Faulty Duet2 WiFi/Duex5???

  • Hi guys!

    I run a Duet2 WiFi and Duex5 setup, and I'm hoping someone could shed some light on a strange issue that I have.

    At power up;
    (1) the Duex E6 Heat LED comes on (no config or connection for this).
    (2) when I start heating up my HE (run from the Duet2), all my fans stops working, and not even the thermo controlled HE fan comes on when the temp reaches the specified level.
    (3) It also seems like the fans are stuggling, but when I measure the voltage on the pins, I get over 20v, even though the Duex5 is set to 12v

    On the Duex5 I have 3 motors (E2 MOT-E4 MOT), parts cooling fan, HE fan, 2 additional cooling fans (Fan3-6), and BLTouch (PWM5), all run from a 24v PSU (VIN+ direct to PSU, VIN- from VIN- on Duet2 [resistance on cable 1.4 ohm])

    I've checked and rechecked for any shorts, or loose cables & connections, but all appears to be ok. It's quite possible that I did something stupid along the way, so might be time for an upgrade to Duet3, but I was hoping it's not that critical

    Below is my current config and diognostic output, but if anyone has any suggestions, I'd really apprecite it!

    ; Configuration file for Duet WiFi (firmware version 3)
    ; executed by the firmware on start-up
    ; generated by RepRapFirmware Configuration Tool v3.1.4 on Sun Aug 16 2020 19:27:08 GMT+0100 (British Summer Time)
    ; General preferences
    G90                                            	; send absolute coordinates...
    M83                                            	; ...but relative extruder moves
    M550 P"RattyXY"                                	; set printer name
    M669 K1                                        	; select CoreXY mode
    ; 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 (Alpha)
    M569 P1 S1                                     	; physical drive 1 goes forwards (Beta)
    M569 P2 S1                                     	; physical drive 2 goes forwards (Extruder)
    M569 P3 S1                                     	; physical drive 3 goes forwards (Extruder)
    M569 P4 S1                                     	; physical drive 4 goes forwards (Extruder)
    M569 P5 S1                                     	; physical drive 5 goes forwards (Z Front Right)
    M569 P6 S1                                     	; physical drive 6 goes forwards (Z Back Middle)
    M569 P7 S1                                     	; physical drive 7 goes forwards (Z Front Left)
    M569 P8 S1                                     	; physical drive 8 goes forwards (Extruder)
    M569 P9 S1                                     	; physical drive 9 goes forwards (Extruder)
    ; Drive mapping for triple Z
    M584 X0 Y1 Z5:6:7 E2:3:4:8:9                    ; set drive mapping
    M350 X16 Y16 Z16 E16 I1                        	; configure microstepping with interpolation
    M92 X80.00 Y80.00 Z400.00 E812.62           	; set steps per mm
    M566 X900.00 Y900.00 Z12.00 E120.00            	; set maximum instantaneous speed changes (mm/min)
    M203 X6000.00 Y6000.00 Z4000.00 E1200.00        ; set maximum speeds (mm/min)
    M201 X500.00 Y500.00 Z75.00 E250.00            	; set accelerations (mm/s^2)
