motor phase A may be disconnected reported by driver(s) 0 1 2

fredvm · 24 Apr 2019, 12:23

Hi!

I keep on getting this warning during calibration & print:

Warning: motor phase A may be disconnected reported by driver(s) 0 1 2

I have been printing for a long time without any issues and this came out of nowhere.
I notice my prints have been shifting too. After reading up on the forum I'm thinking that my stepper driver is faulty.

M122 returns:

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.03beta3 running on Duet WiFi 1.02 or later
Board ID: 08DGM-95BNL-MGPSN-6JKDJ-3SD6T-1LXVW
Used output buffers: 3 of 20 (11 max)
=== RTOS ===
Static ram: 25632
Dynamic ram: 93260 of which 396 recycled
Exception stack ram used: 500
Never used ram: 11284
Tasks: NETWORK(ready,652) HEAT(blocked,1236) MAIN(running,356) IDLE(ready,196)
Owned mutexes:
=== Platform ===
Last reset 00:55:28 ago, cause: power up
Last software reset at 2019-04-23 16:56, reason: User, spinning module GCodes, available RAM 11304 bytes (slot 0)
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0441f000 BFAR 0xe000ed38 SP 0xffffffff Task 0x4e49414d
Error status: 16
Free file entries: 9
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 339.8ms, max retries 0
MCU temperature: min 27.2, current 40.4, max 40.5
Supply voltage: min 11.8, current 12.1, max 12.3, under voltage events: 0, over voltage events: 0, power good: yes
Driver 0: ok, SG min/max 0/607
Driver 1: ok, SG min/max 0/560
Driver 2: ok, SG min/max 0/598
Driver 3: ok, SG min/max 0/1023
Driver 4: standstill, SG min/max not available
Date/time: 2019-04-24 14:21:13
Cache data hit count 4294967295
Slowest loop: 53.05ms; fastest: 0.07ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0
=== Move ===
Hiccups: 56, FreeDm: 161, MinFreeDm: 116, MaxWait: 903214ms
Bed compensation in use: none
Bed probe heights: 0.213 0.010 0.226 -0.125 0.277
=== MainDDARing ===
Scheduled moves: 37707, completed moves: 37686, StepErrors: 0, LaErrors: 0, Underruns: 0, 0
=== AuxDDARing ===
Scheduled moves: 0, completed moves: 0, StepErrors: 0, LaErrors: 0, Underruns: 0, 0
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.0
Heater 1 is on, I-accum = 0.5
=== GCodes ===
Segments left: 1, aux move: no
Stack records: 2 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is doing "G1 X3.325 Y5.336 E0.0371" in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Slowest loop: 341.35ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8

WiFi -
Network state is running
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.22
WiFi MAC address a0:20:a6:2f:96:b4
WiFi Vcc 3.34, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 26928
WiFi IP address 192.168.0.108
WiFi signal strength -75dBm, reconnections 0, sleep mode modem
Socket states: 0 0 0 0 0 0 0 0

M913

M913
Motor current % of normal - X:100, Y:100, Z:100, E100

M906

M906
Motor current (mA) - X:1000, Y:1000, Z:1000, E:1200:1200, idle factor 60%

Can anyone please help me out or confirm the problem?

Thank you!

Veti · 24 Apr 2019, 12:26

check for bad crimps on the stepper cables using a multimeter.

dc42 · 24 Apr 2019, 13:14

Have you changed the motor driver stealthChop settings recently? What M569 commands do you have in config.g?

Veti · 24 Apr 2019, 13:23

it does not look like a duet maestro. so no stealthchop.

fredvm · 24 Apr 2019, 13:26

Thank you for your swift response!

this is what i got:

; Axis and motor configuration
M569 P0 S1 ; Drive 0 goes forwards
M569 P1 S1 ; Drive 1 goes forwards
M569 P2 S1 ; Drive 2 goes forwards
M569 P3 S1 ; Drive 3 goes forwards
M569 P4 S0 ; Drive 4 goes forwards

I didn't change any drivers. Didn't do anything really. I've printed 50+ hours in this configuration and it popped up out of nowhere seemingly. I did do an update after the problem first started occuring.

