CONSTANT AJAX disconnect errors

KeeganB · 23 Oct 2017, 16:00

I've got a few extenders laying around, ill add one to my network and let the Duet be its only client with a different SSID as you suggest. It's worth a shot!

Thanks

KeeganB · 23 Oct 2017, 23:51

Just tested the separate extender with dedicated SSID, and it only took 8 mins of sitting idle to disconnect.

Jarery · 24 Oct 2017, 00:27

I have two duet wifi's, both exhibit same behaviour, so it pretty much has to be a setting in the router.
these are my settings

KeeganB · 24 Oct 2017, 00:34

I was able to reconnect and it actually showed up in my router admin as a connected device. This allowed me to bind a DHCP reservation to it. It has been sitting idle now CONNECTED for 44 mins. I am far from convinced that this will work, but so far it has. I will start a print next and see how that goes.

KeeganB · 24 Oct 2017, 00:57

aaaaaaand about 30 seconds into a print…. DISCONNECT!

number40fan · 24 Oct 2017, 01:06

Jarery, I'd roll one of the Duets back to 1.18.2 and see if you still have issues.

dc42 · 24 Oct 2017, 07:19

KeeganB, please can you try a couple of things:

1. Start a print, wait until the motors are moving, then pause it. If it has disconnected already, reconnect. See whether it stays connected.

2. If it does stay connected, set the motor idle current to 100%, resume the print and pause it again, and once again see if it stays connected.

What I am wondering is whether the current to the stepper motors is causing interference.

KeeganB · 24 Oct 2017, 13:50

@dc42:

KeeganB, please can you try a couple of things:

1. Start a print, wait until the motors are moving, then pause it. If it has disconnected already, reconnect. See whether it stays connected.

2. If it does stay connected, set the motor idle current to 100%, resume the print and pause it again, and once again see if it stays connected.

What I am wondering is whether the current to the stepper motors is causing interference.

I can try this. Are you thinking that the stepper motor wires are creating some level of EMI and interrupting the wifi signal? Should I consider wrapping them in some sort of shielding, and/or re-routing them as far away from the wifi card as possible?

I do have another update. Last night I reinstalled all the latest alpha/beta firmwares and uploaded all new configs generated from the online RRF Configuration tool. I wanted to "start from scratch" with everything that I could think of.

Doing this it stayed connected while printing from 10:28pm until 11:14pm. At this point my computer had gone to sleep, so I woke it back up and DWC had reported "disconnected - timeout". I was able to click "Connect" twice and it reconnected. It then stayed connected until 1am. I'm not sure at that point what may have happened, because I was asleep. I powered off the printer before leaving for work this morning. I am fine with that behavior, as it didn't require pronterface to send M552's to the board. I don't want to have to be constantly tethered to my computer.

dc42 · 24 Oct 2017, 14:46

Yes, I am thinking that EMI from the stepper cables, or the PSU, or the Duet itself could be generating interference.

I haven't ruled out the possibility that the WiFi modules on your Duet is faulty. But as I believe you reported that the connection is much less reliable when you are printing, I don't think that is very likely - unless for some reason the 3.3V power to the WiFi module is dropping for some reason when you are printing.

Interference generated by the Duet or the PSU might also explain why some WiFi channels seem to be more reliable than others.

KeeganB · 24 Oct 2017, 18:40

David,

Aside from maybe the the stepper idle currents, is there ANYTHING in the config.g that could be related to my issues?

dc42 · 25 Oct 2017, 07:21

@KeeganB:

David,

Aside from maybe the the stepper idle currents, is there ANYTHING in the config.g that could be related to my issues?

As long as M122 shows a low MaxReps value after printing, nothing that I can think of.

KeeganB · 25 Oct 2017, 12:57

Well,

I had a really good run yesterday afternoon. I was printing, sitting at idle with and without the steppers powers, and editing configs and etc though DWC for hours and hours yesterday with not issues. I was even able to move all of my network hardware back to its rightful place in my office and move my printer back to its normal spot as well. I powered it all up and it all connected just fine, no usb needed!

and then…. as I'm going to start a print before bed DISCONNECT, and it would not reconnect. I didn't want to mess with pronterface, so I just let it print. As usual about an hour later or so I was able to access DWC again.

dc42 · 25 Oct 2017, 13:39

Did the disconnection happen soon after the stepper motors were powered up?

