SD-card troubles 6XD

[lazy_mosquito]

@droftarts and @Phaedrux as you suggested I started a new thread. Finally found some time to check out the SD-card reader on my 6xd.

Problem: Often (10% of the time?) when I stop my delta printer with the emergency stop in the web interface or with the STOP-button in PanelDue my config-file gets deleted and my delta is not starting up anymore. I have the idea (couldn't check it yet) that the panelDue STOP-button is more destructive. the web interface only deletes sometime the config-file, but I can just put it back and everything works again. This happened rather regularly because I am in the phase of finetuning my servos and very often have to shut down the machine with the emergency stop. I used two weeks ago for the first time the STOP-button in the PanelDue interface and this time not only the config-file disappeared but also the filesystem or the partitioning got messed up. i got it back in windows 11 via diskmanagement. I just got the filesystem corrected again, so i hope i can get this behavior reproduced.

Bought January 9, 2024 at 123-3d(dot)nl

As requested I connected via Yat to my board and run M115, M122, M22 and M21.
Please find the output in attachment Yat SD Card.txt
But you will find in this output that the SD-card is found and recognized.
But if I check the panelDue and click on the SD-card it says no files found. (does it show the files on the SD-card or only the one in the panelDue slot SD-card, which is not used by me)
It also doesn't start up the web interface, and this has almost to be for sure because it doesn't have access to the config file: no ip-adres, no homing option,...)
When I take out the SD-card, the structure of the SD-card seems altered. I made one partition as told in the manual. I named the SD-card/partition "Delta".
IN windows 7 (my atelier PC used for uploading files to my printer and where I created the partition originally) the Delta partition is not accessible anymore in explorer and the name is gone. There is also a new partition (made by duet3D?) called boot and here I find a similar file structure but in this file structure the config file is missing. If I go to disk management I can see now two partitions and an unallocated space of 9,7 GB
At home I have a windows 11 pc and there I can see both partitions and both are accessible.
So, it seems to me that duet is somehow altering the file structure of the SD-card and makes it unreadable in the process. I suspect it is booting from the boot partition but it can't find the config-file.
In attachment some screenshots of the content of the 2 sys-directories in the boot and the original partition (Delta). In the boot partition the configfile is missing.
further some photos of the soldering of the SD-card holder. They look ok.

content of sys-map in new boot partition

content of sys-map in original partition (Delta)

Empty SD card according the panel Due

Diskmanagement windows 7

Diskmanagement windows 11

soldering 1

soldering 2

soldering 3

soldering 4

my printer

Lots of information. Shoot if you have questions.

[droftarts]

@lazy_mosquito Duets used to be supplied (up until RRF 3.5 was released) with an SD card that was ready for SBC. It was partitioned into a FAT32 'BOOT' volume, and a second Linux ext4 (or ext3, not sure) formatted volume that Windows generally couldn't read. When used in standalone, RRF would use the BOOT volume, because it can only read FAT32 partitions. It can't create or format partitions either, only read and write files. If you were going to use the SD card in a standalone system, our advice was to format the SD card as a single volume.

SD cards are now supplied as a single volume, because users were running out of space on the BOOT volume, and setting up the SD card for SBC now involves flashing the SBC image to the SD card.

What I think has happened is that, rather than erasing the whole SD card, you replaced the Linux volume with a FAT32 volume. Normally, this shouldn't be a problem; RRF should only see the first FAT32 volume on an SD card. However, it's possible the SD card volume map is a bit screwed up, and it keeps changing which volume is the first and/or mounted volume. Really not sure!

I think the best thing to do is to backup all relevant files and folders from the SD card, and erase it with the SD card formatting tool, creating a single FAT32 volume. See https://docs.duet3d.com/en/User_manual/RepRapFirmware/SD_card#formatting
Then copy back the files to the SD card. I don't think this is a hardware issue with the 6XD, but lets get the SD card 'right', and see if that improves matters.

Ian

[lazy_mosquito]

@droftarts I am also thinking it is something "soft" related. your explanation makes sense because on the pc I am using in my atelier I couldn't see the linux partition, so I was under the impression that only one partition existed. It is only when I opened the SD-card with the diskmanagement tool on my other pc that I saw the second partition and probably changed something, so it stayed visible for the windows 7 installation on the atelier PC. I will do a complete repartitioning and try again and come back after testing.
Thanks

[lazy_mosquito]

@droftarts Thanks. For now , it looks solved. I did a format with the SD_Card format tool. Checked: only one partition, put the files back and now it starts up again and find it's configfile. I will do the next days intensif testing with the stop and emergency stop and see if the problem still exists. But for now it looks the double partition was the culprit.