Yes, it's not a Duet Meastro. It's a Duet 2 Wifi ( sorry forgot to mention that ).

I'll check for the crimping on the connectors.

dc42 · 24 Apr 2019, 14:36

It's odd that you are getting that error on 3 separate drivers. Is it always phase A? What is the motor specification?

fredvm · 24 Apr 2019, 17:00

The x y z motors are KL17h248-15-4A

Specifications:
Shaft: 5mm diameter with flat
Current Per Phase: 1.5A
Holding Torque: 5.5Kg.cm (76 oz-in)
Rated Voltage: 4.2V
NO.of Phase: 2
Step Angle: 1.8° ± 5%
Resistance Per Phase: 2.8Ω± 10%
Inductance Per Phase: 4.8mH± 20%
Insulation Class: Class B
Dielectric Strength: 100Mohm
Operation Temp Range: -20 ~ +40° C
Lead Wire: 22AWG / 750mm with connector to stepper motor driver

The extruder motor is 42bygh4413ag5.18-x

http://www.promoco-motors.com/products/StepperMotors/42BYGH Planetary Gearmotor Series.pdf

Thank for your assistance.

fredvm · 24 Apr 2019, 17:03

I'm running some test calibrations and it's not only phase A

G32
Warning: motor phase A may be disconnected reported by driver(s) 0 1
Warning: motor phase B may be disconnected reported by driver(s) 0 1

dc42 · 25 Apr 2019, 20:37

Do the warnings appear only when you run the motors at high speeds? What are your axis steps/mm?

fredvm · 26 Apr 2019, 12:12

No, i don't think so. I'm running at an avereage speed of 45 mm/s.

M92 X80 Y80 Z80 ; Set axis steps/mm

i'll put my full config.g below:

; Configuration file for SeeMeCNC Rostock MAX V3

; Communication and general
M111 S0 ; Debug off
M550 PSeeMeCNCRostockMAXV3 ; Machine name and Netbios name (can be anything you like)
M551 Retteket3t ; Machine password (used for FTP)
;*** If you have more than one Duet on your network, they must all have different MAC addresses, so change the last digits
M540 P0xBE:0xEF:0xDE:0xAD:0xFE:0xEA ; MAC Address
;*** Wifi Networking
M552 S1 ; Enable WiFi

M555 P2 ; Set output to look like Marlin
M575 P1 B57600 S1 ; Comms parameters for PanelDue

G21 ; Work in millimeters
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves

; Axis and motor configuration
M569 P0 S1 ; Drive 0 gaxioes forwards
M569 P1 S1 ; Drive 1 goes forwards
M569 P2 S1 ; Drive 2 goes forwards
M569 P3 S1 ; Drive 3 goes forwards
M569 P4 S0 ; Drive 4 goes forwards
M574 X2 Y2 Z2 S1 ; set endstop configuration (all endstops at high end, active high)
;*** The homed height is deliberately set too high in the following - you will adjust it during calibration
M665 R144.158 L291.06 B120 H392.701 X0 Y0 Z0 ; set delta radius, diagonal rod length, printable radius and homed height
M666 X0 Y0 Z0 ; put your endstop adjustments here, or let auto calibration find them
M350 X16 Y16 E16 I1 ; Set 16x microstepping with interpolation
M92 X80 Y80 Z80 ; Set axis steps/mm
M906 X1000 Y1000 Z1000 E1200 I60 ; Set motor currents (mA) and increase idle current to 60%
M201 X1000 Y1000 Z1000 E1000 ; Accelerations (mm/s^2)
M203 X20000 Y20000 Z20000 E3600 ; Maximum speeds (mm/min)
M566 X1200 Y1200 Z1200 E1200 ; Maximum instant speed changes mm/minute

; Thermistors
M305 P0 T100000 B3950 R4700 H30 L0 ; Put your own H and/or L values here to set the bed thermistor ADC correction
M305 P1 T100000 B3974 R4700 H30 L0 ; Put your own H and/or L values here to set the first nozzle thermistor ADC correction
;M305 P2 T100000 B3974 R4700 H30 L0 ; Put your own H and/or L values here to set the second nozzle thermistor ADC correction
M570 S180 ; Hot end may be a little slow to heat up so allow it 180 seconds

