Failed to initialise WiFi module

CreateAndCarveCNC

Hello,

I am really stumped with how to proceed from here, my machine has been running perfectly until a few days ago when it throughout the day it kept dropping out and then right at the end of the day it completely stopped connecting. Here are some messages that are coming up...

M115
FIRMWARE_NAME: RepRapFirmware for Duet 2 WiFi/Ethernet FIRMWARE_VERSION: 3.3 ELECTRONICS: Duet WiFi 1.02 or later FIRMWARE_DATE: 2021-06-15 21:45:03<LF>ok<LF>

M552 S0
ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>

M552
WiFi module is disabled<LF>ok<LF>

M587 S"TP-Link_D0FA" P"96505182":
Error: M587: Failed to add SSID to remembered list: WiFi module is disabled

M588 S"*"
Error: M588: Failed to reset the WiFi module to factory settings: WiFi module is disabled

Is anyone able to help at all please?

jay_s_uk

@CreateAndCarveCNC reflash the WiFi firmware using M997 S1

CreateAndCarveCNC

@jay_s_uk Thank you for replying. I have given this ago and it comes up with this

M997 S1
Trying to connect at 230400 baud: success<LF>Erasing 4096 bytes...<LF>Erasing 196608 bytes...<LF>Uploading file...<LF>5% complete<LF>10% complete<LF>15% complete<LF>20% complete<LF>25% complete<LF>30% complete<LF>35% complete<LF>40% complete<LF>45% complete<LF>50% complete<LF>55% complete<LF>60% complete<LF>65% complete<LF>70% complete<LF>75% complete<LF>80% complete<LF>85% complete<LF>90% complete<LF>95% complete<LF>Upload successful<LF>ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>

dc42

@CreateAndCarveCNC please reconfigure your terminal emulator to recognise <LF> alone as a line terminator, to make the output easier to read.

M552 S0
ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>

Which version of WiFi firmware were you trying to install? Your main board firmware version is old (3.3) and the version of WiFi firmware that you are trying to install may be too recent for it.

CreateAndCarveCNC

@dc42 Thank you for getting back to me. I haven't changed anything just tried to reconnect it again so it did used to work.

Please can I have the instructions on how to get this information for you to check?

Many thanks

Phaedrux

Can you try and configure it to work in access point mode? This will have the Duet create a wifi network that you then connect to. This will help determine if the module is having the problem or something else.

https://docs.duet3d.com/User_manual/Reference/Gcodes#m589-configure-access-point-parameters

dc42

@CreateAndCarveCNC said in Failed to initialise WiFi module:

Please can I have the instructions on how to get this information for you to check?

There isn't an easy way to check what version a particular WiFi file is; but you could compare the exact size of the DuetWiFiServer.bin file on your SD card with the size of the same file in the RRF 3.3 release at https://github.com/Duet3D/RepRapFirmware/releases/tag/3.3.

CreateAndCarveCNC

@dc42 this is the one on the SD card DuetWiFiServer.bin 255 KB Jun 16, 2021

CreateAndCarveCNC

@Phaedrux Unfortunately this hasn't worked, it is still showing the same message

Error: M589: Failed to retrieve own SSID data: WiFi module is disabled<LF>ok<LF>

ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>

Error: M589: Failed to configure access point parameters: WiFi module is disabled<LF>ok<LF>

Phaedrux

Is this a new board, or one that worked previously?
When and where did you purchase it?

CreateAndCarveCNC

@Phaedrux I purchased back in December last year with my CNC machine from Ooznest.
Yeah, It has been working perfectly fine for all this time, with almost daily use, up until the end of last week

Phaedrux

Can you also send the following commands via usb terminal and report what they return?

M552 S-1
M552 S0
M588 S"*"
M552 S1
M997 S1

CreateAndCarveCNC

@Phaedrux

M552 S-1
ok<LF>
M552 S0
ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>
M588 S"*"
Error: M588: Failed to reset the WiFi module to factory settings: WiFi module is disabled<LF>ok<LF>
M552 S1
ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>
M997 S1
Trying to connect at 230400 baud: success<LF>Erasing 4096 bytes...<LF>Erasing 196608 bytes...<LF>Uploading file...<LF>5% complete<LF>10% complete<LF>15% complete<LF>20% complete<LF>25% complete<LF>30% complete<LF>35% complete<LF>40% complete<LF>45% complete<LF>50% complete<LF>55% complete<LF>60% complete<LF>65% complete<LF>70% complete<LF>75% complete<LF>80% complete<LF>85% complete<LF>90% complete<LF>95% complete<LF>Upload successful<LF>ok<LF>WiFi module started<LF>Error: Failed to initialise WiFi module: bad reply format version<LF>

jay_s_uk

@CreateAndCarveCNC looks like your wifi module has died to me

CreateAndCarveCNC

@jay_s_uk Do you think it is unsalvageable?

jay_s_uk

@CreateAndCarveCNC I would guess it will need the wifi module changing. It may be possible with a soldering iron. I usually do it with a hotair station

CreateAndCarveCNC

@jay_s_uk ok, thank you.

Would you say that would solve the problem or would I need a new one all together?

jay_s_uk

@CreateAndCarveCNC i would say that will probably solve the problem, or at least its a good place to start

CreateAndCarveCNC

@jay_s_uk ok thank you, can you suggest the best place to purchase from please?

jay_s_uk

@CreateAndCarveCNC which version of the Duet 2 do you have? The older ones have an ESP-12S. When I replaced them, I went for an ESP-07S so I could use an external aerial