Duet 3 Mini 5+ Wifi multiple issues

selva_tvi

Hi all,

We purchased Duet 3 Mini 5+ by April 22. After 4-5 months of use, it is creating multiple issues.

We built two machines of the same components. The machine is CoreXY 300x300mm with Dual Z.

Last week it had Wifi issue and we updated the firmware. Now it is having X and Z axis issues. In this machine, Wifi issue is solved.

'Left Stepper motor skips the rotation and the bed is tilting because one side motor skips the rotation'

Please find the M122 report.
M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.4.4 (2022-10-20 16:18:28) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: H0WK1-6396U-D65J0-40KML-L403Z-HAR1D
Used output buffers: 3 of 40 (22 max)
=== RTOS ===
Static ram: 103684
Dynamic ram: 112628 of which 20 recycled
Never used RAM 25380, free system stack 194 words
Tasks: NETWORK(notifyWait,13.8%,223) ACCEL(notifyWait,0.0%,346) HEAT(notifyWait,0.0%,358) Move(notifyWait,0.0%,363) CanReceiv(notifyWait,0.0%,942) CanSender(notifyWait,0.0%,336) CanClock(delaying,0.0%,341) TMC(notifyWait,0.7%,115) MAIN(running,84.6%,411) IDLE(ready,0.1%,30) AIN(delaying,0.9%,272), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:15:24 ago, cause: power up
Last software reset at 2022-11-17 17:51, reason: HardFault invState, GCodes spinning, available RAM 25316, slot 1
Software reset code 0x4063 HFSR 0x40000000 CFSR 0x00020000 ICSR 0x00000803 BFAR 0xe000ed38 SP 0x20012590 Task TMC Freestk 127 ok
Stack: 20019470 2001233c 200014e8 e000e000 00000060 00091981 00000000 60000000 00000004 00000000 20011ed4 00031dc9 00000002 20011ed4 20012334 00000004 41008000 a5a5a5a5 a5a5a5a5 00031edf a5a5a5a5 000900f5 a5a5a5a5 00000000 a5720005 0072ff05 d7000000
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 924383, completed 924383, timed out 0, errs 0
Step timer max interval 1488
MCU temperature: min 36.0, current 37.1, max 38.2
Supply voltage: min 23.8, current 23.9, max 24.0, 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
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 9, reads 48612, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 0, ifcnt 9, reads 48612, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 0, ifcnt 9, reads 48611, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 9, reads 48611, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 0, ifcnt 10, reads 48611, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2022-11-22 11:24:32
Cache data hit count 1666974085
Slowest loop: 16.67ms; fastest: 0.13ms
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 5.8ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
=== 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
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 8315, received 0, lost 0, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 18 (min 18), ts 4621/0/0
Tx timeouts 0,0,4620,0,0,3693 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 25.73ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
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 1.27
WiFi MAC address f0:08:d1:03:80:cc
WiFi Vcc 3.42, reset reason Power up
WiFi flash size 2097152, free heap 25240
WiFi IP address 192.168.1.6
WiFi signal strength -49dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

jay_s_uk

@selva_tvi post your config, homing files, bed file and details of the motors you're using

selva_tvi

@jay_s_uk

Please find the attached information. homez.g homey.g homex.g homeall.g config.g bed.g

Please find the motor details:
X & Y - Motech MT-1704HSM168RE
https://e3d-online.com/products/motors

Dual Z - MT-1705HS200AE-Motech-Super Whopper Motor.pdf MT-1704HSM168RE-Motech-High Torque Motor.pdf MT-1705HS200AE

jay_s_uk

@selva_tvi what i would probably suggest on the Z motors is to remove the D3 from M569 on the 0.2 and 0.4 drivers and up the current to 1600.
Make sure you have some active cooling on the board if you're going to do this of course and then report back how that is with the bed levelling.

With X, what speed are you travelling at for it to skip steps?

elmoret

Stepper drivers typically either work or don’t work. Skipping some steps after working successfully points to binding/lubrication.

selva_tvi

@jay_s_uk @Phaedrux @dc42 @T3P3Tony

Thank you. I have changed all the above as suggested.

But the thing is getting worsened.

Now we are getting the following error:

Warning: Driver 0.2 warning: Phase B may be disconnected.

Actually we are FFF machine makers. We used to build custom machines to the needful customers.

