Toolboard 1LC heater falut mid print

fotomas

My toolboard gave up during a 12h+ print.

Duet3 5 Mini, Toolboard 1.1. FW 3.4.0beta2

I started a print, checked on it after about 10 hours and noticed that the hotend cooling fan (noctua 10x40 on a Hemera) spun rather slow, should be max speed above 45 degrees.

Some time later (about an hour) the print failed with heater fault.

I could not get rid of the "heater fault" and 2000c . I checked wiring and found no problems. Checked resistance of thermistor (connected to temp0), no problems found. Hotend fan works, part cooling fan works, BLTouch works. (I have not tested the extruder)

Tried connecting the termistor to the other temp port on the toolboard (temp1), no luck there either.

So I wired the thermistor directly to the main board and the web interface started to display temperatures again. (Panel Due still shows 2000c ?!?) But I still got "fault" on the heater. So something seems to be wrong with my toolboard. So I tried a reset by keeping booth buttons pressed when powering on, did not help either.
Config: config.g

M122 for the toolboard shows "error reg 110000" if that could be a clue?

Is there any hope for recovery ?

M122 B121
Diagnostics for board 121:
Duet TOOL1LC firmware version 3.3 (2021-06-15 16:12:58)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
Never used RAM 2692, free system stack 2789 words
Tasks: Move(notifyWait,0.0%,153) HEAT(delaying,0.1%,117) CanAsync(notifyWait,0.0%,65) CanRecv(notifyWait,0.0%,76) CanClock(notifyWait,0.0%,65) ACCEL(notifyWait,0.0%,61) TMC(delaying,2.8%,57) MAIN(running,92.1%,420) IDLE(ready,0.0%,27) AIN(delaying,4.9%,142), total 100.0%
Last reset 00:02:32 ago, cause: power up
Last software reset data not available
Driver 0: position 0, 840.0 steps/mm, standstill, SG min/max 0/0, read errors 0, write errors 0, ifcnt 12, reads 10446, writes 12, 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 -2/8, peak Rx sync delay 210, resyncs 0/0, no step interrupt scheduled
VIN: 24.5V
MCU temperature: min 19.9C, current 29.8C, max 29.9C
Ticks since heat task active 19, ADC conversions started 152014, completed 152012, timed out 0, errs 0
Last sensors broadcast 0x00000000 found 0 24 ticks ago, loop time 0
CAN messages queued 1248, send timeouts 0, received 1388, lost 0, free buffers 37, min 37, error reg 110000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 0
Accelerometer detected: yes, status: 00
I2C bus errors 0, naks 0, other errors 0

Phaedrux

@fotomas said in Toolboard 1LC heater falut mid print:

Duet3 5 Mini, Toolboard 1.1. FW 3.4.0beta2

3.4b2 or 3.3?

@fotomas said in Toolboard 1LC heater falut mid print:

Duet TOOL1LC firmware version 3.3

fotomas

@phaedrux

It is 3.4b2 on the main board. I have used this firmware since its release, With no trouble until now.

Phaedrux

The firmwares should match.

Vinculum

Ok, I have the exact same issue. I had it before but it coinsided with another error and eventually i ripped the toolboard of the printer (see https://forum.duet3d.com/topic/25908/extruder-motor-suddenly-getting-extremely-hot).
But now I have a completely different printer and a different toolboard but it still happened.

Had a 88 hour print and it failed midway. Temp sensor says 2000 degrees but the printer doesn't go into error mode, it just continues.
I then stopped the print, decoupled the thermistor and connected a brand new one. Temp still at 2000.
Reset just the board with the 2 buttons, no effect. Reset the board with M999 B121, no effect. Unplugged the power from the toolboard, no effect.
Only after a reset of the 6HC it came back online and with the original temperature sensor...
All run the same firmware, 3.4.0beta7.

fotomas

@hbm-3d said in Toolboard 1LC heater falut mid print:

Only after a reset of the 6HC

Interesting, what do you mean by "Only after a reset of the 6HC"?
Pressing reset button or issuing a command?

Vinculum

@fotomas I pressed the reset button on the mainboard.

fotomas

I have picked up this problem again after upgrading my printer to firmware 3.4.

Both my 5+ Mini board and Toolboard run firmware 3.4.

To overcome this issue temporarily I have cameld from the 5+ mini direct to the thermistor and heater.

What I did now was upgrade to 3.4 and reconnected the thermistor to the toolboar again and changed back to my previous config:

;M308 S1 P"temp1" Y"thermistor" T100000 B4725 C7.06e-8 ;
M308 S1 P"121.temp0" Y"thermistor" T100000 B4725 C7.06e-8 ;

Unfortunately the issue remains and I have no clue what to do next ?!!

