Failure commissioning Duet2 on Toolchanger



  • I have built my E3D Toolchanger and motion system and was in the process of commisioning it.
    I have installed RRF 3 and the DC42 configuration for a 4 titan toolchanger.

    I got as far as Home Y, which produced no movement except in Z, possibly because the carriage was already at Y, but Home X made it approximately to the edge of the bed, followed by the motors chattering as if they had crashed into a physical stop.

    I switched the machine off and looked for an obvious cause, I could find none. On turning the Machine on I get
    "Error: short-to-ground reported by driver(s) 5
    Error: over temperature shutdown reported by driver(s) 5"

    I have checked the wiring and there is nothing obviously wrong. I have looked on the net and followed the advice given to similar error messages, essentially check for errors or possibly mismatched config files to RRF version. I had hoped that by using the DC42 files I had minimised chances of that.

    The only niggle is that during early commisioning I was getting a charge building up on the Top plate of the machine, even when operating with nothing connected to the Duet, no sensors, no motors and the Duex cable removed. That appeared to disappear when I replaced the steel standoffs with non conductive material.

    The other suggestion on the web is that either there is a short in motor 5 or that the Duet has a fault.

    Are there other avenues I can explore?

    Robin


  • Moderator

    @robinS3 said in Failure commissioning Duet2 on Toolchanger:

    The only niggle is that during early commisioning I was getting a charge building up on the Top plate of the machine, even when operating with nothing connected to the Duet, no sensors, no motors and the Duex cable removed. That appeared to disappear when I replaced the steel standoffs with non conductive material.

    Sounds like a short. Were you able to find the source? Isolating the bed is good, but what was shorting it out to begin with. It's possible the driver has been damaged.

    Can you post your current configuration files just so we can see what it's using right now.


  • administrators

    @robinS3 said in Failure commissioning Duet2 on Toolchanger:

    The only niggle is that during early commisioning I was getting a charge building up on the Top plate of the machine, even when operating with nothing connected to the Duet, no sensors, no motors and the Duex cable removed. That appeared to disappear when I replaced the steel standoffs with non conductive material.

    That's worrying. The E3D AC mains voltage heater is clearly marked "MUST EARTH". On my TC (which was built by E3D) there is a yellow and green earth wire running through the cable chain, connecting the bed plate to the case of the PSU. The PSU in turn has its earth connection on the input terminal strip connected to the mains IEC connector. From there is should be connected to main earth through the mains cable. I suspect that the earth connection from the PSU to mains earth is broken, and the charge you felt was the current passing through the class Y capacitors in the PSU.



  • @dc42 The earth is intact, tested by using a continuity tester from the mains plug earth pin and the chassis of the TC itself. The chassis is connected to the psu housing by a similar earth wire to the one connecting the psu to the bed chassis and bed plate.

    However the problem was evident originally when the Duet was only connected to a USB cable from my PC, no connection to any sensors,motors or the Duex and no mains power at all. I was testing the Duet communications with YAT as initial attempts to connect with DWC failed with the error message "HTTP request refu8sed". I had to load and reload RRF 2.0.1 and DWC several times before I could navigate via browser to the machine. This was when I isolated the Duet from the standoffs as I could not see how without any connection to to the wiring or the PSU I was getting leakage to the Top plate. (or the capacitors in the PSU unless there's some sort of weird inductance going on across the acrylic . In addition to isolating the Duet, I also removed the sheet of foam from under the feet of the TC which I had used to protect the surface of the table on which I built the machine.

    Then I re- connected the wiring , removed the USB and tried mains power.

    Then I was able to update to RRF 3.0.1 and DWC 2 via the system update and to load your configuration files for the four Titan, non centered XY setup.

    Now the system will recognise and connect to DWC but immediately polls the error on Driver 5 and refuses any input commands.



  • @Phaedrux
    my current configuration files are taken from DC42's posted configuration files, from a thread on this board.
    config.g is

    ; Configuration file for Duet WiFi / Ethernet running RRF3 on E3D Tool Changer
    ; executed by the firmware on start-up

    ; General preferences
    M111 S0 ; Debugging off
    G21 ; Work in millimetres
    G90 ; Send absolute coordinates...
    M83 ; ...but relative extruder moves
    M555 P2 ; Set firmware compatibility to look like Marlin

    ; Network
    M550 P"ToolChanger" ; Set machine name
    M552 S1 ; Enable Networking
    M586 P0 S1 ; Enable HTTP
    M586 P1 S0 ; Disable FTP
    M586 P2 S0 ; Disable Telnet