4 months back we made the following machines - 02 nos (Installed at our customer location). It is targeted as High speed machine with 3000mm/s2 acceleration

CoreXY with CF tube gantry.
Rapido hotend with Orbiter 2 extruder.
E3d High speed motor for X&Y and E3D Super whopper motor for Z.
Duet3 Mini + Wifi board + 4.3 Panel Due. (Board is cooled by 50x15 blower fan across the board). Purchased from E3D.
Gates GT2 9mm belt + 20teeth GT2 pulley.
X+Y is Hiwing MGN 12 guide Rails
Dual Ball screws in Z axis.
3D printed EVA hot end parts.

It was tested at our premised for 2-3 months and installed at the customers location.

We are now facing multiple issues.

Frequently the Wifi is getting disconnected. If this afternoon gets disconnected, then the whole day it wont connect back. The customer tried a lot. Switched off the network, restarted the machine and whatever he does the Wifi doesn't connect. The next day it will connect automatically.
It happened multiple times. We asked him to recheck the Wifi Antenna, interchange Wifi antenna from another machine, recheck their network connectivity, but nothing was useful.
4 days back I raised the query in this forum and someone asked to install the updated Board and Wifi firmware. We tried today and now it is working.
But we are not sure when this Wifi issue is going to come.
Frequenty the driver Warning is coming and either CoreXY is skipping or the Z axis is skipping. We thought that the driver warning is due to wire issues.
If driver warning is due to wire issues, then practically no print should come properly. Some prints are fine, then suddenly Driver warning comes.
We have set the acceleration to 3000mm/s2, but the customer is printing with 60-80mm/s speed only. So he is not trying with high speeds also.
Previously we have used Multiple boards:
Starting from Ramps 1.4, MKS Gen L, MKS Gen V 1,.4, MKS Rumba, MKS E3d, MKS Robin Nano, to the recent BTT Octopus, Octopus Pro. Zero issues due to board after the proper tuning.

None of these boards are having this kind of major issues.

Particularly this Wifi issue and Driver warning issue is killing.

Recently we have build some machines with 500x500 CoreXY with Octopus Pro running with Marlin. Some machines we have used MKS Robin Nano V3. Never we faced these issues. Once tuned it will be like a workhorse.

Now these two machines are customized with Duet boards. This is totally damaging our reputation. The customer is totally angry with us.

I am not sure whether we are doing the wrong things or the board is having these many issues.

Kindly provide us some solution, If we are wrong, guide us in the proper way.

jay_s_uk

@selva_tvi the phase warning on driver 2 usually points to a wiring issue. so I would check your wiring on that port

selva_tvi

@jay_s_uk But i hope i have explained it clearly.

'Frequenty the driver Warning is coming and either CoreXY is skipping or the Z axis is skipping. We thought that the driver warning is due to wire issues.
If driver warning is due to wire issues, then practically no print should come properly. Some prints are fine, then suddenly Driver warning comes'

Either it should be a complete Flop or it should be a complete success.

jay_s_uk

@selva_tvi ok

selva_tvi

@jay_s_uk Sorry, its a surprise to see this message of 'ok'.

For this reply, I didn't write this much detailed query..

I know that you have assisted us in some other queries. But this reply is not acceptable. Thanks anyway.

jay_s_uk

@selva_tvi well i gave you my opinion on the Warning: Driver 0.2 warning: Phase B may be disconnected. issue that its usually down to wiring. this can be intermittent or otherwise but you've seemingly already determined that it isn't
and these skipping steps are almost always mechanical. if the driver had a fault you'd know about it as either the stepper motor would vibrate like mad or it wouldn't move.
so i'd say your issues are there and not with the board
and sorry that my free advice (that is unaffiliated with the duet team) isn't up to your standards so i'm going to gracefully bow out of this conversation

Phaedrux

Just to make sure I'm clear, is this machine having the wifi issue, or was it the other machine? Or both? And is it now resolved?

For the driver issue, can you capture a video of it happening and what the machine is doing at the time?

Have you tried to map to a different stepper driver to see if the problem persists? As in, does it follow the motor/wiring, or the driver?

selva_tvi

@jay_s_uk I always respect your support. As mentioned that you have supported me lot of times. I know that.

Sorry, that my words have hurt you. My apologies for that.

I know that you are supporting from outside, not from Duet Team.