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

[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

[Inlinebrother]

One thing that I forgot to mention, that the PSU keeps running always. It is the board that shuts down. And the led near wifi stops working together with all the fans controlled by the board, but all other LEDs are working fine

[droftarts]

@Inlinebrother See our documentation on grounding here: https://docs.duet3d.com/en/User_manual/Connecting_hardware/Power_wiring#grounding

Basically:

• the incoming earth, from the power socket, should be connected to a ground point.
• parts that require grounding should connect to this ground point: PSU earth (not -V), frame, hot end and extruder metal parts, stepper motor bodies, shielded wire shielding etc.
• PSU -V should not be connected to this grounding point, and should not be bridged to earth.

Not sure what could be causing the 'Vdd brownout' other than PSU, or shorting out wiring. Maybe a failing heater?

Ian

[Inlinebrother]

@infiniteloop Hi, thanks to you and idea came to me to measure resistance with a multimeter for different connections of the PSU
And I found out that I have a direct connection (multimeter beeps) from PSU 24v to the ground when right extruder is connected to the board

Also the resistance between the ground and PSU 24+ is about 1500 om

even without my cables attached that connect the board and the extruder to the ground

[Inlinebrother]

Ok I found an accidental connection between the right extruder pin and the ground
For some reason I was confident that nothing is touching the board. Thank you all for your ideas.

Now I measured all other connections and see that my 24v+ PSU is connected to e0, e1 and bed + and - pins

And the resistance between the - and + for the board power pins and the bed power pins is about 160 oms
Is that ok?

[Inlinebrother]

I started the print, it looks promising, 25% done

Now I googled the datasheet for moons stepper motors (17HD4063-06N) that are installed on my FFCP, and as far as I understand they have a rated current of 630 mA, so I should change my config.

063 / 100 = 0.63 A for the Y axis at least

and for the extruders my FFCP has two 0.8 A rated 42HB34F08AB-22

[infiniteloop]

@Inlinebrother

I am pretty sure that I connected the PSU cables the way they were before upgrade, because I have a photo.

Sorry, I haven’t. That’s why I asked for additional information:
"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?"

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

That’s fine.

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

Thankfully, @droftarts stepped in to clarify this one and some related topics.

I forgot to mention, that the PSU keeps running always. It is the board that shuts down.

From your photo, I can’t figure out how the board is switched off. As a side note: When electricity in your part of the world is not particularly cheap, it might be a good idea to cut power on the AC side. Thinking of safety reasons, this idea even looks better

Ok I found an accidental connection between the right extruder pin and the ground

Glad you spotted this one. Keep reporting on how it works.

Also the resistance between the ground and PSU 24+ is about 1500 om

That value alone isn’t really telling. To check if some component inadvertently bridges to GND (instead of to V-), you’d have to disconnect any and all connections. Then, check the resistance, reconnect a single component, measure again. Repeat this procedure until all connections are back in place. Well, better try to avoid this tedious process - maybe the right extruder turns out to have been the real culprit.

Now I googled the datasheet for moons stepper motors (17HD4063-06N) that are installed on my FFCP, and as far as I understand they have a rated current of 630 mA, so I should change my config.

Don’t know how the steppers are currently configured. The section Stetting motor currents in the support document Configuring stepper motors provides detailed infos - I think even more than you ever wanted to know.

[Inlinebrother]

Ok, yesterday the printer was working for hour and a half until I turned it off. The motors were about 50 degrees celsius and I guess that's why the layers shifted. The current was set to 850 ma for xy and 400 for z, and 900 for extruders

Today I changed the config but the print failed with the 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: 3 of 40 (18 max)
=== RTOS ===
Static ram: 103368
Dynamic ram: 121908 of which 12 recycled
Never used RAM 16460, free system stack 206 words
Tasks: NETWORK(2,nWait 7,14.4%,217) HEAT(3,nWait 6,0.0%,325) 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,83.4%,665) IDLE(0,ready,0.0%,29) AIN(4,delaying,0.8%,264), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:16:28 ago, cause: software
Last software reset at 2024-10-12 09:04, reason: HardFault invState, Gcodes spinning, available RAM 13464, slot 0
Software reset code 0x4063 HFSR 0x40000000 CFSR 0x00020000 ICSR 0x00489803 BFAR 0xe000ed38 SP 0x20012008 Task NETW Freestk 482 ok
Stack: 0000017d 00000002 200014e4 00000000 20032fe9 000a0f9f 00000000 600f0000 00000000 00000000 00000000 00000000 20031e34 00000800 2002c640 2002c640 00000001 2002c496 2001882c 2001ea80 00030523 00000000 00000000 00000000 200120b8 00000014 b5dd500a
Error status: 0x00
MCU revision 3, ADC conversions started 741990, completed 741988, timed out 0, errs 0
MCU temperature: min 29.1, current 31.6, max 31.8
Supply voltage: min 24.0, current 24.1, max 24.1, 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 38, read errors 0, write errors 1, ifcnt 36, reads 24344, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 6, read errors 0, write errors 1, ifcnt 36, reads 24343, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 35, reads 24343, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 32, reads 24343, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 32, reads 24344, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 5: standstill, SG min 0, read errors 0, write errors 1, ifcnt 33, reads 24343, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 6: standstill, SG min 0, read errors 0, write errors 1, ifcnt 32, reads 24343, writes 10, timeouts 0, DMA errors 0, CC errors 0
Date/time: 2024-10-12 09:20:57
Cache data hit count 1872586024
Slowest loop: 7.85ms; fastest: 0.16ms
=== 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 8900, received 0, lost 0, errs 4675536, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 26 (min 26), ts 4945/0/0
Tx timeouts 0,0,4944,0,0,3954 last cancelled message type 4514 dest 127
=== Network ===
Slowest loop: 5.85ms; 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 3.38, flash size 2097152, free heap 42932
WiFi IP address 192.168.1.69
Signal strength -48dBm, channel 7, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0
 
m122p106
Platform 2001d138-2001e737
SbcInterface 2001e740-2001ea70
Network 2001ea80-2001eb67
GCodes 2001eb70-2001ff6f
Move 20023ff8-20024d33
Heat 20025110-20025237
PrintMonitor 20025240-2002544f
FansManager 20025458-200254d7
PortControl 200254e0-2002550f
Display 20025518-20025533
ExpansionManager 20025540-200282f7
 
m122p1007 a{0x2001ea80+8}
2001ea88: 2002c420
 
m122p1007 a{0x2002c420+136}
2002c4a8: 20032e60