SOLVED Issue with HE heater



  • Hi there
    over the past xmax holidays I updated my duet2 Wifi to RRF 3.xx.
    After I changed all the necessary commands the printer ran proper.
    Than just about a week ago I started a 40 hours job.
    After about 20 hours the job was stopped cuased by a temperature problem on heater 1.
    I serched the forum and documentation and ran some tunings.
    Even change to H2 did not solve the problem. Now I'm confused.

    HW: Duet2 / Duex5 / Panel2, RRF 3.1.1, on H1 and H2 I use PT100 thermistors with the separate PT100 board

    these are the parameters for the heaters
    ; Heaters
    M308 S0 P"bed_temp" Y"thermistor" T100000 B3950 ; configure sensor 0 as thermistor on pin bedtemp
    M950 H0 C"bed_heat" T0 ; create bed heater output on bedheat and map it to sensor 0
    M307 H0 R0.524 C443.4 D3.90 S1.00 B1 ; enable bang-bang mode for the bed heater and set PWM limit
    M140 H0 ; map heated bed to heater 0
    M143 H0 S120 ; set temperature limit for heater 0 to 120C
    M308 S1 P"spi.cs1" Y"rtd-max31865" R395 F50
    M950 H1 C"e0_heat" T1 ; create nozzle heater output on e0heat and map it to sensor 1
    M307 H1 R2.400 C92.3 D6.80 S1.00 B0 ; disable bang-bang mode for heater and set PWM limit
    M143 H1 S280 ; set temperature limit for heater 1 to 280C
    M308 S2 P"spi.cs2" Y"rtd-max31865" R395 F50
    M950 H2 C"e1_heat" T2 ; create nozzle heater output on e1heat and map it to sensor 2
    M307 H2 R2.663 C208.6 D6.60 S1.00 B0 ; disable bang-bang mode for heater and set PWM limit
    M143 H2 S280 ; set temperature limit for heater 2 to 280C

    Would it help to use one heater of the duex5?
    I do have no further idea what to do.

    Regards Martin


  • Moderator

    @Morane_3803 said in Issue with HE heater:

    M308 S1 P"spi.cs1" Y"rtd-max31865" R395 F50

    Remove the R395 and F50. They don't belong on that line when using a PT100. Same for the H2.

    Please send M122 and M98 P"config.g" and post the results.



  • @Phaedrux I would've said the F is valid

    Fnn (where nn is 50 or 60) The local mains frequency. Readings will be timed to optimise rejection of interference at this frequency.

  • Moderator

    @jay_s_uk said in Issue with HE heater:

    @Phaedrux I would've said the F is valid

    Fnn (where nn is 50 or 60) The local mains frequency. Readings will be timed to optimise rejection of interference at this frequency.
    

    Ah yes, fair enough.

    Additional parameters for MAX31865-based PT100 sensors

    Rnnn Series resistor value. Leave blank to use the default for your board.
    Fnn (where nn is 50 or 60) The local mains frequency. Readings will be timed to optimise rejection of interference at this frequency.



  • Thanks Phaedrux and jay_s_uk
    I will try today and post the result.
    Have a great day
    Martin



  • It still does interrupt the printing always after about 5 to 10 min. The temperature is set to 220C. It changes in between 227 and 210 anf finally it drops down to 203 or so and then it pauses the print and goes to error.
    I already changed the heater, the Thermistor PT100 and the special board for PT100!

    This is what M122 and M98 shows:

    === Diagnostics ===
    RepRapFirmware for Duet 2 WiFi/Ethernet version 3.2 running on Duet WiFi 1.02 or later + DueX5
    Board ID: 08DGM-95BLL-N6PSS-6J1F8-3SD6T-9KTML
    Used output buffers: 3 of 24 (16 max)
    === RTOS ===
    Static ram: 23460
    Dynamic ram: 75664 of which 60 recycled
    Never used RAM 12896, free system stack 112 words
    Tasks: NETWORK(ready,186) HEAT(blocked,173) DUEX(blocked,35) MAIN(running,448) IDLE(ready,19)
    Owned mutexes: WiFi(NETWORK)
    === Platform ===
    Last reset 00:19:45 ago, cause: power up
    Last software reset at 2021-02-13 10:01, reason: User, GCodes spinning, available RAM 13140, slot 1
    Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0041f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
    Error status: 0x08
    Aux0 errors 337,337,337
    MCU temperature: min 27.5, current 31.3, max 31.9
    Supply voltage: min 24.0, current 24.2, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
    Driver 0: position 0, standstill, SG min/max 0/132
    Driver 1: position 0, standstill, SG min/max 0/140
    Driver 2: position 3876, standstill, SG min/max not available
    Driver 3: position 0, standstill, SG min/max not available
    Driver 4: position 0, standstill, SG min/max not available
    Driver 5: position 0, standstill, SG min/max not available
    Driver 6: position 0, standstill, SG min/max not available
    Driver 7: position 0, standstill, SG min/max not available
    Driver 8: position 0, standstill, SG min/max not available
    Driver 9: position 0, standstill, SG min/max not available
    Driver 10: position 0
    Driver 11: position 0
    Date/time: 2021-02-13 10:39:10
    Cache data hit count 1427548707
    Slowest loop: 369.01ms; fastest: 0.08ms
    I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
    === Storage ===
    Free file entries: 9
    SD card 0 detected, interface speed: 20.0MBytes/sec
    SD card longest read time 1.1ms, write time 58.0ms, max retries 0
    === Move ===
    DMs created 83, maxWait 163553ms, bed compensation in use: mesh, comp offset 0.000
    === MainDDARing ===
    Scheduled moves 1892, completed moves 1892, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 2], CDDA state -1
    === AuxDDARing ===
    Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
    === Heat ===
    Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1 -1 -1
    Heater 0 is on, I-accum = 0.0
    === 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
    LCD 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: 16.06ms; 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 2c:3a:e8:0b:34:bc
      WiFi Vcc 3.39, reset reason Turned on by main processor
      WiFi flash size 4194304, free heap 24280
      WiFi IP address 192.168.1.45
      WiFi signal strength -43dBm, mode none, reconnections 0, sleep mode modem
      Clock register ffffffff
      Socket states: 0 0 0 0 0 0 0 0
      === DueX ===
      Read count 1, 0.05 reads/min

