Duet wifi: printer stalls/stops, no errors



  • I have a very weird issue which i have been breaking my head over this weekend. I use a corexy printer (hypercube evolution) and last week had the first good prints with the duet wifi as controller.

    This weekend however, the printer started to stop/stall for it seems no reason at all. When it stops, i can still use the webinterface, except for the printing part (doesn't react anymore). I did some testing and tried 2 different gcode-files: both have the same issue. It prints for a layer or 10 perfectly and just hangs, for both prints always on the exact same point. This made me wonder if it was related to some slicing issue, resliced the stl-file, printed again, same thing, same point. If I change the gcode-file (eg. % of infill or more or less support), the place where it stops changes.

    3 times the same print, the blob on the print is where it stops every time(0_1523344399104_duet.jpg image url)

    I have fired on the debugging / logging on the duet, but it just doesn't show any error.

    Things I have tried:

    • running the duet from a different sdcard (freshly formatted), no joy
    • tried a different slicer (prusa slic3r is my standard one, also tried the cura), this gives me the same issue, only with Cura the point where the printer stops is different
    • different stl's, no joy, even gcode-files i have previously printed succesful, like the 20mm xyztestcube, now stall
    • checked the wiring, all seems just fine
    • config has not changed from the duet wifi
    • i can't get to see a single error happening in whatever loggingmode the firmware offers

    Symptons:

    • the duet works still partly when the print stops
    • it keeps the heatbed and the nozzle on temperature
    • the gcodefiles are fine (since a previously succesful printed one, now has the same issue)

    Firmware/settings:

    Firmware Name: RepRapFirmware for Duet 2 WiFi/Ethernet
    Firmware Electronics: Duet WiFi 1.02 or later
    Firmware Version: 1.21 (2018-03-21)
    WiFi Server Version: 1.21
    Web Interface Version: 1.21

    Config:
    ; Configuration file for Duet WiFi (firmware version 1.20 or newer)
    ; executed by the firmware on start-up
    ;
    ; generated by RepRapFirmware Configuration Tool on Sun Mar 25 2018 16:19:40 GMT+0200 (W. Europe Daylight Time)

    ; General preferences
    G90 ; Send absolute coordinates...
    M83 ; ...but relative extruder moves

    M667 S1 X1 Y1 ; Select CoreXY mode

    ; Network
    M550 Ppolprint ; Set machine name
    M552 S1 ; Enable network
    M587 S"xxx" P"xxx" ; Configure access point. You can delete this line once connected
    M586 P0 S1 ; Enable HTTP
    M586 P1 S0 ; Disable FTP
    M586 P2 S0 ; Disable Telnet

    ; Drives
    M569 P0 S0 ; Drive 0 goes forwards
    M569 P1 S0 ; Drive 1 goes forwards
    M569 P2 S1 ; Drive 2 goes forwards
    M569 P3 S1 ; Drive 3 goes forwards
    M350 X256 Y256 I1
    M350 Z16 E32 I0
    M92 X1280 Y1280 Z382 E200 ; Set steps per mm
    M566 X1500 Y1500 Z600 E600 ; Set maximum instantaneous speed changes (mm/min)
    M203 X12000 Y12000 Z600 E12000 ; Set maximum speeds (mm/min)
    M201 X1000 Y1000 Z20 E1000 ; Set accelerations (mm/s^2)
    M906 X1000 Y1000 Z1000 E1400 ; Set motor currents (mA) and motor idle factor in per cent

    ; Axis Limits
    M208 X0 Y0 Z0 S1 ; Set axis minima
    M208 X220 Y220 Z260 ; Set axis maxima

    ; Endstops
    M574 X1 Y1 S3 ; Set endstops controlled by motor load detection
    M574 Z1 S1
    ; Z-Probe

    ; Heaters
    M301 H0 S1.00 P10 I0.1 D200 T0.4 W180 B30 ; Use PID on bed heater (may require further tuning)
    M305 P0 T100000 B4138 C0 R4700 ; Set thermistor + ADC parameters for heater 0
    M143 H0 S90 ; Set temperature limit for heater 0 to 90C
    M305 P1 T100000 B4725 C7.06e-8 R4700 ; Set thermistor + ADC parameters for heater 1
    M143 H1 S280 ; Set temperature limit for heater 1 to 280C

    ; Fans
    M106 P0 S1 I0 F500 H1 T45 ; Set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned on
    M106 P1 S0 I0 F500 H-1 ; Set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned off
    M106 P2 S0 I0 F500 H-1 ; Set fan 2 value, PWM signal inversion and frequency. Thermostatic control is turned off

    ; Tools
    M563 P1 D0 H1 F1
    ; Automatic saving after power loss is not enabled

    ; Custom settings are not configured
    ;M572 D0 S0.1
    M207 S3.4 F2500 Z0.2


  • administrators

    To clarify: the print always stops at the same XY position, but after a variable number of layers. Correct?

