Duet 3 mini 5+/FYSETC Big Dipper on FFCP/Flashforge Creator Pro

Inlinebrother

Ok I started from scratch
I think the problem was with the board loosely fixed, it might have touched some parts of the case
I also checked all the wires and reinserted them, trying to fix them as tight as possible
Now it seem to work

Started the test print, I'll write an update after that
For now I hear the sound of silence and it is great
I'll have to change the coordinates though, the print started on the corner of the build plate

Inlinebrother

This post is deleted!

Inlinebrother

Finally it is working
Though I need to adjust tool offsets a bit more
And I also had to change the cooling fan number in cura settings for every extruder to the pin number of the fan (in my case fan #3)
And I need to try dual extruder printing

Thank you all who helped me achieve this.
Hope my story will help somebody)

I'll publish my design for the Big Dipper holder and my configs a bit later.

Inlinebrother

Here is my design for the holder
https://www.thingiverse.com/thing:6781025/files

Configs have to be refined, so I will post them some time in the future

Inlinebrother

New update:
After some prints, I saw issues with layers positioning at different heights. Tried to tighten the belts aaand my printer stopped working)

For some reason the problem occured only when the bed was heating, so I recrimped the thermistor, because I made a mistake and the cables were in reverse order. Then I recrimped the bed power cables that are connected to the PSU. And I did that for a week or even more every evening)
I found out that I used 1.27 mm2 cable for bed power and that I had to use the right crimper tool
And I tried and tried, again and again to crimp even better
Until I checked the bottom of the board holder and found out that extruder cables touched the screw
I guess that was enough to short the board
My board firmware even got corrupted and I had to reflash it via USB
It even stopped connecting via serial port, only direct USB download of the .uf file helped me

Then i also had to fix other cables as well that touch the closing door of the bottom side of the printer

So I write this to warn you to be careful with your wiring)

But I still have this issue with my layers though. So I will continue to look for a solution.

Also I took the opportunity and installed the Z-probe, though I need a holder to start using it
And I haven't configured it yet

Also I found some useful resources along the road
For example a video about crimping -

And a guide with pictures how to wire a dual extruder printer to the Big Dipper
https://www.youtube.com/watch?v=GZOh1NzqzzU
Although the cooling and board fans seem to be wired incorrectly there
https://github.com/FYSETC/FYSETC-BIG_DIPPER/tree/main/example/Independent Dual Extruder

Inlinebrother

I guess another problem is with my power supply like @garyd9 had when turning on the bed heater
https://forum.duet3d.com/topic/3553/converting-a-flashforge-creator-pro-to-use-duet/3

I wonder what should I take into account if I want to use a 500w 24v PSU
Should I replace the original 1.5 mm2 power cables?
Will the board survive the current?

PS: it is interesting that I had some almost successful prints even with a 320w PSU
Although there were signs of missed steps

Inlinebrother

Ok, I think the PSU was not a problem, because I get shutdowns even with the 500w PSU after trying to run a bed heater. Though I had some restarts in the idle mode too. Also after the shutdown it was hard to recover on the old PSU. With a new PSU it's the board manages to restart. Or maybe I crimped the wires a bit better now, but not enough for the bed heating