    M906 X1920 Y1920 Z1200 E1200 I10                ; set motor currents (mA) and motor idle factor in per cent
    M84 S30                                        	; Set idle timeout
    ; Bed Levelling
    M671 X-49:132:311 Y58:352:58 S3.0 				; leadscrews at front left #1 (DueX5 P5), back middle #2 (DueX5 P6) and front right #3 (DueX5 P7)
    ; Axis Limits
    M208 X0 Y0 Z0 S1                               	; set axis minima
    M208 X280 Y280 Z300 S0                         	; set axis maxima
    ; Endstops
    M574 X1 S1 P"!^xstop"                           ; configure active-low endstop for low end on X via pin xstop
    M574 Y1 S1 P"!^ystop"                           ; configure active-low endstop for low end on Y via pin ystop
    M574 Z1 S2										; Define Z to use Probe. Home to Min
    ; Z-Probe
    M950 S0 C"duex.pwm5"                         	; use Duex5 PWM5 for BLTouch
    M558 P9 C"^zprobe.in" H5 F120 T6000            	; set Z probe type to bltouch and the dive height + speeds
    G31 P500 X0 Y-48 Z1.82                          ; set Z probe trigger value, offset and trigger height
    M557 X0:280 Y0:258 S70                       	; define mesh grid
    ; Heaters
    M308 S0 P"bedtemp" Y"thermistor" T100000 B4138 	; configure sensor 0 as thermistor on pin bedtemp
    M950 H0 C"bedheat" T0                          	; create bed heater output on bedheat and map it to sensor 0
    M307 H0 A426.1 C576.0 D3.4 V23.6 B1 S1.00      	; enable bang-bang mode for the bed heater and set PWM limit
    M140 H0                                        	; map heated bed to heater 0
    M143 H0 S100                                   	; set temperature limit for heater 0 to 100C
    M308 S1 P"e0temp" Y"thermistor" T100000 B4138  	; configure sensor 1 as thermistor on pin e0temp
    M950 H1 C"e0heat" T1                           	; create nozzle heater output on e0heat and map it to sensor 1
    M307 H1 A637.5 C254.0 D4.4 V23.5 B0 S1.00      	; disable bang-bang mode for heater  and set PWM limit
    ; Fans
    M950 F0 C"duex.fan3" Q500                       ; create fan 0 on pin fan0 and set its frequency
    M106 P0 S0 H-1                                 	; set fan 0 value. Thermostatic control is turned off
    M950 F1 C"duex.fan4" Q500                       ; create fan 1 on pin fan1 and set its frequency
    M106 P1 S1 H1 T45                              	; set fan 1 value. Thermostatic control is turned on
    M950 F2 C"duex.fan5" Q500                       ; create fan 2 on pin fan2 and set its frequency
    M106 P2 S0.6			                        ; set fan 0 value. Thermostatic control is turned off
    M950 F3 C"duex.fan6" Q500                       ; create fan 3 on pin fan3 and set its frequency
    M106 P3 S0.5			                        ; set fan 0 value. Thermostatic control is turned off
    ; Tools
    M563 P0 D0 H1 F0                               	; 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
    M572 D0 S0.050									; set pressure advance for titan aero
    ; Custom settings are not defined
    ; Miscellaneous
    M575 P1 S1 B57600                              	; enable support for PanelDue

