Motor phase disconnected problem?

siblues

I just finished rewiring my machine and it has been printing fine for a day or two and it started displaying this message

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

This is my config file

; Configuration file for Duet WiFi (firmware version 1.21)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool on Mon Nov 05 2018 12:42:23 GMT-0500 (Eastern Standard Time)

; General preferences
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves

; Network
; Set machine name
; Set password
M552 S1 ; Enable network
;*** Access point is configured manually via M587
M586 P0 S1 ; Enable HTTP
M586 P1 S0 ; Disable FTP
M586 P2 S0 ; Disable Telnet

; 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

; Axis Limits
M208 X-25 Y0 Z0 S1 ; Set axis minima
M208 X220 Y320 Z200 S0 ; Set axis maxima

; Endstops
M574 Y1 S0 ; Set active low endstops
M574 X1 S1 ; Set active high endstops
M574 Z1 S2 ; Use zprobe for zmin

; Z-Probe
M307 H3 A-1 C-1 D-1 ; Disable heater on PWM channel for BLTouch
M558 P9 H3 F200 T6000 ; Set Z probe type to bltouch and the dive height + speeds
G31 P25 X24 Y0 Z3.385 ; Set Z probe trigger value, offset and trigger height
M557 X25:200 Y30:300 S40 ; Define mesh grid

; Heaters
M307 H0 B0 S1.00 ; Disable bang-bang mode for the bed heater and set PWM limit
M305 P0 T100000 B3950 C0 R4700 ; Set thermistor + ADC parameters for heater 0
M143 H0 S110 ; Set temperature limit for heater 0 to 120C
M305 P1 T100000 B4725 C7.06e-8 ; Set thermistor + ADC parameters for heater 1
M143 H1 S290 ; Set temperature limit for heater 1 to 290C

; Fans
M106 P0 S0.3 I0 F500 H-1 ; Set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned off
M106 P1 S1 I0 F500 H0:1 T45 ; Set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned on
M106 P2 S1 I0 F500 H0:1 T45 ; Set fan 2 value, PWM signal inversion and frequency. Thermostatic control is turned on

; Tools
M563 P0 D0 H1 ; Define tool 0
G10 P0 X0 Y0 Z0 ; Set tool 0 axis offsets
G10 P0 R0 S0 ; Set initial tool 0 active and standby temperatures to 0C

M501 ; Override

; Automatic saving after power loss is not enabled

; Custom settings are not configured

This is the software information

Firmware Name: RepRapFirmware for Duet 2 WiFi/Ethernet
Firmware Electronics: Duet WiFi 1.02 or later
Firmware Version: 2.03beta2 (2019-02-16b1)
WiFi Server Version: 1.22
Web Interface Version: 1.22.5

siblues

The wiring and connectors seem fine and the connectors are firmly seated onto the board.

siblues

I rewired the motor and endstop with a new harness to make sure it wasn't a wire that may have gotten loose or a terminal that wasn't crimped tightly but no luck with the new harness.

siblues

I contacted Filastruder to see if this is a warranty repair or if I need to pay for the repair myself.I really would like to know what is going on.I can't seem to find much information on what may be causing this.

I hve also tried this version of firmware with no change

2.02RC2(RTOS) (2018-09-07b2)

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.