Two times I managed to catch an error Vdd Brownout

m122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.3 (2024-09-18 11:25:48) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: RHYS5-6J9MK-K65J0-40TK2-JRW2Z-ZLX8A
Used output buffers: 3 of 40 (18 max)
=== RTOS ===
Static ram: 103368
Dynamic ram: 121884 of which 12 recycled
Never used RAM 16484, free system stack 206 words
Tasks: NETWORK(2,nWait 7,9.7%,211) HEAT(3,nWait 1,0.0%,331) Move(4,nWait 6,0.0%,355) CanReceiv(6,nWait 1,0.0%,939) CanSender(5,nWait 7,0.0%,336) CanClock(7,delaying,0.0%,334) TMC(4,nWait 6,1.4%,110) MAIN(1,running,86.3%,665) IDLE(0,ready,1.8%,29) AIN(4,delaying,0.8%,264), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:00:12 ago, cause: Vdd brownout
Last software reset at 2024-10-06 18:52, reason: User, Gcodes spinning, available RAM 16484, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
MCU revision 3, ADC conversions started 9505, completed 9505, timed out 0, errs 0
MCU temperature: min 31.1, current 31.8, max 32.0
Supply voltage: min 24.3, current 24.3, max 24.4, 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 11, reads 1101, writes 11, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 0, ifcnt 11, reads 1101, writes 11, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 0, ifcnt 10, reads 1101, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 10, reads 1101, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 0, ifcnt 10, reads 1102, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 5: standstill, SG min 0, read errors 0, write errors 0, ifcnt 11, reads 1101, writes 11, timeouts 0, DMA errors 0, CC errors 0
Driver 6: standstill, SG min 0, read errors 0, write errors 0, ifcnt 10, reads 1101, writes 10, timeouts 0, DMA errors 0, CC errors 0
Date/time: 2024-10-06 18:53:48
Cache data hit count 24606480
Slowest loop: 4.50ms; fastest: 0.16ms
=== Storage ===
Free file entries: 20
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 0.7ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: none, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
no step interrupt scheduled
Moves shaped first try 0, on retry 0, too short 0, wrong shape 0, maybepossible 0
=== DDARing 0 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== DDARing 1 ===
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 ===
Movement locks held by null, 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
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000000
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 111, received 0, lost 0, errs 59936, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 26 (min 26), ts 63/0/0
Tx timeouts 0,0,62,0,0,47 last cancelled message type 4514 dest 127
=== Network ===
Slowest loop: 5.81ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(2) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1.0
MAC address 08:3a:8d:eb:24:44
Module reset reason: Power up, Vcc 3.36, flash size 2097152, free heap 37728
WiFi IP address 192.168.1.69
Signal strength -46dBm, channel 7, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

and once I had a HardFault

m122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.3 (2024-09-18 11:25:48) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: RHYS5-6J9MK-K65J0-40TK2-JRW2Z-ZLX8A
Used output buffers: 2 of 40 (18 max)
=== RTOS ===
Static ram: 103368
Dynamic ram: 128524 of which 12 recycled
Never used RAM 9844, free system stack 206 words
Tasks: NETWORK(1,ready,3.7%,234) HEAT(3,nWait 1,0.0%,341) Move(4,nWait 6,0.0%,355) CanReceiv(6,nWait 1,0.0%,939) CanSender(5,nWait 7,0.0%,336) CanClock(7,delaying,0.0%,334) TMC(4,nWait 6,1.4%,110) MAIN(1,running,91.9%,665) IDLE(0,ready,2.2%,29) AIN(4,delaying,0.8%,264), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:00:13 ago, cause: software
Last software reset at 2024-10-06 09:35, reason: HardFault invState, Display spinning, available RAM 9844, slot 1
Software reset code 0x406f HFSR 0x40000000 CFSR 0x00020000 ICSR 0x0045f803 BFAR 0xe000ed38 SP 0x20012008 Task NETW Freestk 482 ok
Stack: 0000017f 00000002 200014e4 00000000 200349db 000a0f9f 00000000 600f0000 00000000 00000000 00000000 00000000 20033824 00000800 20037538 2002c640 2001882c 2002c496 2001882c 2001ea80 00030523 00000000 00000000 00000000 200120b8 00000014 b5dd6ada
Error status: 0x00
MCU revision 3, ADC conversions started 10020, completed 10019, timed out 0, errs 0
MCU temperature: min 31.1, current 31.6, max 31.6
Supply voltage: min 24.1, current 24.1, max 24.2, 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 1, ifcnt 55, reads 1152, writes 13, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 55, reads 1152, writes 13, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 55, reads 1152, writes 13, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 43, reads 1155, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 43, reads 1155, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 5: standstill, SG min 0, read errors 0, write errors 1, ifcnt 55, reads 1152, writes 13, timeouts 0, DMA errors 0, CC errors 0
Driver 6: standstill, SG min 0, read errors 0, write errors 1, ifcnt 55, reads 1152, writes 13, timeouts 0, DMA errors 0, CC errors 0
Date/time: 2024-10-06 09:35:23
Cache data hit count 13985808
Slowest loop: 5.59ms; fastest: 1.19ms
=== Storage ===
Free file entries: 20
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 1.4ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: none, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
no step interrupt scheduled
Moves shaped first try 0, on retry 0, too short 0, wrong shape 0, maybepossible 0
=== DDARing 0 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== DDARing 1 ===
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 ===
Movement locks held by null, 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
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000000
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 116, received 0, lost 0, errs 61873, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 26 (min 26), ts 66/0/0
Tx timeouts 0,0,65,0,0,49 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 3.91ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1.0
MAC address 08:3a:8d:eb:24:44
Module reset reason: Power up, Vcc 3.36, flash size 2097152, free heap 42932
WiFi IP address 192.168.1.69
Signal strength -38dBm, channel 7, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

