Printer resetting mid print



  • Hi,
    lately my printer is just resetting mid print. I'm driving a Duet Wifi with an E3D Chimera with the latest stable firmware. The reset is mostly happening after a while and never at the beginning. It's happening with Cura and Prusaslicer generated gcode files and with different STL's. I also tried a different SD card with no effect.

    Here's the M122 output directly after a reset:

    M122
    === Diagnostics ===
    RepRapFirmware for Duet 2 WiFi/Ethernet version 2.04 running on Duet WiFi 1.02 or later
    Board ID: 08DGM-956GU-DJMSJ-6J9FJ-3SD6N-KTPZG
    Used output buffers: 3 of 24 (13 max)
    === RTOS ===
    Static ram: 25680
    Dynamic ram: 93080 of which 0 recycled
    Exception stack ram used: 268
    Never used ram: 12044
    Tasks: NETWORK(ready,764) HEAT(blocked,1232) MAIN(running,3768) IDLE(ready,200)
    Owned mutexes:
    === Platform ===
    Last reset 00:00:23 ago, cause: power up
    Last software reset at 2019-12-10 00:27, reason: User, spinning module GCodes, available RAM 11924 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 38.6, current 39.8, max 40.1
    Supply voltage: min 24.4, current 24.5, max 24.7, under voltage events: 0, over voltage events: 0, power good: yes
    Driver 0: standstill, SG min/max not available
    Driver 1: standstill, SG min/max not available
    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: 2019-12-10 01:47:47
    Cache data hit count 73739878
    Slowest loop: 2.08ms; fastest: 0.06ms
    I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
    === Move ===
    Hiccups: 0, FreeDm: 160, MinFreeDm: 160, MaxWait: 0ms
    Bed compensation in use: none, comp offset 0.000
    === DDARing ===
    Scheduled moves: 0, completed moves: 0, StepErrors: 0, LaErrors: 0, Underruns: 0, 0
    === 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: 15.79ms; 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 1.23
    WiFi MAC address 5c:cf:7f:76:64:03
    WiFi Vcc 3.33, reset reason Turned on by main processor
    WiFi flash size 4194304, free heap 25464
    WiFi IP address 192.168.175.48
    WiFi signal strength -48dBm, reconnections 0, sleep mode modem
    Socket states: 0 0 0 0 0 0 0 0
    

    Let me know if you need any more information. Thanks in advance,

    Christian



  • Can you include your config.g and a description of the printer hardware?



  • @Phaedrux said in Printer resetting mid print:

    Can you include your config.g and a description of the printer hardware?

    Sure.
    Here's my config.g:

    ; Configuration file for Duet WiFi (firmware version 2.03)
    ; executed by the firmware on start-up
    ;
    ; generated by RepRapFirmware Configuration Tool v2.1.3 on Thu Dec 05 2019 12:55:57 GMT+0100 (Mitteleuropäische Normalzeit)
    
    ; General preferences
    G90                                             ; send absolute coordinates...
    M83                                             ; ...but relative extruder moves
    M550 P"CW7_MK II"                                 ; set printer name
    
    ; Network
    M552 S1                                         ; enable network
    M586 P0 S1                                      ; enable HTTP
    M586 P1 S0                                      ; disable FTP
    M586 P2 S0                                      ; disable Telnet
    
    ; Drives
    M569 P0 S1                                      ; physical drive 0 goes forwards
    M569 P1 S0                                      ; physical drive 1 goes backwards
    M569 P2 S0                                      ; physical drive 2 goes backwards
    M569 P3 S0                                      ; physical drive 3 goes forwards
    M569 P4 S0                                      ; physical drive 4 goes backwards
    M584 X0 Y1 Z2 E3:4                              ; set drive mapping
    M350 X16 Y16 Z16 E16:16 I1                      ; configure microstepping with interpolation
    M92 X100.00 Y100.00 Z400.00 E470.60:474.63      ; Set steps per mm
    M566 X800.00 Y800.00 Z12.00 E100.00:100.00      ; set maximum instantaneous speed changes (mm/min)
    M203 X6000.00 Y6000.00 Z180.00 E1200.00:1200.00 ; set maximum speeds (mm/min)
    M201 X500.00 Y500.00 Z20.00 E250.00:250.00      ; set accelerations (mm/s^2)
    M906 X700 Y700 Z700 E700:700 I30                ; set motor currents (mA) and motor idle factor in per cent
    M84 S30                                         ; Set idle timeout
    
    ; Axis Limits
    M208 X-31 Y-7 Z0 S1                             ; set axis minima
    M208 X220 Y220 Z220 S0                          ; set axis maxima
    
    ; Endstops
    M574 Z1 S0                                      ; set active low and disabled endstops
    M574 X1 Y1 S3                                   ; set endstops controlled by motor stall detection
    