    Is it a Duet WiFi or a Duet Ethernet?

    When this happens, what is the status shown at the top right of DWC, to the left of the Emergency Stop button? Is it Idle, Printing, or something else?

    Please be aware than enabling debugging when you do not have the USB port connected to a PC and a host program or terminal emulator running on the PC is not recommended.



  • It stops at the same layer (for the same gcode 🙂 if i slice the stl different (other percentage support), it stops at another layer). For each different stl i have, the layer and xy at which it stops is different. When I run the same stl several times, the layer and xy at which it stops is the same.

    At the topright it still says 'Printing', however, in the printer module there is no reaction on whatever. Pause and babystepping do not trigger any reaction.

    It is a duet wifi


  • administrators

    Please provide a gcode file that shows this problem, preferably after not many layers, and tell me the approximate layer or object height at which it stalls. Also your config.g file. I will try to reproduce it.



  • the config-files
    0_1523349898943_config-override.g 0_1523350166726_config.g

    and the g-code files via wetransfer (both give the issue here, though every gcode file does currently :P). The printer stalls at around ~1.35mm height (printing at 0.2 layerheight) :
    https://we.tl/2hXLfVSJQb



  • just did another test: still the same. In the printing module, the layertime keeps counting though. Maybe another clue of some sort.

    Also after a firmware reflash: still the same thing


  • administrators

    I just tried printing your file and it stopped at height 0.3mm. I'm still trying to work out why.

    I noticed something odd with that GCode file. You appear to be using firmware retraction, yet the slicer is generating Z hop around the travel moves. Normally if you are using firmware retraction, you should configure the Z hop in the M207 command, not in the slicer.


  • administrators

    More progress. I noticed that your MaxReps figure was very high (over 900), and on investigation I found that you are using x256 microstepping. A MaxReps figure over 50 is not advisable. So I changed the X and Y microstepping back to x16 with interpolation (after the M92 command, so that the steps/mm gets adjusted properly). Now the print no longer stalls at 0.3mm. As I write this, the print has reached 4.15mm and is still going.

    There is still a bug for me to investigate, because even with MaxReps far too high the print shouldn't stall. However, I suspect that your print will complete if you reduce microstepping.

    I may eventually implement dynamically varying microstepping, so that you can select x256 and it will be reduced automatically when the speed is high enough to make the step rate too high. But for now I suggest you reduce microstepping. The default of x16 with interpolation works well for most people, but try x32 or x64 instead if you like.



  • @dc42 you really rock! Thanks for your help, it was driving me mad here haha 😄 It still is very weird that it does print a few layers very nicely (that's how i think i managed to get those numbers so high, it printed fine). Will try your solution now asap.


  • administrators

    @janko said in Duet wifi: printer stalls/stops, no errors:

    @dc42 you really rock! Thanks for your help, it was driving me mad here haha 😄 It still is very weird that it does print a few layers very nicely (that's how i think i managed to get those numbers so high, it printed fine). Will try your solution now asap.

    It might be that the speeds are lower for the first layer, or couple of layers?



  • @t3p3tony it not even might be, they are. However, the feedback i got from printing was a bit mixed. I had one which only did the first layer outline before just stopping. I'm now trying dc42 his solution, see what it brings.


  • administrators

    Yeah i am sure @dc42's solution is the way to go. I just meant that it could be that the reason it made it part way into the print was that the early layers were printed slower.



  • @t3p3tony it does call for some testing, doesn't it? 😉 After the mount for my psu and my xcarrage has finished, i'll see what happens if i thinker with the layerspeed at 256 microstepping.



