Extruder motor no longer turns

[deathbydeltabot]

Hi I have a Duet3 Mini that has been working great for about a year. Around a month ago I started having a problem where the extruder motor no longer turns. Sometimes it slightly turns but makes a loud humming noise. The last line in my config.g is M84 but after I turn on the printer and try turn the motor with my hands, I can feel the motor is resisting the movement and seems to be on. I swapped out the stepper motor but the symptoms remained. At one point I turned it off and left it off for a couple days then I powered it on and it worked for a while. I don't remember changing my configuration but maybe I did? Does anyone have any idea what is going wrong? Thanks!

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 Fri Apr 16 2021 20:49:23 GMT-0600 (Mountain Daylight Time)

; General preferences
G90                                                   ; send absolute coordinates...
M83                                                   ; ...but relative extruder moves
M550 P"Deltabot"                                      ; set printer name
M665 R135.508 L288.1 B120 H270.981                    ; Set delta radius, diagonal rod length, printable radius and homed height
M666 X-1.12 Y0.79 Z0.34                               ; put your endstop adjustments here, or let auto calibration find them

M552 S1                                               ; enable/disable network

; Drives
M569 P0.0 S1                                          ; physical drive 0.0 goes forwards
M569 P0.1 S1                                          ; physical drive 0.1 goes forwards
M569 P0.2 S1                                          ; physical drive 0.2 goes forwards
M569 P0.4 S1                                          ; physical drive 0.4 goes forwards
M584 X0.0 Y0.1 Z0.2 E0.4                          ; set drive mapping
M350 X16 Y16 Z16 E16 I1                            ; configure microstepping with interpolation

M92 X80.00 Y80.00 Z80.00 E414.341367639 ; set steps per mm
M566 X1200 Y1200 Z1200 E300 P1                   ; set maximum instantaneous speed changes (mm/min)
M203 X18000 Y18000 Z18000 E6000                 ; set maximum speeds (mm/min)
M201 X1000 Y1000 Z1000 E1000                    ; set accelerations (mm/s^2)

M906 X1100 Y1100 Z1100 E1000 I30                 ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                               ; Set idle timeout

; Axis Limits
M208 Z0 S1                                            ; set minimum Z

; Endstops
M574 X2 S1 P"io0.in"                                  ; configure active-high endstop for high end on X via pin io0.in
M574 Y2 S1 P"io1.in"                                  ; configure active-high endstop for high end on Y via pin io1.in
M574 Z2 S1 P"io2.in"                                  ; configure active-high endstop for high end on Z via pin io2.in

; Z-Probe
M558 P5 C"^io3.in" H5 F120 T3600                      ; set Z probe type to switch and the dive height + speeds
;G31 P500 X0 Y-5 Z14.6                                 ; ZSYong steel nozzle
G31 P500 X0 Y-5 Z14.72                                ;v6 brass nozzle
M557 R115 S20                                         ; define mesh grid

; Heaters
;M308 S0 P"temp0" Y"thermistor" T100000 B4267          ; configure sensor 0 as thermistor on pin temp1
M308 S0 P"temp0" Y"thermistor" T100000 B4725 C7.060000e-8          ; configure sensor 0 as thermistor on pin temp1
M950 H0 C"out0" T0                                    ; create bed heater output on out1 and map it to sensor 0
M307 H0 B0 S1.00                                      ; disable bang-bang mode for the bed heater and set PWM limit
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 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin temp0
M950 H1 C"out1" T1                                    ; create nozzle heater output on 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

; Fans
M950 F0 C"out3" Q500                                  ; create fan 0 on pin out3 and set its frequency
M106 P0 S0 H-1                                        ; set fan 0 value. Thermostatic control is turned off

M950 F1 C"out4" Q500                                  ; create fan 1 on pin out4 and set its frequency
M106 P1 S1 H1 T45                                     ; set fan 1 value. Thermostatic control is turned on

; Tools
M563 P0 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

;Firmware retract
;M207 S5 F1800 Z0.3
M207 S4 F1800

;Pressure Advance 
M572 D0 S0

;Read settings from config.g.override
M501 

T0

;Shut off steppers
M84

config-override.g

; config-override.g file generated in response to M500 at 2022-12-14 22:22
; This is a system-generated file - do not edit
; Delta parameters
M665 L288.100:288.100:288.100 R137.401 H273.134 B120.0 X0.374 Y0.223 Z0.000
M666 X-0.513 Y0.309 Z0.203 A0.00 B0.00
; Heater model parameters
M307 H0 R0.267 C646.752:646.752 D0.89 S1.00 V12.3 B0 I0
M307 H1 R2.363 C272.190:146.837 D5.68 S1.00 V12.4 B0 I0
; Workplace coordinates
G10 L2 P1 X0.00 Y0.00 Z0.00
G10 L2 P2 X0.00 Y0.00 Z0.00
G10 L2 P3 X0.00 Y0.00 Z0.00
G10 L2 P4 X0.00 Y0.00 Z0.00
G10 L2 P5 X0.00 Y0.00 Z0.00
G10 L2 P6 X0.00 Y0.00 Z0.00
G10 L2 P7 X0.00 Y0.00 Z0.00
G10 L2 P8 X0.00 Y0.00 Z0.00
G10 L2 P9 X0.00 Y0.00 Z0.00

[dc42]

@deathbydeltabot most likely only one phase of the stepper motor is getting energised. You are running the motor at 300mA, and the open load detection doesn't function below 500mA.

When you swapped the stepper motor, did you use the same cable as before, or did the new motor have a cable already attached?

If you used the same cable, the problem is most likely a bad crimp connection at the Duet end of the cable.

If you used a different cable, then unless that one also has a bad crimp connection, the problem is most likely bad soldering of a component in the vicinity of the stepper motor output on the Duet. If you post close up photos of the board (both sides) in the vicinity of that connector and the associated stepper driver chip, we may be able to spot that.

[deathbydeltabot]

@dc42 said in Extruder motor no longer turns:

@deathbydeltabot most likely only one phase of the stepper motor is getting energised. You are running the motor at 300mA, and the open load detection doesn't function below 500mA.

When you swapped the stepper motor, did you use the same cable as before, or did the new motor have a cable already attached?

If you used the same cable, the problem is most likely a bad crimp connection at the Duet end of the cable.

If you used a different cable, then unless that one also has a bad crimp connection, the problem is most likely bad soldering of a component in the vicinity of the stepper motor output on the Duet. If you post close up photos of the board (both sides) in the vicinity of that connector and the associated stepper driver chip, we may be able to spot that.

Should I increase the idle factor above to 500ma?

Previously I had used a new motor with the existing cable. I just now used a new motor with a new cable and the motor hummed a high pitched noise for about a second and was on (couldn't turn the shaft). I went to DWC to try to move the motor via console and I was getting spammed with this message "Error: over temperature shutdown reported by driver(s) 4". I've never seen this before and I don't think I would have missed it as it's just coming in every second or so.

Are these pictures good enough? Nothing jumped out at me as damaged.

Thank you for your help!

[dc42]

@deathbydeltabot yes those are good enough. I don't see a problem in those photos.

According to your config.g file, driver 3 is free. Does the extruder motor work if you connect it to driver 3 and change the M584 command to suit?

[deathbydeltabot]

@dc42 I made the changes to just those two lines 0.4 -> 0.3 and moved the cable. Every time I turn on the printer the big gear on my Bondtech BMG immediately turns (about a quarter turn), I don't remember that ever happening before. When I do a G1 E100 the motor appears to turn normally.

[deathbydeltabot]

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