    And this is the M122 output

    === Diagnostics ===
    RepRapFirmware for Duet 2 WiFi/Ethernet version 3.1.1 running on Duet WiFi 1.02 or later + DueX5
    Board ID: 08DGM-917DA-G4MS4-6J9DL-3S86S-TBY7B
    Used output buffers: 3 of 24 (15 max)
    === RTOS ===
    Static ram: 27980
    Dynamic ram: 94576 of which 52 recycled
    Exception stack ram used: 528
    Never used ram: 7936
    Tasks: NETWORK(ready,368) HEAT(blocked,1224) DUEX(suspended,160) MAIN(running,1816) IDLE(ready,80)
    Owned mutexes: WiFi(NETWORK)
    === Platform ===
    Last reset 01:30:20 ago, cause: software
    Last software reset at 2021-02-11 10:42, reason: User, spinning module GCodes, available RAM 8400 bytes (slot 3)
    Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0441f000 BFAR 0xe000ed38 SP 0xffffffff Task MAIN
    Error status: 0
    MCU temperature: min 28.6, current 36.8, max 37.1
    Supply voltage: min 23.4, current 23.7, max 23.9, under voltage events: 0, over voltage events: 0, power good: yes
    Driver 0: standstill, SG min/max 0/131
    Driver 1: standstill, SG min/max 0/0
    Driver 2: standstill, SG min/max not available
    Driver 3: standstill, SG min/max not available
    Driver 4: standstill, SG min/max not available
    Driver 5: standstill, SG min/max 0/242
    Driver 6: standstill, SG min/max 0/140
    Driver 7: standstill, SG min/max 0/168
    Driver 8: standstill, SG min/max not available
    Driver 9: standstill, SG min/max not available
    Date/time: 2021-02-11 12:12:41
    Cache data hit count 4294967295
    Slowest loop: 8.18ms; fastest: 0.14ms
    I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
    === Storage ===
    Free file entries: 10
    SD card 0 detected, interface speed: 20.0MBytes/sec
    SD card longest read time 1.7ms, write time 0.0ms, max retries 0
    === Move ===
    Hiccups: 0(0), FreeDm: 169, MinFreeDm: 167, MaxWait: 1739507ms
    Bed compensation in use: none, comp offset 0.000
    === MainDDARing ===
    Scheduled moves: 13, completed moves: 13, StepErrors: 0, LaErrors: 0, Underruns: 0, 0  CDDA state: -1
    === AuxDDARing ===
    Scheduled moves: 0, completed moves: 0, StepErrors: 0, LaErrors: 0, Underruns: 0, 0  CDDA state: -1
    === Heat ===
    Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1 -1 -1
    === GCodes ===
    Segments left: 0
    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
    USB is idle in state(s) 0
    Aux is idle in state(s) 0
    Trigger is idle in state(s) 0
    Queue is idle in state(s) 0
    Daemon is idle in state(s) 0
    Autopause is idle in state(s) 0
    Code queue is empty.
    === Network ===
    Slowest loop: 15.95ms; fastest: 0.00ms
    Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
    HTTP sessions: 1 of 8
    - WiFi -
    Network state is active
    WiFi module is connected to access point 
    Failed messages: pending 0, notready 0, noresp 0
    WiFi firmware version 1.23
    WiFi MAC address ec:fa:bc:2d:de:e6
    WiFi Vcc 3.44, reset reason Unknown
    WiFi flash size 4194304, free heap 25144
    WiFi IP address
    WiFi signal strength -52dBm, reconnections 0, sleep mode modem
    Socket states: 0 0 0 0 0 0 0 0
    === DueX ===
    Read count 1, 0.01 reads/min

    Thanks in advance!

  • I've done some tests on the Duex5 board, and it seems there is an issue with the 12v side. When I change the fan voltage jumper to VIN, I get just under 24v over the fan pins, but when I set it to 12v, I get something like 7mV. Could I have blown something in the process of setting up the board?

  • Moderator

    Photos of the wiring? Did anything change recently?

  • did you check the firmware limitations to to verify that the heaters, therms and fans can get arranged between boards?

    if i understand it rignt (not sure if i do) you have to have all the associated heater/fan/therms on the same board.

  • Thanks @Phaedrux & @sinned6915 for your comments. I have, however, found the issue, and it does appear I have fried my boards :(.

    I used a little toolboard I found online (see pic), and although it worked for a few months, it appears that the 12v on the HE and Parts fan, is also connected to the HE heater on this little board, so is shorting. Although not immediately, I expect this has caused severe damage to both boards over time, which has now shown itself.

    I guess you live and learn! Something I should've double checked prior to using this board!!

  • Moderator

    Yes the Duet switches PWM on the negative side, so you can share the power line, but not the ground lines.

  • what did you fry exactly ?
    did you check the fuses?

  • hey @hackinistrator, definitely the 12v side on the duex5. There are no blown fuses, but the 12v does not work at all anymore. I'm still checking the duet2, but there are a couple of headers that no longer works (1 x pwm fan & 1 x always on fan). Can maybe save some of the board and use on a smaller printer (maybe a board for my ender3)...

  • @jch what is "12V" ? is that your input voltage ?

    you have 3 leds on the side of the board - Vin 3.3v and 5V , do all work ?

  • @hackinistrator the Duet2 board is still partly functional, although the two headers I mentioned is still not working, so trying to see what's up there.

    I have found the issue on the Duex5 board, however. The 4403T regulator IC has blown, so I expect this is the cause of the Duex5 failure. I will see if I can get another IC and try a repair, but I expect if this regulator has gone, there are likely other components that's failed as well.

    The 12v I mentioned relates to the Duex5 and the "Fan Voltage Select"

  • @hackinistrator I also now found the issue with the Duet2. I've got a failed component on the Fan0 Mosfet Control. Component TR5 has failed. Well, actually more than that. It's got a "big" chunk missing.

    Maybe I can repair the two boards.......

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