Help please Duet 3 mini randomly resets during printing

[MikeNative]

This is M22 generated after printing for half hour, cannot see any obvious faults, there is a slight voltage drop but that is it.

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.3 (2021-06-15 21:46:11) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: 95T1H-7396U-D65J0-40KMQ-L413Z-76AHS
Used output buffers: 3 of 40 (26 max)
=== RTOS ===
Static ram: 102724
Dynamic ram: 106536 of which 0 recycled
Never used RAM 31588, free system stack 120 words
Tasks: NETWORK(ready,15.6%,226) HEAT(notifyWait,0.0%,366) Move(notifyWait,0.1%,292) CanReceiv(notifyWait,0.0%,941) CanSender(notifyWait,0.0%,357) CanClock(delaying,0.0%,340) TMC(notifyWait,0.7%,114) MAIN(running,82.8%,412) IDLE(ready,0.0%,29) AIN(delaying,0.8%,266), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 01:40:30 ago, cause: software
Last software reset at 2021-10-28 08:41, reason: User, GCodes spinning, available RAM 34444, slot 1
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
MCU revision 3, ADC conversions started 6030451, completed 6030451, timed out 0, errs 0
Step timer max interval 1488
MCU temperature: min 21.9, current 25.2, max 25.4
Supply voltage: min 12.8, current 13.9, max 14.2, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/1, heap memory allocated/used/recyclable 2048/14/0, gc cycles 0
Driver 0: position 9961, ok, SG min/max 0/118, read errors 0, write errors 0, ifcnt 21, reads 26584, writes 2, timeouts 0, DMA errors 0
Driver 1: position 15309, ok, SG min/max 0/92, read errors 0, write errors 0, ifcnt 21, reads 26584, writes 2, timeouts 0, DMA errors 0
Driver 2: position 1047, standstill, SG min/max 0/18, read errors 0, write errors 0, ifcnt 21, reads 26584, writes 2, timeouts 0, DMA errors 0
Driver 3: position 0, standstill, SG min/max 0/16, read errors 0, write errors 0, ifcnt 21, reads 26584, writes 2, timeouts 0, DMA errors 0
Driver 4: position 0, ok, SG min/max 0/34, read errors 0, write errors 0, ifcnt 21, reads 26584, writes 2, timeouts 0, DMA errors 0
Driver 5: position 0, assumed not present
Driver 6: position 0, assumed not present
Date/time: 2021-10-28 10:22:01
Cache data hit count 4294967295
Slowest loop: 375.89ms; fastest: 0.10ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 4.1ms, write time 208.5ms, max retries 0
=== Move ===
DMs created 83, maxWait 3188961ms, bed compensation in use: mesh, comp offset 0.000
=== MainDDARing ===
Scheduled moves 7524, completed moves 7513, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== 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, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.3
Heater 1 is on, I-accum = 0.8
=== GCodes ===
Segments left: 1
Movement lock held by null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X125.206 Y237.314 E48.3477" 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
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty.
=== CAN ===
Messages queued 26967, received 0, lost 0, longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 17 (min 17), ts 14979/0/0
Tx timeouts 0,4,14979,0,0,11983 last cancelled message type 30 dest 127

=== Network ===
Slowest loop: 658.01ms; fastest: 0.06ms
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 4
WiFi firmware version 1.26
WiFi MAC address d8:bf:c0:14:e7:e9
WiFi Vcc 3.40, reset reason Power up
WiFi flash size 2097152, free heap 26072
WiFi IP address 192.168.4.103
WiFi signal strength -54dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

[T3P3Tony]

@mikenative

how is the board mounted and when did this start happening? How long had you used the board before it started?

Do you get the cause "reset button" on every time you get a reset? when you send M122?

READ: Last reset 07:27:49 ago, cause: reset button

[T3P3Tony]

@mikenative and can you send a high res picture of the board. want to see if that air compressor blew off any tiny components.

[MikeNative]

@t3p3tony The board is mounted inside the original creality case on a 3D printed adapter.

It has a cooling fan either side to prevent overheating and nothing could touch the reset button as there are no moving parts.

Here is a picture. Normally there would be a power supply board in there below the duet but I have that externally for the moment whilst it is having problems.

[MikeNative]

@t3p3tony I will try and get a picture. Just testing the printer with a lower PWM speed for the bed SSR as that was the last thing on my list of possible issues that could be causing power supply problems. Will have to unplug everything to get to the board. I did examine it very carefully both before and after blasting it with air as I was specifically looking for anything that could possibly cause a short circuit. It looked like what it was, a brand new board

[dc42]

@mikenative are you by any chance printing multiple objects, with more than 20 on the build plate?

[MikeNative]

@dc42 No just one big object at a time, usually around 1kg of filament per print.

I did read about a glitch that effected prints containing more than a certain number of objects, however the stuff we print is so big it has to get chopped up to even fit on the printer bed. The job I need the printer for is going to use around 35kg of filament and each section is roughly 300mm of square tube with 4.5mm wall thickness. Should be an easy job for the printer. You can see roughly what I mean in the picture. Prints are between 300mm-350mm tall. Excuse the sketchy glass bed, the bed on our other CR10-5s broke and I grabbed a random bit of toughened glass and stuck it on this printer as the touch probe can accommodate the difference in z height and the other printer has a fixed z endstop.

6FEC339A-5A27-4A2D-A928-0ADCCF4D9547.jpeg tall

When the printer is running it is absolutely perfect, basically silent and very smooth. Being a bed slinger with a massive bed and using a big nozzle to print heavy parts means I have the speeds turned right down.

[T3P3Tony]

@mikenative At this point i just need a picture in the area of the reset switch and SWD header specifically the components highlighted here:

[MikeNative]

@t3p3tony Ok cool I will get one in the morning. Thanks for the help

[MikeNative]

@t3p3tony I have solved it

Was kind of my fault. When I originally setup the printer it had no heated bed as a wire was broken. When I recommissioned the bed I activated it in the firmware but forgot all about setting a PWM frequency for the SSR. After experiencing the issue with the printer hanging up multiple times I went totally through the whole power supply chain and replaced everything with components I 100% knew to be working.

After this didn’t work I racked my brain and remembered there was a SSR being controlled with a PWM signal. As soon as I put in a frequency parameter of 10hz the issue went away. The printer has now completed 3 x 24 to 30 hour prints.

My guess is the default PWM frequency was causing the SSR to leak or feedback power which effected the reliability of the board and made it reset after a few hours. I am not an electronic engineer by any standard so this is just an assumption.

Thank you for your help. Hopefully if anyone else experiences a similar issue this information might come in handy and allow them to resolve the problem.

All the best