Suddenly my extruder stopped working - Driver Issue???

Phaedrux

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

I get "Warning: Driver 4 warning: phase A may be disconnected, phase B may be disconnected" in the console

I tried another cable. Nope. I tried another motor, nope. So I tried this motor in another driver and the motor works.

This does sound like a failed driver. Either internally the driver failed or there was an intermitent connection on the wiring that may have done some damage.

Just to be sure though, how did you test the motor on an alternate driver? Did you remap the driver for E in the M584 command?

GPetropoulos

@Phaedrux Yes. I remapped the driver. I also just connected the motor to another driver from xy without remapping, and connected the y motor to drive 4 while it was mapped for extruder. In all cases driver 3 and 4 show the same.

Any way to make sure it is gone? I get the same in drives 3 and 4 so I have no driver left for the extruder.

What are my options here?

Phaedrux

Unfortunately it sounds like the drivers have failed.

Assuming you are outside of the warranty window, your options are

Replace the board
Add a Duex expansion for additional drivers
Add external drivers
Attempt to replace the drivers with hot air soldering

GPetropoulos

@Phaedrux I am definitely outside warranty. And I am in Greece so finding parts is not quite easy.

If I would attempt to replace the drivers you thing it would be solved or could it be a deeper issue in the board. I don't see any burn marks though.

Is there a way to confirm if the drivers are specifically at fault?

GPetropoulos

@GPetropoulos If I consider getting another board, is duet 3 mini the logical upgrade for 1z 1 x 1y and 1 extruder?

Phaedrux

@GPetropoulos Yes the mini5+ would be the logical successor for a basic Duet 2 setup.

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

If I would attempt to replace the drivers you thing it would be solved or could it be a deeper issue in the board.

Yes everything seems to point to the drivers. Can you think of anything that may have happened to cause an issue?

GPetropoulos

@Phaedrux No idea really. I remember it was saying high temp detected at driver 3 as it was the one I was using, but after I corrected the temp calculation for the mcu it stopped. Then suddenly one day it just stopped moving. Then I tried the driver 4 and it was doing the same too.. So it feels weird for both drivers 3 and 4 to be gone at the same time. Unless anything happened to driver 4 and I dont remember it.

Even then it is weird as the extruder motor is a pancake and was working at 1400 ma, while the motion steppers were working at 2A and never reported a temp issue.

gloomyandy

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

after I corrected the temp calculation for the mcu it stopped

What exactly did you do here?

dc42

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

@GPetropoulos If I consider getting another board, is duet 3 mini the logical upgrade for 1z 1 x 1y and 1 extruder?

Yes, unless you need to use motor currents of 2A or greater.

GPetropoulos

@dc42 If I run the motion motors at 1.8A is it safe? I noticed it mentions 1.4 A and peak at 2A?

Phaedrux

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

1.8A is it safe?

Yes. You'll want to actively cool the board.

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

high temp detected at driver 3

@GPetropoulos said in Suddenly my extruder stopped working - Driver Issue???:

I corrected the temp calculation for the mcu

Driver temp and MCU temp are two different things. The drivers have a warning temp and a shutdown temp. The MCU doesn't give a warning, and you do need to calibrate the temp for it to be accurate, but it's not the same as the driver temp.

If the driver temp warning was a one time thing and ran for a long time without issue it probably wasn't the cause. Was the board being actively cooled with a fan? Extended operation time without cooling may have been a factor.

engikeneer

@GPetropoulos I notice in your picture that most of your motor connectors are just the black dupont plugs going into the Duet, and that the one proper one has some scorch marks.

Whilst neither of these are a definite source of your fault, they are not ideal. It could be a poor connection in the connector (crimp or pin contact) caused overheating and/or a short? Not much you could do about it now, but it's worth taking the time over the wiring if you invest in a new board

GPetropoulos

@Phaedrux said in Suddenly my extruder stopped working - Driver Issue???:

e cause. Was the board being actively cooled with a fan? Extended operation time without cooling may have been a factor.

It was running like this for years. The board is not actively cooled as having a fan on it per se, but I have a fan running when we have hot weather in the closet where the printer is in.

The driver temp issue showed up a couple of times, but did not see it lately. It was working like normal and then stopped.

@engikeneer It has been set up like this for 5 years. Not sure if dupont is not good enough, but back when I built it many people used them instead of molex.

@Phaedrux Do you think my dupont connectors might be an issue?

@gloomyandy I added this

; CPU TEMP CALIBRATION
;
M912 P0 S-11.6					   ; MCU temperature sensor calibration offset (M112 to view current temp. Should match room temp.)

Phaedrux

If the error seems to follow the driver and now the motor/cable then it would seem the connectors are alright and the fault is in the driver.