Duet mini 5+ freezes and shuts off heaters

Michael Hathaway

 Config.g
; Configuration file for Duet 3 Mini 5+ (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.2.3 on Sun May 23 2021 16:36:21 GMT-0700 (Pacific Daylight Time)

; General preferences
G90                                                ; send absolute coordinates...
M83                                                ; ...but relative extruder moves
M550 P"Pulse E-423S"                               ; set printer name

; Network
M552 P0.0.0.0 S1                                   ; enable network and acquire dynamic address via DHCP
M586 P0 S1                                         ; enable HTTP
M586 P1 S0                                         ; disable FTP
M586 P2 S0                                         ; disable Telnet

; Drives
M569 P0.0 S0                                       ; X-axis drive 0.0 goes backwards
M569 P0.1 S1                                       ; Y-axis drive 0.1 goes forwards
M569 P0.2 S1                                       ; Z-axis drive 0.2 goes backwards
M569 P0.3 S0                                       ; Extruder drive 0.3 goes forwards
M584 X0.0 Y0.1 Z0.2 E0.3                           ; set drive mapping
M350 X16 Y16 Z16 E16 I1                            ; configure microstepping with interpolation
M92 X80.00 Y80.00 Z400.00 E409.00                  ; set steps per mm
M566 X600.00 Y600.00 Z30.00 E270.00                ; set maximum instantaneous speed changes *(mm/min)(8x60=480) 'jerk speed'
M203 X12000.00 Y12000.00 Z12000.00 E7200.00        ; set maximum speeds *(mm/min)
M201 X1000.00 Y1000.00 Z1000.00 E5000.00           ; set accelerations (mm/s^2)
M906 X1000 Y1200 Z1000 E1000 I40                   ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                            ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z0 S1                                   ; set axis minima
M208 X250 Y225 Z227 S0                             ; set axis maxima

; Endstops
M574 X1 S1 P"io5.in"                               ; configure active-high endstop for low end on X via pin io5.in
M574 Y1 S1 P"io6.in"                               ; configure active-high endstop for low end on Y via pin io6.in
M574 Z1 S1 P"io2.in"                               ; configure active-high endstop for low end on Z via pin io2.in

; Z-Probe
M950 S0 C"io3.out"                                 ; create servo pin 0 for BLTouch
M558 P9 C"io3.in" H5 F1000 T8000                  ; set Z probe type to bltouch and the dive height + speeds F1000 T600
G31 P500 X23 Y10 Z 0.88                         ; *** set Z probe trigger value, offset and trigger height (increase to lower nozzle) glass, g10=0.85
M557 X23:240 Y25:205 S20                           ; define mesh grid M557 X25:225 Y25:205 S20 S40

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4066       ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0                                 ; create bed heater output on out0 and map it to sensor 0
; M307 H0 R0.25 C860.4 D14.2 S1.00 V24.0 B0         ; disable bang-bang mode for the bed heater and set PWM limit
M307 H0 R0.210 K0.413:0.000 D7.79 E1.35 S1.00 B0
M140 H0                                            ; map heated bed to heater 0
M143 H0 S120                                       ; set temperature limit for heater 0 to 120C
; M308 S1 P"temp1" Y"thermistor" T100000 B4275 C7.06e-8 ; configure sensor 1 as thermistor on pin temp1 E3D low temp sensor
; M308 S1 P"temp1" Y"thermistor" T500000 B3800     ; configure sensor 1 as thermistor on pin temp1 Slice Engineering 450C
M308 S1 P"temp1" Y"pt1000"                       ; configure sensor for pt1000 high temp sensor Slice Engineering or Filastruder
M950 H1 C"out1" T1                                 ; create nozzle heater output on out1 and map it to sensor 1
; M307 H1 R2.648 C163.1:161.1 D6.32 S1.00          ; OLD disable bang-bang mode for heater  and set PWM limit
M307 H1 R2.168 K0.365:0.000 D7.57 E1.35 S1.00 B0 V23.9 ; new T0 tuning result
M143 H1 S500                                       ; set temperature limit for heater 1 to 500C

; Fans
; M950 F0 C"out3" Q500                               ; create fan 0 on pin out3 and set its frequency
; M106 P0 C"PartCool" S0 H-1                         ; set fan 0 name and value. Thermostatic control is turned off
M950 F1 C"out4" Q500                               ; create fan 1 on pin out4 and set its frequency
M106 P1 C"HotEnd" S1 H1:0 T35                      ; set fan 1 name and value. Thermostatic control is turned on
M950 F2 C"out5" Q500                               ; create fan 2 on pin out5 and set its frequency
M106 P2 C"CaseFan" S1 H1:0 T35                     ; set fan 2 name and value. Thermostatic control is turned on

; Tools
M563 P0 S"Hotend" D0 H1 F0                         ; define tool 0
G10 P0 X0 Y0 Z0                                    ; set tool 0 axis offsets
G10 P0 R0 S0                                       ; set initial tool 0 active and standby temperatures to 0C

; Filament Runout Switch
M591 D0 P1 C"io_4.in" S1                           ; P0 P1 NO/NC 

; Pressure Advance                                 ; D = extruder drive number, S =amount of pressure advance
; M572 D0 S0.5


; Custom settings
M280 P0 S160					                   ; Clear any alarms
M402							                   ; Retract pin just in case         
M929 P"eventlog.txt" S3                            ; start logging to file eventlog.txt

; Miscellaneous
M911 S10 R11 P"M913 X0 Y0 G91 M83 G1 Z3 E-5 F1000" ; set voltage thresholds and actions to run on power loss
T0                                                 ; select first tool
G29 S1                                             ; Load Height Map

Michael Hathaway

I can try replacing the power supply. I have no idea what else could be causing this issue.