    M98 P"config.g"
    HTTP is enabled on port 80
    FTP is disabled
    TELNET is disabled
    Error: Fan number 3 not found This error I have corrected!!

    What goes on here?

    Thanks to anyone


  • Moderator

    What does the temp graph look like when it faults?

    Are you using a nozzle sock?



  • @Phaedrux
    the temperature starts normal up to the setted 220°C.
    It overshots the 220 up to 227 / 228. Then it settles to around +/- 3°.
    After start printing the temperature starts to move extremly.
    By means first within down to arround 215 up to 223.
    But suddenly it drops and drops down to finally 203.
    Where at 205 the systems pauses itself and stop printing.
    No I'm not using a nozzle sock. Earlier I did use some!

    As I mentioned above, the first prints after upgrading to RRF3.2 went well.
    The problem became active during this long print!

    Strange anyway.



  • @Morane_3803 I guess its when the fan comes on and the firmware is struggling to compensate for the temperature swing.
    Have you PID tuned the hotend as a tool rather than a hotend? E.g. M303 T0 S220
    Also its best to fit a sock to protect from temperature changes caused by the fan



  • I know you said that you already replaced the thermistor but in my experience, when the temperature fluctuates rapidly (as in instantaneous), it is either a bad contact in the thermistor line someplace or more often a dud thermistor.
    If the temperature drops gradually over the period of say 30 seconds or more then you can have a heater or heater wire problem.
    This happened to me just a few days ago and although the screw connections to the heater wire on the Duet were what I considered 'tight', i tightened them just a tad more and it solved all my problems. I suspect that I had some oxidation.
    The other issue I have seen was when I used regular dupont type connectors when extending the heater wires. The connections heated up causing a higher resistance with time and a lower power output for the heater over time. I ended up going with a 24V power supply to cut the current in half.


  • Moderator

    @Morane_3803 said in Issue with HE heater:

    WiFi firmware version 1.23

    I think you've missed updating the wifi firmware.

    Upload this full zip file, as is, to the system tab. That should take care of everything that needs updating.

    https://github.com/Duet3D/RepRapFirmware/releases/download/3.2.2/Duet2and3Firmware-3.2.2.zip

    I think @jay_s_uk is on to something with tuning the hotend heater as a tool to take the fan into account.



  • @jay_s_uk
    The testpart is that big that the cooling fan did not even start yet.
    It will turn on beginning at layer 2
    M303 T0 220 i will try. I believe it was M303 H1 220 I've tried!

    Ok and the socks I have and will put it on again!
    I will report again.
    Thanks a lot



  • @jens55
    Hi Jens55
    this is an interesting view I did not consider yet. Even though I changed the cabling from H1 to H2 and vise versa.
    I'm using 24V power supply.
    I will check those kind off possible errors and report again.
    Thanks a lot



  • @Phaedrux
    Hi Phaedrux
    just did uploaded the ZIP-file. I will try tomorrow evening and will report again.
    Thanks a lot and have a great evening!
    Martin



  • If you have trouble getting the PID dialed in, you can always change how sensitive the thermal error check is.
    (If saw, you have a really low mass hot-end and you keep meaning to do the auto-tune propperly but squirrel........)

    Sorry, where was I?

    Oh yes.

    M570

    If you know that your fan on tool 0 causes a 15 degree drop that only lasts 20 seconds (and isn't causing printing issues) you might put in:

    M570 H0 P30 S20

    IMHO the default error parameters are quite strict... but I can't say that's bad, I know people will shoot video of the burning printer before they try and put out the fire 😉



  • Hi there
    Today I've tried all the suggestions you gave...but no changes at all 😠
    But you wouldn't believe what I found!
    Jens55 wrote about the cable issue. So finally I tried another file to print, a much smaller part as the other
    which I first had that issue.
    All printing went well. PID on H1 worked just perfect.
    As a conclusion I believe there is a problem with the heater cable within the nice cable drag chain.
    Most probably the cable is somewhere broken or overstretched, whatever!
    So tomorrow evening I change this cable and give it another trial.
    Stand by.
    Anyway guys thanks a lot for your help. One way or the other, I've lerned a lot.
    Regards Martin



  • Hi
    Today I replaced this faulty cable and everything works fine!
    It is unbelievable but a fact!
    Thanks to all of you guys for the support.
    Have a great time!
    Regards Martin


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