Duet 2/Duex driver errors

droftarts

@FreddyB428 Had you already tested all motors to see if they were working? Please post your config.g, and send M115 in the console, and post the response, so we can see what firmware version you are using.

Disconnect the DueX and test the motors on the Duet board on it's own. Incorrect driver error messages can be generated if:

the ribbon cable between the Duet and Duex is damaged
the grounding wire between them is not good (see https://docs.duet3d.com/Duet3D_hardware/Duet_2_family/DueX2_and_DueX5#power)
high current wires (like heater wires) run close to the ribbon cable (which is not shielded)

Disconnecting the Duex and testing the Duet will narrow down if the issue is one of the above, or if the Duet has actually failed.

Regarding the fuses, there should be a 15A fuse for the heated bed, (between the VIN and bed terminals) 7.5A fuse for the heaters and stepper drivers, and a 1A fuse for the fans. Were the bed and heater/stepper drivers fuses swapped, or did you have 15A in both? If you could post a picture of the Duet, that might help.

Ian

FreddyB428

@o_lampe

I Checked both plugs, driver 1 (brown yellow green white at the board) and followed it all the way to the X motor, no issues, did the same for driver 3 (primary extruder motor, white pink purple blue). Everything looks brand new. plugged and un-plugged still the same error codes without the 7.5 amp fuse. With the fuse installed I just get flashing lights.

FreddyB428

@droftarts

I have the firmware 3.4.5. I did not test the motors prior to install, looking around the web I have found that a small number of stepper motors become faulty within a few hours of use, but this maybe had 5 minutes of calibration run time. I'll pull the config.g and the M115 code here shortly and then follow your steps of diagnosis.

Regarding the fuses, there were 2 15 amp fuses and only 1 7.5 amp fuse. I'll also get a picture of the board once I get a chance. Thank you for the help.

FreddyB428

are all the DUEX board lights supposed to be red?

FreddyB428

I found a wire swap that came pre-installed. the E1 and E0 wires on the duet were swapped. I'm not sure if this helps. I just swapped them into their original location.

FreddyB428

@droftarts

I Disconnected the DueX and the error codes when away. There are no other error codes. I inspected the ribbon cable and it looks good. no physical signs of damage.
I inspected the grounding wire and cleaned both end on the Duet and DueX.

droftarts

@FreddyB428 said in Duet 2/Duex driver errors:

plugged and un-plugged still the same error codes without the 7.5 amp fuse.

Is that with the motor unplugged, or the ribbon cable to the Duex unplugged?

With the fuse installed I just get flashing lights.

Which lights are flashing?

are all the DUEX board lights supposed to be red?

Those are the endstop lights. They can be on when the endstop is triggered, and of when it is not triggered, or vice versa, depending how the endstop is configured.

I Disconnected the DueX and the error codes when away. There are no other error codes. I inspected the ribbon cable and it looks good. no physical signs of damage.
I inspected the grounding wire and cleaned both end on the Duet and DueX.

That's good, it sounds like the problem is the Duex end, at least.

In your picture, there is no fuse in the Duex? There should be a 7.5A fuse behind the VIN power connector. Without that, it's drawing power from the Duet, which may be dragging the voltage down and causing the errors.

Ian

FreddyB428

@droftarts

@droftarts said in Duet 2/Duex driver errors:

plugged and un-plugged still the same error codes without the 7.5 amp fuse.

Is that with the motor unplugged, or the ribbon cable to the Duex unplugged?

It is with the motor unplugged.

@droftarts said in Duet 2/Duex driver errors:

With the fuse installed I just get flashing lights.

Which lights are flashing?

@droftarts said in Duet 2/Duex driver errors:

With the fuse installed I just get flashing lights.

Which lights are flashing?

all lights on the Duet 2 and DueX

@droftarts said in Duet 2/Duex driver errors:

are all the DUEX board lights supposed to be red?

Those are the endstop lights. They can be on when the endstop is triggered, and of when it is not triggered, or vice versa, depending how the endstop is configured.

Ack. I just wasn't sure what to make of all the lights.

@droftarts said in Duet 2/Duex driver errors:

I Disconnected the DueX and the error codes when away. There are no other error codes. I inspected the ribbon cable and it looks good. no physical signs of damage.
I inspected the grounding wire and cleaned both end on the Duet and DueX.

That's good, it sounds like the problem is the Duex end, at least.
In your picture, there is no fuse in the Duex? There should be a 7.5A fuse behind the VIN power connector. Without that, it's drawing power from the Duet, which may be dragging the voltage down and causing the errors.

Correct there was no fuse in the DueX, Which was the only way to turn the printer on.

Since I thought it was the Duex that was the issue I unplugged everything except the ribbon connector and started plugging in everything one by one and turning the machine on until it wouldn't start. It started on all wires plugged in except for the last cable that connects to the secondary hot end fan (HF1).

So can I assume that the DueX is not the issue, and it is the Hot end fan wire/fan itself?

droftarts

@FreddyB428 said in Duet 2/Duex driver errors:

So can I assume that the DueX is not the issue, and it is the Hot end fan wire/fan itself?

Possibly. It sounds like it might have a dead short, so shorting out VIN power, possibly dragging the power down on the Duet. It might still be the Duex, though ie if the MOSFET on the fan connector has failed. Also check underneath the boards to check nothing is touching the pins on the back.

Does disconnecting that fan mean you can put the 7.5A fuse back in the Duex and it works now?

Ian

FreddyB428

@droftarts said in Duet 2/Duex driver errors:

Does disconnecting that fan mean you can put the 7.5A fuse back in the Duex and it works now?

Yes.

FreddyB428

@o_lampe, @droftarts you both have been so helpful. Thank you so much.

FreddyB428

Since it was the heater fan, I pulled it off and found the problem. shorted wires.jpg

Wires made contact with the hot-end. Thank god that's the only issue.

droftarts

@FreddyB428 Phew, a lucky escape!

Note that fans and heaters that are controlled by a MOSFET have the MOSFET on the GND side, ie voltage is flowing to them all the time, just waiting for a chance to short to ground. Unfortunately, this is just the way MOSFETs work; they need to be after the load, not before.

Hopefully the rest of the build goes a bit smoother now!

Ian

FreddyB428

@droftarts

Thank you, I'll remember that for next time. you both as well as this forum have been beyond helpful. Can't wait to get this printer running!