Duet 3 Mini 5+ Wifi multiple issues

[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.

1. 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.

2. 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.

3. 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.

4. But we are not sure when this Wifi issue is going to come.

5. 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.

6. 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.

7. 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.