    ; Z-Probe
    M558 P5 H5 F120 T6000                           ; set Z probe type to switch and the dive height + speeds
    G31 P500 X0 Y0 Z0                               ; set Z probe trigger value, offset and trigger height
    M557 X15:195 Y15:195 S20                        ; define mesh grid
    
    ; Heaters
    M307 H0 B0 S0.60                                ; disable bang-bang mode for the bed heater and set PWM limit
    M305 P0 T100000 B4138 R4700                     ; set thermistor + ADC parameters for heater 0
    M143 H0 S130                                    ; set temperature limit for heater 0 to 130C
    M301 H1 S0.60                                   ; set heater 1 PWM limit to 60%
    M305 P1 T100000 B4138 R4700                     ; set thermistor + ADC parameters for heater 1
    M143 H1 S285                                    ; set temperature limit for heater 1 to 285C
    M301 H2 S0.60                                   ; set heater 2 PWM limit to 60%
    M305 P2 T100000 B4138 R4700                     ; set thermistor + ADC parameters for heater 2
    M143 H2 S285                                    ; set temperature limit for heater 2 to 285C
    
    ; Fans
    M106 P0 S0 I0 F250 H-1                          ; set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned off
    M106 P1 S0.5 I0 F250 H1:2 T45                    ; set fan 1 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
    M563 P1 D1 H2                                   ; Define tool 1
    G10 P1 X20 Y0 Z0                                ; Set tool 1 axis offsets
    G10 P1 R0 S0                                    ; Set initial tool 1 active and standby temperatures to 0C
    
    ; Custom settings
    M501
    M915 Y H400					; stall config for Y
    M915 X H400					; stall config for X
    M671 X30:30:150:150 Y30:150:150:30 P0.5 	; Bed leveling Points (X0/Y0, X0/Y190, X175/Y190, X175/Y0)
    M581 X T2 C0 S0					; Configure trigger
    

    The printer itself is pretty much custom build. It origins from an Anet A8 but there are pretty much only the stepper motors and the z spindles left. It's running on 24V, powered by a Meanwell 320W power supply.
    The E3D Chimera is set up with 24V 40W heating cartridges and 100k NTC thermistors and the heated bed is an Anycubic Ultrabase.
    alt text

    Let me know if I missed anything.

    Christian



  • The only thing that occurs to me is that the MCU temps reported by the M122 and then seeing that the printer may be in an enclosure?

    Have you gone through this process to calibrate the MCU temp sensor?

    https://duet3d.dozuki.com/Wiki/Calibrating_the_CPU_temperature

    Is there any active cooling on the board?



  • @Phaedrux said in Printer resetting mid print:

    The only thing that occurs to me is that the MCU temps reported by the M122 and then seeing that the printer may be in an enclosure?

    Have you gone through this process to calibrate the MCU temp sensor?

    https://duet3d.dozuki.com/Wiki/Calibrating_the_CPU_temperature

    Is there any active cooling on the board?

    There are actually two fans. You can barely see them on the picture. One going directly onto the board, and one exhaust fan above.
    alt text
    Usually the temperature in the enclosure doesn't exceed 30°C, even with the heated bed set to 100°C. As far as I can tell the MCU temperature is at around 40°C when printing. The last two prints failed at around 45 minutes.
    I'll try to calibrate the MCU temperature sensor tomorrow and report back.

    Thanks for your help so far.

    Christian



  • The reported last reset in the M122 is power up. Which I think would indicate a powerloss. Is the PSU also in the enclosure? Could it be failing?



  • @Phaedrux said in Printer resetting mid print:

    The reported last reset in the M122 is power up. Which I think would indicate a powerloss. Is the PSU also in the enclosure? Could it be failing?

    Yeah, the PSU is mounted to the printer. It's a Meanwell RSP-320 with a fan so I'm not sure if that can fail.



  • @Phaedrux I just remembered I had some issues when I initially set up the Duet. It would restart if I set the PWM limit for the heaters too high. So my guess would be that something draws too much power and when the PSU gets a little warm it just cuts off. Do you think that'd be a possibility?
    This is my heater configuration

    Christian



  • What is the wattage of the heated bed? Are you sure it's a 24V heater?

    The greatest draw would be during the warm up phase. Once it's at temp it doesn't take as much power to keep it warm, especially since you have it in an enclosure.



  • @Phaedrux it should draw 140-145 watts. Here's the data sheet:
    Heat Bed Power: 140-145W
    Heat bed Specification:
    (1)Material: Aluminum base
    (2)Voltage: 12V/24V
    (3)Max Temperature: 120 Degree Celsius
    (4)Dimensions: 220mm x 220mm
    (5)Thickness: heat bed 1.5mm
    (6)Resistance around 0.9ohm for 12V
    (7)Resistance around 3.6ohm for 24V
    (8)100 Degree Celsius supported for both 12V and 24V


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