[3.4.0beta6] random mid print crash continuing....

[Nuramori]

This has been happening for most of the 3.4 betas for me. This was the latest M122 data for both the toolboard (v1.1) and the main duet3 board.

Toolboard M122 Data:

11/23/2021, 8:06:10 AM	M122 B20
Diagnostics for board 20:
Duet TOOL1LC rev 1.1 or later firmware version 3.4.0beta6 (2021-11-06 11:56:11)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
Never used RAM 3032, free system stack 2788 words
Tasks: Move(notifyWait,0.0%,153) HEAT(notifyWait,0.1%,99) CanAsync(notifyWait,0.0%,64) CanRecv(notifyWait,0.0%,77) CanClock(notifyWait,0.0%,64) ACCEL(notifyWait,0.0%,61) TMC(notifyWait,3.0%,57) MAIN(running,92.0%,440) IDLE(ready,0.0%,27) AIN(delaying,4.9%,148), total 100.0%
Last reset 01:05:22 ago, cause: software
Last software reset at 2021-08-23 15:12, reason: WatchdogTimeout, available RAM 2680, slot 0
Software reset code 0x00a0 ICSR 0x14413011 SP 0x20007f28 Task MAIN Freestk 5938 ok
Stack: 00000000 41000000 00000015 00000000 41000000 0000a78d 00016a4c 01000013 a5a5a5a5 00000000 20003324 20003360 20003364 fffffffd a29e9d69 00000000 00000002 00000000 00000002 00019477 00000000 2000213c 200020e0 20002088 00022640 200020e0 2000213c
Driver 0: pos 0, 80.0 steps/mm,standstill, SG min 2, read errors 0, write errors 1, ifcnt 24, reads 60695, writes 9, timeouts 0, DMA errors 0, steps req 0 done 0
Moves scheduled 0, completed 0, in progress 0, hiccups 0, step errors 0, maxPrep 0, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter 6/8, peak Rx sync delay 189, resyncs 0/0, no step interrupt scheduled
VIN voltage: min 23.5, current 23.5, max 23.5
MCU temperature: min 39.2C, current 39.7C, max 54.4C
Last sensors broadcast 0x00000000 found 0 30 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 32717, send timeouts 3910, received 51, lost 0, free buffers 37, min 37, error reg 110000
Last cancelled message type 4525 dest 127
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 0
Accelerometer detected: yes, status: 00
I2C bus errors 0, naks 3, other errors 0

This is the report using M122 with the main board....