  • @dc42 your solution is confirmed, tried it on the same file again i sended you, it now continues


  • administrators

    @janko said in Duet wifi: printer stalls/stops, no errors:

    @t3p3tony it does call for some testing, doesn't it? 😉 After the mount for my psu and my xcarrage has finished, i'll see what happens if i thinker with the layerspeed at 256 microstepping.

    Well it does not hurt to understand what is going on for sure. use the max reps report in the M122 report, rather than waiting for the print to fail.



  • I seem to be having the same issue. First it only happened in the first few layers like in the pictures. Usually in the same spot but not always. I was generally able to just restart the print and have it work fine. However, I just lost one halfway through. The printer just stops, heater and fans are still running and the web interface thinks that the print is still running. It give me the option to pause but nothing happens. Very weird. I have included an m122 readout below. I will reduce the microstepping as you suggest. Just doing my part to help diagnose.

    M122
    === Diagnostics ===
    Used output buffers: 3 of 32 (9 max)
    === Platform ===
    RepRapFirmware for Duet 2 WiFi/Ethernet version 1.21 running on Duet WiFi 1.02 or later + DueX5
    Board ID: 08DDM-9FAM2-LW4S8-6JTDG-3SD6R-13YMX
    Static ram used: 16152
    Dynamic ram used: 100536
    Recycled dynamic ram: 2096
    Stack ram used: 1224 current, 6632 maximum
    Never used ram: 5656
    Last reset 01:30:37 ago, cause: power up
    Last software reset at 2018-04-29 01:54, reason: User, spinning module GCodes, available RAM 5656 bytes (slot 3)
    Software reset code 0x0003 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x04417000, BFAR 0xe000ed38, SP 0xffffffff
    Error status: 0
    Free file entries: 9
    SD card 0 detected, interface speed: 20.0MBytes/sec
    SD card longest block write time: 126.7ms
    MCU temperature: min 19.7, current 30.5, max 31.0
    Supply voltage: min 23.7, current 23.8, max 24.3, under voltage events: 0, over voltage events: 0
    Driver 0: standstill, SG min/max 0/393
    Driver 1: standstill, SG min/max 0/1023
    Driver 2: standstill, SG min/max 0/267
    Driver 3: standstill, SG min/max 0/1023
    Driver 4: standstill, SG min/max not available
    Driver 5: standstill, SG min/max not available
    Driver 6: standstill, SG min/max not available
    Driver 7: standstill, SG min/max not available
    Driver 8: standstill, SG min/max not available
    Driver 9: standstill, SG min/max not available
    Expansion motor(s) stall indication: no
    Date/time: 2018-04-30 14:58:10
    Slowest main loop (seconds): 0.980719; fastest: 0.000051
    === Move ===
    MaxReps: 508091, StepErrors: 0, LaErrors: 0, FreeDm: 121, MinFreeDm 120, MaxWait: 3635039563ms, Underruns: 277, 0
    Scheduled moves: 64659, completed moves: 64629
    Bed compensation in use: mesh
    Bed probe heights: 0.000 0.000 0.000 0.000 0.000
    === Heat ===
    Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
    Heater 0 is on, I-accum = 0.0
    Heater 1 is on, I-accum = 0.8
    === GCodes ===
    Segments left: 1
    Stack records: 2 allocated, 0 in use
    Movement lock held by null
    http is idle in state(s) 0
    telnet is idle in state(s) 0
    file is doing "G1 X135.148 Y112.675 E0.0579" in state(s) 0
    serial is idle in state(s) 0
    aux is idle in state(s) 0
    daemon is idle in state(s) 0
    queue is idle in state(s) 0
    autopause is idle in state(s) 0
    Code queue is empty.
    === Network ===
    Responder states: HTTP(1) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
    HTTP sessions: 1 of 8

    • WiFi -
      Network state is running
      WiFi module is connected to access point
      Failed messages: pending 0, notready 0, noresp 0
      WiFi firmware version 1.21
      WiFi MAC address 5c:cf:7f:a4:89:b8
      WiFi Vcc 3.38, reset reason Turned on by main processor
      WiFi flash size 4194304, free heap 15552
      WiFi IP address 192.168.1.201
      WiFi signal strength -64dBm, reconnections 0, sleep mode modem
      Socket states: 2 0 0 0 0 0 0 0
      === Expansion ===
      DueX I2C errors 0

  • administrators

    I believe this issue is fixed in the 2.0beta series firmware. Bete 3 seems to be stable with no known bugs, so please try that version.


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