Screenshot 2022-03-19 201929.png

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.4.0 (2022-03-15 09:00:04)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 2804, free system stack 88 words
Tasks: Move(notifyWait,0.0%,153) HEAT(notifyWait,0.1%,115) CanAsync(notifyWait,0.0%,65) CanRecv(notifyWait,0.0%,76) CanClock(notifyWait,0.0%,65) ACCEL(notifyWait,0.0%,61) TMC(notifyWait,3.0%,57) MAIN(running,92.0%,351) IDLE(ready,0.0%,26) AIN(delaying,4.9%,142), total 100.0%
Last reset 00:05:30 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 840.0 steps/mm,standstill, SG min 0, read errors 0, write errors 1, ifcnt 25, reads 34192, writes 12, timeouts 0, DMA errors 0, CC 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 -2/10, peak Rx sync delay 205, resyncs 0/0, no step interrupt scheduled
VIN voltage: min 24.5, current 24.5, max 24.5
MCU temperature: min 35.7C, current 37.9C, max 38.0C
Last sensors broadcast 0x00000002 found 1 89 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 5312, send timeouts 0, received 2989, lost 0, free buffers 37, min 37, error reg 110000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 0
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, other errors 0

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.4.0 (2022-03-15 18:59:15) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: DL70G-S396U-D65J0-40KMW-2303Z-HP9WR
Used output buffers: 11 of 40 (23 max)
=== RTOS ===
Static ram: 103684
Dynamic ram: 110360 of which 28 recycled
Never used RAM 27640, free system stack 190 words
Tasks: NETWORK(ready,14.1%,255) HEAT(notifyWait,0.0%,367) Move(notifyWait,0.0%,363) CanReceiv(notifyWait,0.0%,772) CanSender(notifyWait,0.0%,372) CanClock(delaying,0.0%,346) TMC(notifyWait,0.7%,105) MAIN(running,84.3%,428) IDLE(ready,0.1%,29) AIN(delaying,0.8%,264), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:06:55 ago, cause: software
Last software reset at 2022-03-19 20:03, reason: User, GCodes spinning, available RAM 27592, 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
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 415196, completed 415194, timed out 0, errs 0
Step timer max interval 1065
MCU temperature: min 34.4, current 36.6, max 36.6
Supply voltage: min 24.4, current 24.4, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 1, ifcnt 24, reads 21825, writes 11, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 26, reads 21824, writes 12, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 19, reads 21827, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 25, reads 21823, writes 12, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 24, reads 21825, writes 11, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2022-03-19 20:10:28
Cache data hit count 788041111
Slowest loop: 27.07ms; fastest: 0.13ms
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 3.3ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, 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 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 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
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 3755, received 6679, lost 0, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 251, free buffers 18 (min 17), ts 2076/2075/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 16.85ms; fastest: 0.00ms
Responder states: HTTP(2) 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 1.26
WiFi MAC address f0:08:d1:02:ef:4b
WiFi Vcc 3.40, reset reason Power up
WiFi flash size 2097152, free heap 25200
WiFi IP address 192.168.0.117
WiFi signal strength -48dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 4 0 0 0 0 0 0 0

jay_s_uk

@fotomas can you try using temp1?

fotomas

@jay_s_uk Maybe I was not clear in my explanation. After this happened I added four wires from the Mini 5+ to the heater and thermistor, That have worked fine, but partly defeats the purpose of havinga toolboard.

After upgrading both the toolboard an main board to firmware 3.4 I switched back to using the toolboard for the thermistor and the issue still remains. In other words the firmware upgrade and bringing the toolboard to the same firmware version as the main board did not help.

jay_s_uk

@fotomas I meant using temp1 on the toolboard

fotomas

@jay_s_uk Ah.. sorry

Connected the thermistor to the toolboars temp1 connector, the beside IO2,

changed config.g as listed below:


;M308 S1 P"temp1" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin temp1
M308 S1 P"121.temp1" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin 121.temp1
;M308 S1 P"121.temp0" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin 121.temp0
M950 H1 C"out2" T1                                  ; create nozzle heater output on out2 and map it to sensor 1
;M950 H1 C"121.out0" T1                                  ; create nozzle heater output on 121.out0 and map it to sensor 1
M307 H1 B0 S1.00                                        ; disable bang-bang mode for heater  and set PWM limit
M143 H1 S280                                            ; set temperature limit for heater 1 to 280C

And got:

Screenshot 2022-03-20 103410.png

I have dome my best to verify that the wiring is not the problem but I get the same message with the thermistor disconnected.

for those who have not read the whole thread:
The Hotend heater connection (OUT0) does not function either but all the other stuff works:

Part cooling fan,
Hotend cooling fan,
BL-Toouch,
X endstop & Y endstop (IO3)
Extruder stepper motor

I am starting to think that my toolboard is broken in some way.

What else can I try?

jay_s_uk

@fotomas when and where did you buy it?
One for @Phaedrux to comment on

fotomas

@jay_s_uk

17.05.2021
https://www.dold-mechatronik.de

Phaedrux

Please send an email to warranty@duet3d.com and CC your reseller. Include a link to this forum thread and the details of your original purchase. You'll receive a reply with a form to fill out.