrees

Nothing has changed in my config or macro files and bearing in mind that the machine stopped towards the end of a print and the head stayed at the last extruder position instead of moving to the park position at the end of the print, I think it must be the processor at fault.

Has there been any changes in the firmware since the beta version of 3.4.1 that would require config or macro changes?

this is the start up macro:-
; Conditional Startup Macro
M98 P"0:/macros/extra/Set LED Red"

M561 ; clear any existing bed transforms
T0 ; select first hot end
M501 ; Load override
M584 X0:3 Y1:4 Z7:8:9 E2:5:6 P3
M291 P"Preheating bed and nozzle for accurate probing " R" Conditional Startup Macro " S1 T0; Display message

if heat.heaters[0].current <=65 && heat.heaters[1].current <=195
if heat.heaters[0].current <60
M104 S0 ; Set tool to 0
M140 S60 ; Set bed temperature to 60
M116 ; waiting for bed to reach temperature
M140 S65
if heat.heaters[0].current >60
M104 S195 ; Set current tool temperature to 195C
M116 S3 ; waiting for heaters to reach temperature

M98 P"0:/macros/Auto Bed Levelling"

M291 P"Reducing Nozzle heater 120" R"Startup Macro" S1 T0; Display message
M400 ; Wait for moves to complete
G92 E0 ; Zero Extruder
M104 S120 R120 ; Set current tool temperature to 120C

M98 P"0:/macros/extra/Set LED Green"

M291 P"Startup Completed " R" Conditional Startup Macro" S1 T5; Display message

Phaedrux · 15 Jul 2022, 22:32

Waiting for @DC42 to have a look. I haven't seen a CPU failure like this before. Usually it either works or it's dead.

dc42 · 16 Jul 2022, 13:51

@appjaws said in Printer just stopped, can't find the reason:

@Phaedrux thanks for any help, I am at a loss.
Hope the file has been uploaded this time.
M122-output.txt

That output just shows that the last reset was a software reset commanded by you 5 min 21 seconds before you ran M122.

After the update I homed all XU, YV, Z which worked fine but the homeall button just showed a rotating circle. Eventually that stopped and the button label was correct so I tried my macro auto bed levelling, nothing happened except a rotating circle against the maco entry.

Check that your versions of RRF and DWC are in step.
One reason for the printer doing nothing and DWC showing a wait-circle which goes away after a while is that the motors were unable to move, for example because the Duet had 5V power but not VIN power. Are you using external 5V power?

appjaws · 16 Jul 2022, 14:16

@dc42 Thank you for your interest.
RRF and DWC are in step both at v3.4.1
I am not using an external 5V system, The whole system is powered by a 24V supply
I can move each motor set XU, YV, Z individually and they move as expected.
If I home just the XU then when the moves are finished, I just get the rotating circle on the "HomeX" button and I can't do anything else.
It is the same if I Home YV or Z

very strange.

appjaws · 17 Jul 2022, 12:55

Just disconnected the boards and have found no signs of burning on the duet or the deuX5.
So still baffled by this strange fault.

Tinchus · 17 Jul 2022, 21:39

I was having some time ago the same exact problem. What I found finally was that for some reason, the gcode file I was uploading thorugh wifi, was being uploaded incomplete. So I started the prints and the print finished when the gcode just ended. Since the endgcode was not there, everything was on: nozzle, bed...
To check this: download the file you have on the printer and open in and check if the file is complete..
In my case the problem was caused by a bad wifi conection

appjaws · 18 Jul 2022, 09:47

@tinchus Thank you for the info but I don't think this is my problem, I can't even get the printer setup to do a print. Hopefully another board will arrive today, which I hope will solve the problem.