Could the behaviour be related to temperature? i.e. it works OK when the ambient temperature is low and the machine is not printing, but the connection fails when the wifi module gets a bit warmer due to higher ambient temperature or heating due to the stepper drivers passing current?

I don't suppose you have a radio taxi station, ATC beacon or other high-power transmission source in your vicinity?

KeeganB · 25 Oct 2017, 17:29

Hey David,

To start, I did your previously requested test in relation to the motor idle current and didn't get any disconnects. This was done during that really long stretch of good connection.

Yes, the disconnect last night happened probably 30 seconds or so after the print started. I do a G32 as part of the print, and after that completed, while working on the first layer it disconnected.
I have been keeping an eye on the MCU temp via DWC and it stays in the mid 30s Celsius.
I could add another small cooling fan to blow direction onto the wifi module if you think the is the problem. I can test that tonight. honestly though, if that is the problem I would have to question the quality of the module, or its ability to withstand heat. I don't think it is working under any extreme conditions at all.

No, no high power transmission sources nearby.

dc42 · 25 Oct 2017, 22:47

Keegan, please try firmware 1.20beta2 and the DuetWiFiServer that goes with it. It stops the WiFi module going into sleep mode and the M122 report includes additional network diagnostics.

I'm discussing with my colleagues the possibility of loaning you another Duet WiFi to test, in case the WiFi module on your Duet is faulty. Meanwhile, if you can temporarily add a fan to cool the WiFi module, that would test the temperature theory.

When you did that test with the motors energised but idle, what idle current factor were you using? Please re-test it at 100% idle current if you haven't already.

KeeganB · 25 Oct 2017, 23:49

Hey David,

I will test with a fan on the module tonight as well as upload the newest firmwares.

For the idle test, i tested with a print paused with both a factor of 60 and 100.

Thank You

dc42 · 25 Oct 2017, 23:57

Thanks. Can you confirm that you set the idle current to 100% before the motors went into idle hold? I'm not sure whether using M906 to adjust the idle current affects motors that have already been switched to idle.

Jarery · 26 Oct 2017, 00:02

Ive installed the new firmware.
confused by this statement :

Duet WiFi user can use either DuetWiFiServer 1.20beta2 (which disables WiFi module sleep) or 1.20alpha1 (which uses the default "modem sleep" mode)

My M122 has the following, but I'm using 1.20beta2, where above states modem sleep is only available with 1.20alpha1

WiFi signal strength -47dBm, reconnections 0, sleep mode modem

KeeganB · 26 Oct 2017, 02:04

@dc42:

Thanks. Can you confirm that you set the idle current to 100% before the motors went into idle hold? I'm not sure whether using M906 to adjust the idle current affects motors that have already been switched to idle.

I can't confirm that. I used M906 I100 to set it to 100. I could do the test again with the idles set to 100 in the config.g before starting a print.

I did a little temp testing by setting my bed heat to 100C, closing up all panels in the base of the machine (rostock max v2) and also setting the hot end to 200C with it about .5mm above the bed. I wanted to get the base of the machine as warm as possible. It sat like that for over an hour with no issue, and the MCU temp never exceeded 35C.

Also, I updated to the latest firmwares and afterwards I was homing the machine again, and again, back to back to back, and on the probably 4th or 5th time, it disconnected and would not reconnect via the browser. I plugged in the USB and connected to pronterface to run M122. here are the results:

[c]>>> M122
SENDING:M122
=== Diagnostics ===
Used output buffers: 1 of 32 (14 max)
=== Platform ===
RepRapFirmware for Duet WiFi version 1.20beta2 running on Duet WiFi 1.0
Board ID: 08DDM-9FAM2-LW4SD-6JTF0-3S86N-TLWZX
Static ram used: 15136
Dynamic ram used: 96560
Recycled dynamic ram: 2992
Stack ram used: 4000 current, 4808 maximum
Never used ram: 11576
Last reset 00:04:50 ago, cause: software
Last software reset reason: User, spinning module GCodes, available RAM 11496 bytes (slot 3)
Software reset code 0x0003, HFSR 0x00000000, CFSR 0x00000000, ICSR 0x00400000, BFAR 0xe000ed38, SP 0xffffffff
Error status: 0
[ERROR] Error status: 0

Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 41.9ms
MCU temperature: min 32.4, current 32.6, max 36.5
Supply voltage: min 12.0, current 12.1, max 12.2, under voltage events: 0, over voltage events: 0
Driver 0: stalled standstill
Driver 1: stalled standstill
Driver 2: stalled standstill
Driver 3: standstill
Driver 4: standstill
Date/time: 2017-10-25 22:00:43
Slowest main loop (seconds): 2.390603; fastest: 0.000032
=== Move ===
MaxReps: 3, StepErrors: 0, FreeDm: 240, MinFreeDm 234, MaxWait: 3783856217ms, Underruns: 0, 0
Scheduled moves: 30, completed moves: 30
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heater = 0, chamber heater = -1
Heater 0 is on, I-accum = 0.0
=== 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 ready with "M122" 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 state is running
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.20beta2
WiFi MAC address 5c:cf:7f:ef:51:6f
WiFi Vcc 3.10, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 39160
WiFi IP address 10.0.1.158
WiFi signal strength -52dBm, reconnections 0, sleep mode modem
HTTP sessions: 1 of 8
Socket states: 0 0 0 0 0 0 0 0
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)[/c]

KeeganB · 26 Oct 2017, 02:11

got it reconnected, and it disconnected before i could home it even once.

ran through M552 S-1/S1 and it connected again, immediate disconnect again. It did this pattern 3 times. on the third time it stayed connected for about 45 seconds and then disconnected.

Here is the M122 from IMMEDIATELY after the last disconnect.

[c]>>> M122
SENDING:M122
=== Diagnostics ===
Used output buffers: 1 of 32 (14 max)
=== Platform ===
RepRapFirmware for Duet WiFi version 1.20beta2 running on Duet WiFi 1.0
Board ID: 08DDM-9FAM2-LW4SD-6JTF0-3S86N-TLWZX
Static ram used: 15136
Dynamic ram used: 96560
Recycled dynamic ram: 2992
Stack ram used: 4000 current, 5172 maximum
Never used ram: 11212
Last reset 00:13:49 ago, cause: software
Last software reset reason: User, spinning module GCodes, available RAM 11496 bytes (slot 3)
Software reset code 0x0003, HFSR 0x00000000, CFSR 0x00000000, ICSR 0x00400000, BFAR 0xe000ed38, SP 0xffffffff
Error status: 0
[ERROR] Error status: 0

Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 30.9, current 31.2, max 31.5
Supply voltage: min 12.0, current 12.1, max 12.2, under voltage events: 0, over voltage events: 0
Driver 0: stalled standstill
Driver 1: stalled standstill
Driver 2: stalled standstill
Driver 3: standstill
Driver 4: standstill
Date/time: 2017-10-25 22:09:42
Slowest main loop (seconds): 0.006131; fastest: 0.000098
=== Move ===
MaxReps: 0, StepErrors: 0, FreeDm: 240, MinFreeDm 240, MaxWait: 0ms, Underruns: 0, 0
Scheduled moves: 107, completed moves: 107
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heater = 0, chamber heater = -1
Heater 0 is on, I-accum = 0.0
=== 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 ready with "M122" 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 state is running
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.20beta2
WiFi MAC address 5c:cf:7f:ef:51:6f
WiFi Vcc 3.10, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 38240
WiFi IP address 10.0.1.158
WiFi signal strength -50dBm, reconnections 0, sleep mode modem
HTTP sessions: 1 of 8
Socket states: 0 0 0 0 0 0 0 0
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)[/c]

EDIT: all of that occurred with the front panel off the romax, and a small fan blowing directly on the wifi module.