jay_s_uk

@Inlinebrother although your board is a big dipper as it uses the same MCU, dc42 may be interested in the output of the hard fault issue.
Please see the thread here https://forum.duet3d.com/topic/36689/random-hard-fault-resets-on-duet-3-mini-wifi/

Inlinebrother

@jay_s_uk Hi, thank you, I updated my config file, and if I encounter HardFault again I will definitely write back

Inlinebrother

Next update:
So I received better crimping tools for ring connectors and ferrules, and I am pretty sure they should not be the problem

But the nature of the problem is EMI I think

For some time now I had a suspicion that the original board was grounded and that might be the issue
The case itself is connected to the PSU ground, and i checked with multimeter that the screws my holder is connected to the case with are connected to the ground, but the board is connected to the plastic holder and not the grounded case
Today I tried to connect one of the screws to the ground, and I think that did help a bit
But still there is a lot of current when the target temperature is reached and the power is turned on/off multiple times
Next time I think I'll try to connect all possible screws of the board to the ground or to the grounded case

Inlinebrother

Grounding two screws that are near the power line seem to be helping

Inlinebrother

But that wasn't the solution for the problem
It did help to protect the board and it stopped to restart, but now I heard a sound of a breakdown, so I have to continue my search

Inlinebrother

I installed the default 320w psu and now it seems to work without any extra sounds

Inlinebrother

So now the board is able to heat the bed and start to print
But the board shuts down after several minutes of printing
I even grounded the extruder, but that didn't help a lot

I wonder what I did wrong

jay_s_uk

@Inlinebrother does it give you an error why?

Inlinebrother

@jay_s_uk Hi, sometimes it gives Vdd brownout, but most of the times just shuts down and the only way to turn it on is to turn off the power and turn it back on

jay_s_uk

@Inlinebrother that doesn't sound good but I still think it probably points to the PSU, especially the not coming back on until power is reset

infiniteloop

@Inlinebrother Staring at your above photo for a while, I can’t quite figure out the exact meaning of all lines attached to the three leftmost contacts of the PSU, labelled L, N and GND (sorry, proper symbol for „Earth“ not available).

Three lines arrive from your AC power plug: red at L, black on N, yellow on GND. The colours do not match any convention I am familiar with, so I have no real clue.

The black wire seems to be thinner than the other two. Are you sure you didn’t swap black and yellow? Depending on you country’s AC system, such a swap could possibly work … well, somehow. In this context: is the power outlet you use protected by an earth leakage circuit breaker? Is there any one of these installed in your house? Which country are you located in?

At the PSU, GND has two additional wires attached: a yellow one with black crimp connector (to ground the metal casing), and a black line, blue connector. Where does this black line go?

Sorry for being curious - just one last question: is there, in your device, any electrical connection between GND and V- (i.e. DC negative), either intentional or by accident?

Inlinebrother

@infiniteloop Hi, thank you for being so interested in the case, I am pretty sure that I connected the PSU cables the way they were before upgrade, because I have a photo.

My own decision was to connect a screw of the board to the PSU ground, that is where the black cable with blue ring connector is going

I didn't intentionally connect GND and V-, although I saw some guys do that on the internet.

My next guess is damaged wiring of the extruder heaters, or at least exposed wiring

As far as I remember I had to get rid of insulation l, when I installed the flexion extruder, but for some reason that didn't bother me in the past

Inlinebrother

Also I mistakingly connected the ground to the wrong part of the extruder frame that wasn't a conductor, so connecting it the right way also might help

Update: fixing that didn't help