    M667 S1 ; Select CoreXY mode

    ; Drive direction
    M569 P0 S0 ; Drive 0 X
    M569 P1 S0 ; Drive 1 Y
    M569 P2 S1 ; Drive 2 Z
    M569 P3 S0 ; Drive 3 E0
    M569 P4 S0 ; Drive 4 E1
    M569 P5 S1 ; Drive 5 E2
    M569 P6 S1 ; Drive 6 E3
    M569 P7 S0 ; Drive 7 COUPLER
    M569 P8 S0 ; Drive 8 UNUSED
    M569 P9 S0 ; Drive 9 UNUSED

    M584 X0 Y1 Z2 C7 E3:4:5:6 ; Apply custom drive mapping
    M208 X-35:328.5 Y-49:243 Z0:300 C0:500 ; Set axis maxima & minima
    M92 X100 Y100 Z1600 C200 E834:834:834:834 ; Set steps per mm assuming x16 microstepping
    M350 E16:16:16:16 I1 ; Configure microstepping with interpolation
    M350 C16 I1
    M350 X16 Y16 Z16 I1 ; Configure microstepping with interpolation
    M566 X400 Y400 Z8 C2 E2:2:2:2 ; Set maximum instantaneous speed changes (mm/min)
    M203 X35000 Y35000 Z1200 C10000 E5000:5000:5000:5000 ; Set maximum speeds (mm/min)
    M201 X6000 Y6000 Z400 C500 E2500:2500:2500:2500 ; Set accelerations (mm/s^2)
    M906 X2000 Y2000 Z1330 C500 E1600:1600:1600:1600 I30 ; Set motor currents (mA) and motor idle factor in percent
    M84 S120 ; Set idle timeout

    ; Endstops
    M574 X1 Y1 S3 ; Set X / Y endstop stall detection
    M574 Z0 ; No Z endstop
    M574 C1 S3 ; Stall detect coupler at low end of its range

    ; Z probe
    M558 P8 C"zstop" H3 F360 I0 T20000 ; Set Z probe type to switch, the axes for which it is used and the dive height + speeds
    G31 P200 X0 Y0 Z0 ; Set Z probe trigger value, offset and trigger height
    M557 X10:290 Y20:180 S40 ; Define mesh grid

    ;Stall Detection
    M915 C S6 F0 H200 R4700 ; Coupler

    ;Stall Detection
    M915 X Y S3 F0 H400 R4700 ; X / Y Axes

    ; Heaters
    M308 S0 P"bedtemp" Y"thermistor" T100000 B4138 C0 ; Set thermistor
    M950 H0 C"bedheat" T0 ; Bed heater
    M143 H0 S225 ; Set temperature limit for heater 0 to 225C

    M308 S1 P"e0temp" Y"thermistor" A"T0" T100000 B4725 C7.06e-8 ; Set thermistor
    M950 H1 C"e0heat" T1 ; Extruder 0 heater
    M143 H1 S300 ; Set temperature limit for heater 1 to 300C

    M308 S2 P"e1temp" Y"thermistor" A"T1" T100000 B4725 C7.06e-8 ; Set thermistor
    M950 H2 C"e1heat" T2 ; Extruder 0 heater
    M143 H2 S300 ; Set temperature limit for heater 2 to 300C

    M308 S3 P"e2temp" Y"thermistor" A"T2" T100000 B4725 C7.06e-8 ; Set thermistor
    M950 H3 C"duex.e2heat" T3 ; Extruder 0 heater
    M143 H3 S300 ; Set temperature limit for heater 3 to 300C

    M308 S4 P"e3temp" Y"thermistor" A"T0" T100000 B4725 C7.06e-8 ; Set thermistor
    M950 H4 C"duex.e3heat" T4 ; Extruder 0 heater
    M143 H4 S300 ; Set temperature limit for heater 4 to 300C

    ; Tools
    M563 P0 S"T0" D0 H1 F2 ; Define tool 0
    G10 P0 X0 Y0 Z0 ; Reset tool 0 axis offsets
    G10 P0 R0 S0 ; Reset initial tool 0 active and standby temperatures to 0C

    M563 P1 S"T1" D1 H2 F4 ; Define tool 1
    G10 P1 X0 Y0 Z0 ; Reset tool 1 axis offsets
    G10 P1 R0 S0 ; Reset initial tool 1 active and standby temperatures to 0C

    M563 P2 S"T2" D2 H3 F6 ; Define tool 2
    G10 P2 X0 Y0 Z0 ; Reset tool 2 axis offsets
    G10 P2 R0 S0 ; Reset initial tool 2 active and standby temperatures to 0C

    M563 P3 S"T3" D3 H4 F8 ; Define tool 3
    G10 P3 X0 Y0 Z0 ; Reset tool 3 axis offsets
    G10 P3 R0 S0 ; Reset initial tool 3 active and standby temperatures to 0C

