Duet Wifi Hangs up after booting about 1 out of 5 times

dc42

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

Hopefully some simple fix to get v3 working.

Quite a lot of changes to config are needed when changing from RRF2 to RRF3. If your machine has no unusual features, It is simplest to use the online configurator to generate new files. Otherwise, see https://duet3d.dozuki.com/Wiki/RepRapFirmware_3_overview#Section_Summary_of_what_you_need_to_do_to_convert_your_configuration_and_other_files.

gta18

So I have got the v3 running successfully but still suffering from the random bootup hanging up as before in any version. Is there anything wrong with my config?

Everything works now except random bootup issues.

Were u able to see any problems with the m122 report I posted?
Thanks

@dc42 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

Hopefully some simple fix to get v3 working.

Quite a lot of changes to config are needed when changing from RRF2 to RRF3. If your machine has no unusual features, It is simplest to use the online configurator to generate new files. Otherwise, see https://duet3d.dozuki.com/Wiki/RepRapFirmware_3_overview#Section_Summary_of_what_you_need_to_do_to_convert_your_configuration_and_other_files.

Phaedrux

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

except random bootup issues.

I would check things like the power supply and the SD card. As in, perhaps you have flaky PSU, or the SD card is dying.

gta18

@Phaedrux I have used 3 sd cards and all have failures.

Ill check power supply make sure my input voltage is stable at 24v during startup.

gta18

I checked power supply during bootup and its rock solid at 24.13 to 24.15v all the way according to my Fluke 789.

Still experiencing bootup hang ups.

droftarts

@gta18 After reading through this thread, it seems likely this is a hardware issue. To confirm, the main issue is now that the board fails to boot reliably every time? The problem of external comms stopping has been solved with firmware updates? Also, how is the board mounted? Is there any possibility of short circuiting the board to it's mounting location (metal enclosure/loose wiring)? Is the board clean, ie no metal filings that could cause shorts on the board (I'd give it a vacuum clean with a soft brush to make sure)? I couldn't see any obvious problems in the M122 reports you posted.

Assuming the above is all fine, I'd guess there is a floating (ie unsoldered or poorly soldered) pin or faulty component somewhere on the board, and could be almost anything connected to the processor. Can you post clear pictures of top and bottom of the board, and particular around this area?

Did any of the M111 reports happen during a freeze? Actually, I'd set M111 S1 to capture all debug info (P3 is just the webserver), though don't leave this on all the time as it can affect printing because of the volume of data sent to USB. Connect USB, and connect to the Duet as quickly as possible after power up, to see if you can catch it when it hangs. This may be able to determine what's causing the hang, and indicate where to look on the board, eg gets stuck waiting for SD card, or initialising Wifi module.

Ian

gta18

@droftarts Ill check/do what u suggested when I get home tonight.

This is the 2nd board from amazon and did the exact same hanging up.

My board right now just sits on top of an MDF board with nothing below it.

One sign that I see on the paneldue when it is about to hang is that the wifi connection pop up does not show up.

100% of the time I'm able to hit home and the machine finishes the homing though, but one indication that it won't respond to any more commands is that after the homing procedure it does not update where the nozzle final location is (x45 y25,z7.8) for me.

But when I get a successful bootup, I'm able to print for 10hours without any snag and print again and again, just don't reboot it.

It seems like to me, that some part of the external comms of the board quits working or doesn't initialize properly, both wifi and serial.

dc42

To eliminate issues with the config, try an SD card with a very simple config.g on it, for example M552 S1 to turn on the network and nothing else. Then see whether that boots up reliably. If it doesn't, try without even the M552 S1 and see whether you can connect via USB after each reboot.

Phaedrux

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

This is the 2nd board from amazon and did the exact same hanging up.

So they are clone boards?

gta18

not sure if they're clones. I just needed to get it same day when I bought it.

gta18

@dc42 I tried the M552 S1 only on the config, I got successful boot 10 out of 10.

Should I just add the config line by line? Or is there an option to step it out?

Thanks!

Phaedrux

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

Should I just add the config line by line? Or is there an option to step it out?

There's no option to step through it. You'd either have to add one line at a time and try booting, or you could connect via USB and send line by line that way. Or you could rename the config.g something else so that it isn't loaded automatically, and then when it's booted up you could send M98 Pconfigcopy.g from USB and see if you get any error messages.

Duet doesn't sell via amazon, so it's definitely a clone.

A Former User

This is the 2nd board from amazon and did the exact same hanging up.

Duet doesn't sell via amazon, so it's definitely a clone.

That begs the question of when asked to confirm the power supply being stable and answering "its rock solid at 24.13 to 24.15v" how does the 3.3v line look? And if the problems started after adding BLTouch does it work without the BLTouch?

And its a moot point to measure the 3.3v line with a multi-meter to reveal any power issues, it would take a oscilloscope to be certain in any case. Removing the BLTouch if not already done might be a better place to start if lacking a scope.

gta18

@bearer Ill check the 3.3v as well, i have the scope but it doesn't record.

my fluke 789 has the MIN-Max function that can hopefully capture if there is a blip in the 3.3v stage.

So after adding back chunks at a time the config.g and rebooting each time, I probably have about 12 to 15 reboots now without a hitch.

Only difference with my config.g is that I created the file within the web gui.

I will still check the 3.3v tonight when I get back.

Thanks!

A Former User

MIN-MAX won't help as you want to view the part that goes from 0v to 3.3v and possibly back down below some value causing a brownout. Fiddle with the scope trigger settings just below 3.3v until it doesn't trigger in normal use and reduce it a little more, then try starting up to see if it hangs and something triggers the scope.

If unsuccesfull you can always try to see if the BLtouch makes a difference.

droftarts

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

I created the file within the web gui.

It's possible a blip caused some file corruption when saving, but I've never had any problem doing this. And if there was file corruption or some stray character, why would it work sometimes and not others? But perhaps worth looking at the SD card slot soldering. If you could share a picture of your two Duets, it would be interesting to see.

When you say that it doesn't boot up properly, do you mean it boots and 100% of the time you can run homing, but it's during homing that it will drop out? Because I wouldn't call that a boot-up hang! And it narrows the issue down to homing.

Which means, if it only started happening when the BLTouch was added (I missed this earlier), and it usually drops out during homing, I'd guess there's a wiring issue with the BLTouch, and something it's doing is causing the loss of communication. Check the BLTouch wiring loom for continuity, loose connections and shorts, particularly at any point the wiring hinges or pulls on connections.

Ian

gta18

@droftarts What I meant about homing is, if i push the home button right away after power up, it homes 100% of the time but during the failed bootup im talking about the home or any other functions does not work.

Homing always finishes if triggered early enough, either on success or failed boot. Thats why i mentioned that the external comms to paneldue and usb diaappers.

So it seems to me that it always successfully loads the limits and home configuration.

gta18

Im happy and pleased to report back that I have not experienced a bad bootup for about 96 hour printing time and about more than 50 reboots manually.

Still not sure why creating the config.g file using the web interface made a difference.

Phaedrux

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

Still not sure why creating the config.g file using the web interface made a difference.

Corrupt file? bad character?

dc42

@Phaedrux said in Duet Wifi Hangs up after booting about 1 out of 5 times:

@gta18 said in Duet Wifi Hangs up after booting about 1 out of 5 times:

Still not sure why creating the config.g file using the web interface made a difference.

Corrupt file? bad character?

Or a bad block on the SD card that sometimes can't be read? Writing a new config.g will have used a different block. Or did you try a different SD card?