; Fans
M106 P1 H-1 ; disable thermostatic mode for fan 1

; Tool definitions
M563 P0 D0 H1 ; Define tool 0
G10 P0 S0 R0 ; Set tool 0 operating and standby temperatures
;*** If you have a single-nozzle build, comment the next 2 lines
;M563 P1 D1 H2 ; Define tool 1
;G10 P1 S0 R0 ; Set tool 1 operating and standby temperatures
M92 E450:450 ; Set extruder steps per mm

; Z probe and compensation definition
M558 P5 X0 Y0 Z1 H5 F1200 T2400

; grid compensation
M557 R110 S15

G31 X0 Y0 Z-0,5 P500 ; Set the zprobe offset and threshold (determine your printer's Z offset value). For a delta, use zero X and Y offset.

;*** If you are using axis compensation, put the figures in the following command
M556 S78 X0 Y0 Z0 ; Axis compensation here

M501;

T0 ; select first hot end

Phaedrux · 27 Apr 2019, 01:39

@fredvm said in motor phase A may be disconnected reported by driver(s) 0 1 2:

M350 X16 Y16 E16 I1 ; Set 16x microstepping with interpolation
M92 X80 Y80 Z80 ; Set axis steps/mm

Your M350 is missing a value for Z and your M92 is missing a value for E

fredvm · 27 Apr 2019, 06:03

@fredvm said in motor phase A may be disconnected reported by driver(s) 0 1 2:

M350

wow, thanks for noticing that!
I'll add the right values and see what happens.

fredvm · 27 Apr 2019, 07:04

Nope, still got the warning:

G32

Warning: motor phase A may be disconnected reported by driver(s) 0 1
Warning: motor phase B may be disconnected reported by driver(s) 0 1

wilriker · 27 Apr 2019, 08:46

@phaedrux said in motor phase A may be disconnected reported by driver(s) 0 1 2:

@fredvm said in motor phase A may be disconnected reported by driver(s) 0 1 2:

M350 X16 Y16 E16 I1 ; Set 16x microstepping with interpolation
M92 X80 Y80 Z80 ; Set axis steps/mm

Your M350 is missing a value for Z and your M92 is missing a value for E

Just for the sake of completeness: default value for M350 is 16x interpolated (all axes) and default for M92 Ennn is 420 (X, Y=80 and Z=4000).

Veti · 27 Apr 2019, 09:33

@wilriker said in motor phase A may be disconnected reported by driver(s) 0 1 2:

default for M92 Ennn is 420 (X, Y=80 and Z=4000).

not 400?

wilriker · 27 Apr 2019, 18:13

@veti said in motor phase A may be disconnected reported by driver(s) 0 1 2:

not 400?

Here's the responsible part of Configuration.h

constexpr float DefaultXYDriveStepsPerUnit = 80.0;		// steps/mm
constexpr float DefaultZDriveStepsPerUnit = 4000.0;
constexpr float DefaultEDriveStepsPerUnit = 420.0;

Veti · 27 Apr 2019, 18:18

@wilriker said in motor phase A may be disconnected reported by driver(s) 0 1 2:

Here's the responsible part of Configuration.h

i would say that might be an oversight. 400 is way more common than 4000. I dont even know how you would get that.

wilriker · 28 Apr 2019, 07:21

@veti said in motor phase A may be disconnected reported by driver(s) 0 1 2:

i would say that might be an oversight. 400 is way more common than 4000. I dont even know how you would get that.

M5 threaded rod with a lead of 0.8mm. I think this was the default in Mendel printers - and Adrian Bowyer the original author of RRF is also the creator of that printer. I guess that setting stuck since.

Phaedrux · 28 Apr 2019, 20:32

@wilriker Having used a printer with 0.8mm M5 threaded rod I can say that it actually worked quite well. So long as the rods were straight and the threads of the rod and nuts held out. Proper lubrication was a must. Those things would get hot during a long Z axis move.

dc42 · 14 May 2019, 08:12

I have moved a number of posts from this thread to topic "Duet sometimes really slow? - I2C error or?".