    ; Fans
    ; Fan0 output is not used
    M950 F1 C"fan1"
    M950 F2 C"fan2"
    M950 F3 C"duex.fan3"
    M950 F4 C"duex.fan4"
    M950 F5 C"duex.fan5"
    M950 F6 C"duex.fan6"
    M950 F7 C"duex.fan7"
    M950 F8 C"duex.fan8"

    M106 P1 S255 H1 T70 ; T0 HE
    M106 P2 S0 ; T0 PCF
    M106 P3 S255 H2 T70 ; T1 HE
    M106 P4 S0 ; T1 PCF
    M106 P5 S255 H3 T70 ; T2 HE
    M106 P6 S0 ; T2 PCF
    M106 P7 S255 H4 T70 ; T3 HE
    M106 P8 S0 ; T3 PCF

    M593 F50 ; cancel ringing at 50Hz (https://forum.e3d-online.com/threads/accelerometer-and-resonance-measurements-of-the-motion-system.3445/)
    M376 H15 ; bed compensation taper

    ;tool offsets
    G10 P0 X-9 Y39 Z-5 ; T0
    G10 P1 X-9 Y39 Z-5 ; T1
    G10 P2 X-9 Y39 Z-5 ; T2
    G10 P3 X-9 Y39 Z-5 ; T3

    ; Bowden tubes are ~700mm long so PA almost certainly needs to be increased
    M572 D0 S0.2 ; pressure advance T0
    M572 D1 S0.2 ; pressure advance T1
    M572 D2 S0.2 ; pressure advance T2
    M572 D3 S0.2 ; pressure advance T3



  • @robinS3
    Basic troubleshooting:
    Isolate, test with known good parts, replace possible failure points until you have identified the source of the problem.

    In this case, connect a known good stepper motor, with a known good cable, directly to the Duet, see if it still reports the same error.
    This will isolate all the wiring and everything else.
    If that works, start working through the setup, away from the Duet till you add something that breaks it again.
    If that doesn't work, remove the Duet from the machine, put it on an insulating surface (a clean one!) give it some external power and see if it will work with that known good stepper.


  • administrators

    @robinS3 said in Failure commissioning Duet2 on Toolchanger:

    I switched the machine off and looked for an obvious cause, I could find none. On turning the Machine on I get
    "Error: short-to-ground reported by driver(s) 5
    Error: over temperature shutdown reported by driver(s) 5"

    Do you get that error even with no motor connected to motor output 5 (aka the connector labeled E2 MOT on the DueX5)?



  • @dc42 I'd obviously been working on the problem far too long. Loading the config.g for phaedrux made me realise that motor 5 corresponded to E2 and it's defined in the config; but I had just been too fuddled and tired for it to make sense. Time to stop.

    So this morning I disconnected E2, the error message disappeared, I could then home X and Y but they kept stalling out and 'homing' to false positions. But this is a CoreXY which uses both motors for a move in X or Y and if one of them isn't working then the stall detect registers the extra load as 'Home'. The Y motor plug wasn't completely settled.

    I reconnected E2 and the error message did not re-appear and the static zap from the Top Plate has disappeared.

    So, thank you all for refocusing me, there are a trio of lessons learned by me

    1. When you are so tired nothing makes sense, stop and go to sleep. Don't keep digging.
    2. Look at the evidence you have, the answer is probably staring you in the face.
      3, The responses you get on this board are very helpful (and very quick).

    Problem apparently solved.


  • administrators

    @robinS3 said in Failure commissioning Duet2 on Toolchanger:

    So this morning I disconnected E2, the error message disappeared, I could then home X and Y but they kept stalling out and 'homing' to false positions.

    You probably need to adjust the M915 stall threshold and/or the M913 current reduction during homing for the X and Y motors.



  • I've taken this as 'Cured'. Greg suggested the problem as being self generated static and recommended I take my shoes off.

    it worked, suggesting that it wasn't static arcing from the TC to me but very much the other way round. Fixated as I was on 'the machine' I didn't reason it out. The reason I was getting such a reaction was that the earth is very effective, from the top plate down a back pillar through the earthing strap to the PSU and then down the power cable Earth.

    I'd also forgotten that a Core XY printer uses both X and Y motors for any change in the XY position, where a Cartesian Printer is isolated in X or Y. If one motor isn't pulling its weight, the other will see the drag as potentially a stall (and the config I downloaded has a number of notations where DC42 had made variations from the 'standard' values in the config.g example. The 'Homing buttons tend to bang into the end stops and I haven't yet tuned stall detection.


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