Motor phase disconnected problem?

siblues

I had the fault happen again and ran M122 afterwards to see if tht would clear anything up and here are the results

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.02RC2(RTOS) running on Duet WiFi 1.02 or later
Board ID: 08DGM-9T6BU-FG3SN-6JKD6-3S06P-KAYBD
Used output buffers: 3 of 20 (12 max)
=== RTOS ===
Static ram: 28460
Dynamic ram: 98312 of which 0 recycled
Exception stack ram used: 356
Never used ram: 3944
Tasks: NETWORK(ready,328) HEAT(blocked,1232) MAIN(running,3540)
Owned mutexes:
=== Platform ===
Last reset 02:00:41 ago, cause: software
Last software reset at 2019-05-20 22:28, reason: User, spinning module GCodes, available RAM 4016 bytes (slot 0)
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0441f000 BFAR 0xe000ed38 SP 0xffffffff Task 0x4e49414d
Error status: 0
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms, max retries 0
MCU temperature: min 35.3, current 35.9, max 36.7
Supply voltage: min 12.6, current 12.8, max 12.9, under voltage events: 0, over voltage events: 0
Driver 0: standstill, SG min/max 0/73
Driver 1: standstill, SG min/max 0/221
Driver 2: standstill, SG min/max not available
Driver 3: standstill, SG min/max not available
Driver 4: standstill, SG min/max not available
Date/time: 2019-05-21 00:29:29
Slowest loop: 5.22ms; fastest: 0.06ms
=== Move ===
Hiccups: 0, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm: 234, MaxWait: 6955014ms, Underruns: 0, 0
Scheduled moves: 45, completed moves: 45
Bed compensation in use: mesh
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
=== GCodes ===
Segments left: 0
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 idle 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: 22.84ms; fastest: 0.01ms
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 84:f3:eb:42:a9:91
WiFi Vcc 3.45, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 25504
WiFi IP address 192.168.1.6
WiFi signal strength -37dBm, reconnections 0, sleep mode modem
Socket states: 0 0 0 0 0 0 0 0
=== Expansion ===

Veti

update to the latest 2.03 firmware. DC made a fix for that message i think

siblues

I was using 2.03 and he recommended reverting back to 2.02 RC2 and I tried that too with no luck.

elmoret

@dc42 - How do you think we should proceed here?

siblues

Are you asking me?That is what I am trying to figure out.I was hoping DC42 would chime in since he usually has a quick solution or ways of figuring out if the board is damaged.

dc42

@siblues, please can you do the following:

Make sure you are running either 2.02 stable firmware (not a 2.02beta or 2.02RC version), or 2.03RC2.
Next time this problem occurs, please run M906 without parameters and check that it reports the motor currents are as you set them (1200mA). Also run M913 and check they are at 100%.
Do you have anything connected to the expansion connector?
Do the warning messages mention just phase A and just driver 1? Or more drivers and/or both phases?

siblues

6:54:46 PMM906
Motor current (mA) - X:1500, Y:1500, Z:1500, E:1200:1200, idle factor 30%
6:54:34 PMError: motor phase A disconnected on drivers 1

6:57:27 PMM913
Motor current % of normal - X:100, Y:100, Z:100, E100
6:56:51 PMError: motor phase A disconnected on drivers 1

I only have the BLTouch connections on the expansion header on heater 3. The X axis motor and extruder motor aren't and haven't given me the error while the Y axis and z axis both have given me the error but I couldn't reproduce the x motor having the issue at the moment.Here is the current software information

Firmware Name: RepRapFirmware for Duet 2 WiFi/Ethernet
Firmware Electronics: Duet WiFi 1.02 or later
Firmware Version: 2.02RC2(RTOS) (2018-09-07b2)
WiFi Server Version: 1.22
Web Interface Version: 1.22.6
Web Interface by Christian Hammacher
Licensed under the terms of the GPL v3

Veti

so you swapped the wiring. can you swap the motor to make sure its not the motor?

siblues

It is 3 different motors that are all giving me the message but I can swap the motors if that would make it easier to diagnose?

Veti

so far you have only shown the error message about phase A on driver 1.

does it happen with all phases on all drivers?

siblues

I was also getting the error message on the Z axis motors but that error message is random and hasn't happened again.The Y axis does it everytime.

siblues

The motors attempt to move when using DWC but they stutter shaking back and forth. I attempted raising the voltages slightly but it made no difference.

Veti

@siblues said in Motor phase disconnected problem?:

6:54:46 PMM906
Motor current (mA) - X:1500, Y:1500, Z:1500, E:1200:1200, idle factor 30%

M906 X1200 Y1200 Z1200 E1200 I30 ; Set motor currents (mA) and motor idle factor in per cent

this does not match

but you have a M501

so please post your overwrite.

dc42

@siblues said in Motor phase disconnected problem?:

The motors attempt to move when using DWC but they stutter shaking back and forth. I attempted raising the voltages slightly but it made no difference.

Common reasons for this:

Motors not phased correctly. This is serious as it can cause the drivers to be damaged. So check that the motor phases are connected correctly first.
Bad crimp connection in the motor wires, so that only one phase is being energised.
Speed and/or acceleration set too high, bearing in mind the steps/mm (higher steps/mm => lower accelerations and speeds possible).
Weak PSU, so that the voltage drops below 10V when the motors draw current.
Blown stepper driver.
Blown motor.

siblues

@veti Here is the override and the current was changed to 1500 to test it is set at 1200 usually.

@dc42 The motors have been working just fine for a while with that original harness and the harness has since been replaced.The printer has a genuine Meanwell 450watt 12v psu and it only fluctuates .02 volts.Here are the current motor settings for what I have set for speed.

; Drives
M569 P0 S0 ; Drive 0 goes forwards reversed
M569 P1 S1 ; Drive 1 goes forwards
M569 P2 S0 ; Drive 2 goes forwards reversed
M569 P3 S1 ; Drive 3 goes forwards
M350 X16 Y16 Z16 E16 I1 ; Configure microstepping with interpolation
M92 X80 Y80 Z400 E415 ; Set steps per mm
M566 X900 Y900 Z12 E1200 ; Set maximum instantaneous speed changes (mm/min)
M203 X6000 Y6000 Z180 E1200 ; Set maximum speeds (mm/min)
M201 X500 Y250 Z250 E2500 ; Set accelerations (mm/s^2)
M906 X1200 Y1200 Z1200 E1200 I30 ; Set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

I can check the motor but how would I check for a blown driver and what would cause that to happen all of a sudden?

T3P3Tony

@siblues you can check to see if it's a driver by swapping the motors plugged into a working axis with the not working one. Drivers can get blown when wiring develops intermittent faults in a single phase.

siblues

I had some motors on the way so I tried what Tony mentioned and it was a bad motor.