Michael Hathaway

The only spare power supply I had on hand is a Mean Well SE-600-24, 600W. I have it sitting outside the enclosure this time. It is overkill for this printer, I use these on my industrial printers. Ok for testing I hope.

Michael Hathaway

The printer went 5 layers and stopped. I have no idea why it is freezing.

jay_s_uk

@michael-hathaway Is the M122 output you posted from directly after the freeze?

Michael Hathaway

@jay_s_uk

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.4.1 (2022-06-01 21:06:56) running on Duet 3 Mini5plus Ethernet (standalone mode)
Board ID: 6G14B-Z096U-D65J0-40KMD-2113Z-7JZ07
Used output buffers: 1 of 40 (22 max)
=== RTOS ===
Static ram: 103684
Dynamic ram: 105204 of which 0 recycled
Never used RAM 32824, free system stack 204 words
Tasks: NETWORK(ready,26.4%,238) ETHERNET(notifyWait,0.3%,568) HEAT(notifyWait,0.0%,358) Move(notifyWait,0.0%,363) CanReceiv(notifyWait,0.0%,942) CanSender(notifyWait,0.0%,372) CanClock(delaying,0.0%,339) TMC(notifyWait,0.7%,105) MAIN(running,71.7%,422) IDLE(ready,0.1%,29) AIN(delaying,0.8%,264), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:03:26 ago, cause: reset button
Last software reset at 2022-09-06 10:42, reason: User, GCodes spinning, available RAM 32536, 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 206480, completed 206480, timed out 0, errs 0
Step timer max interval 751
MCU temperature: min 48.7, current 48.7, max 51.8
Supply voltage: min 24.0, current 24.0, max 24.0, 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: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 1, ifcnt 27, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 29, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 2, read errors 0, write errors 1, ifcnt 33, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 54, read errors 0, write errors 1, ifcnt 21, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 19, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2022-09-07 02:37:14
Cache data hit count 353060786
Slowest loop: 8.73ms; fastest: 0.13ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 5.2ms, write time 44.1ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: mesh, 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
Heater 1 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
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
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 1856, received 0, lost 0, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 18 (min 18), ts 1032/0/0
Tx timeouts 0,0,1031,0,0,823 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 12.40ms; fastest: 0.03ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 2 of 8
- Ethernet -
State: active
Error counts: 0 0 0 0 0
Socket states: 2 2 2 2 2 0 0 0

Michael Hathaway

This one is directly after freeze

jay_s_uk

@michael-hathaway said in Duet mini 5+ freezes and shuts off heaters:

Last reset 00:03:26 ago, cause: reset button

this is the reason for the "freezes". now its just understanding why this is happening.
Might be a good idea to post a high res picture of the reset button area

Michael Hathaway

@jay_s_uk So the reset button on the board is being triggered?

jay_s_uk

@michael-hathaway yep

Michael Hathaway

Michael Hathaway

Michael Hathaway

Is there anyway of resetting besides pressing that button?

jay_s_uk

@michael-hathaway i suppose the question is when and where did you purchase?
one for @Phaedrux or maybe @droftarts

jay_s_uk

@michael-hathaway said in Duet mini 5+ freezes and shuts off heaters:

Is there anyway of resetting besides pressing that button?

not that i'm aware of

Michael Hathaway

My old board just started doing this recently after 1.5 years use. And my new board does the same exact thing. I purchased from Filastruder 1.5 years ago.

droftarts

@michael-hathaway I just did a quick test on my Mini 5+ to see what a power cycle, M999 (reset) and reset button press reports on restart in M122.
M999:

=== Platform ===
Last reset 00:00:12 ago, cause: software
Last software reset at 2022-09-07 11:54, reason: User, GCodes spinning, available RAM 27680, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00

Reset button:

=== Platform ===
Last reset 00:00:13 ago, cause: reset button
Last software reset at 2022-09-07 11:54, reason: User, GCodes spinning, available RAM 27680, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00

Power cycle:

=== Platform ===
Last reset 00:00:22 ago, cause: power up
Last software reset at 2022-09-07 11:54, reason: User, GCodes spinning, available RAM 27680, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00

I did the M999 first, and that is what the subsequent M122 'Last software reset...' is reporting. I notice that your M122 also reports the same time for 'Last software reset...' so I don't think the reset is coming from the firmware or gcode file.

I think if the firmware is reporting a reset button press, it probably actually is a reset button press or short. Is the printed case you have the Duet in new? My guess is that, as the board heats up, it's flexing slightly and somehow shorting out on the case. Maybe add some nylon washers under your mounting screws (ideally the board should be mounted using nylon washers), to lift the board up a little?

Ian

Michael Hathaway

@droftarts Thank you, I will try that. I will also order a new board just in case I have fried this one.

droftarts

@michael-hathaway Looking at the Mini 5+ schematic (https://raw.githubusercontent.com/Duet3D/Duet3-Mini5plus/main/v1.01/Duet3_5%2B_Wifi_schematic_v1.01.pdf), there are also reset pins on the 12864_EXP2 connector, SWD connector (just behind the reset button, but as it is unpopulated with a header, this shouldn't be a problem) and there's also a test point (on the back of the board, by the SWD connector pins, I think). I don't think you have anything plugged into the 12864 connector, but again check that it is not shorting out to anything, top or bottom.

Ian

Michael Hathaway

I ordered a new Duet mini 5 plus board with overnight postage, should have it tomorrow. I also ordered nylon washers as recommended.

This time when mounting in the petg enclosure, I will allow to board to float and not be fastened down so well.

I have found new Samsung endurance sdcards, which are designed to be powered on continuously. I am hopeful this increases reliability.

I appreciate everyone's help I have received and I will update with my progress as I proceed.