11/23/2021, 8:06:05 AM	M122
=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.4.0beta6 (2021-11-06 11:38:57) running on Duet 3 MB6HC v0.6 or 1.0 (SBC mode)
Board ID: 08DJM-956L2-G43S4-6J1F2-3SJ6T-1A6QH
Used output buffers: 1 of 40 (12 max)
=== RTOS ===
Static ram: 151136
Dynamic ram: 64492 of which 0 recycled
Never used RAM 135044, free system stack 200 words
Tasks: SBC(ready,0.6%,518) HEAT(notifyWait,0.0%,374) Move(notifyWait,0.0%,352) CanReceiv(notifyWait,3.3%,796) CanSender(notifyWait,0.0%,373) CanClock(delaying,0.0%,352) TMC(notifyWait,7.1%,92) MAIN(running,83.5%,1261) IDLE(ready,5.4%,30), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 00:00:02 ago, cause: software
Last software reset at 2021-11-23 13:06, reason: HardFault, GCodes spinning, available RAM 112740, slot 2
Software reset code 0x4063 HFSR 0x40000000 CFSR 0x00000082 ICSR 0x0044a803 BFAR 0x00000038 SP 0x2041b000 Task MAIN Freestk 1416 ok
Stack: 00000000 2041b098 2041b09c 2041b0a0 00000000 00475b67 0047c6a0 61000200 0a302029 0a302000 00000000 00481fdf 00000000 00000000 2041b02c ffffffff 0000000a 2041970c 20419984 30000001 2042156c 30000001 20428428 004820fb 00000001 2041b080 2041b0a8
Error status: 0x00
Aux0 errors 0,0,0
Step timer max interval 1473
MCU temperature: min 29.8, current 29.9, max 30.1
Supply voltage: min 23.2, current 23.3, max 23.3, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.0, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Driver 0: pos 0, standstill, SG min 0, mspos 536, reads 15646, writes 11 timeouts 0
Driver 1: pos 0, standstill, SG min 0, mspos 248, reads 15646, writes 11 timeouts 0
Driver 2: pos 0, standstill, SG min 0, mspos 456, reads 15646, writes 11 timeouts 0
Driver 3: pos 0, standstill, SG min 0, mspos 856, reads 15646, writes 11 timeouts 0
Driver 4: pos 0, standstill, SG min 0, mspos 120, reads 15646, writes 11 timeouts 0
Driver 5: pos 0, standstill, SG min 0, mspos 8, reads 15646, writes 11 timeouts 0
Date/time: 2021-11-23 13:06:46
Slowest loop: 1.04ms; fastest: 0.00ms
=== Storage ===
Free file entries: 10
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 0, maxWait 0ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
=== GCodes ===
Segments left: 0
Movement lock held by null
HTTP* is doing "M122" 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 doing "G4 S6" in state(s) 0 0, running macro
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 20, received 11072, lost 0, longest wait 0ms for reply type 0, peak Tx sync delay 238, free buffers 49 (min 49), ts 15/14/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 4, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 63345/112
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0, IAP RAM available 0x2b68c
Buffer RX/TX: 120/484-0
=== Duet Control Server ===
Duet Control Server v3.4-b6
Trigger:
Buffered code: G4 S6 ; Wait for toolboard to start
Buffered code: M584 X0.3 Y0.2 Z0.0:0.1:0.4 E20.0 ; set drive mapping to each axis
Buffered code: M669 K1 ; Select CoreXY mode - New format
Buffered code: M569 P0.0 S0 ; physical drive 0 goes backwards - Z Axis Left (1)
Buffered code: M569 P0.1 S0 ; physical drive 1 goes backwards - Z Axis Right Back (2)
Buffered code: M569 P0.2 S0 ; physical drive 2 goes backwards - Y Axis, activate Stealthchop
Buffered code: M569 P0.3 S0 ; physical drive 3 goes backwards - X Axis, activate Stealthchop
Buffered code: M569 P0.4 S0 ; physical drive 4 goes backwards - Z Axis Right Front (3)
Buffered code: M569 P20.0 S1 ; physical drive 5 goes forwards - Extruder 1
==> 372 bytes
Executing macro config.g, started by system
> Next stack level
Code buffer space: 3612
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 36.54, max wait times: 216.5ms/10.2ms
Codes per second: 23.86
Maximum length of RX/TX data transfers: 3228/1684

When this crash occurs, a dialog box pops up in the middle of the screen saying that a reset is required to continue, but I was able to not click on that and instead go to the console window and send the M122 commands. I'm hoping the data points to what may be causing this.

[Nuramori]

@dc42 any thoughts?

[chrishamm]

@nuramori Is it reproducible? If yes, please share your config.g and the print job file.

[dc42]

@nuramori what's happened is that an emergency stop has been executed. This could occur because a M112 command has been executed, or there has been a heater fault that has not been acknowledged by the user within the allowed time (in which case there should be a message on the console).

Your M122 report has highlighted a bug (not the cause of the emergency stop) that causes the machine to reset if you run M122 when the machine is in the halted state after an emergency stop. I will fix that in 3.4.0beta7.

So the question is: what caused the emergency stop?

[Nuramori]

@dc42 I hadn’t seen any other errors. In the abundance of caution I am replacing the heater and sensor, and will run prints again. The stoppage is rather random and doesn’t happen all the time, but I e posted about the issue since the first beta. It had not been happening prior to that.

That being said I have had with the previous beta where the printer hadn’t stopped but the head was cold and had not been extruding at all; without an error report of some kind, the head was moving, but the heater was not operational.