Heater Faults

Mysta

So I am printing fantasy castle as a sort of endurance test and a good ways in I got a heater fault, resumed print, another. Tried turning off cooling fan and that didn't make a difference. So ran a PID tune with 30% fan on and saved parameters and still, another heat fault.

I sat and watched it each time and noticed the temp would dip quite a bit and the heater would not be on(I have a smart effector so I could see the light) - should I continue to PID tune? Seems very strange that it would just not power it for long enough to throw a heater fault. If I upgrade to RTOS and try will the resurrect file stay/work?

11:43:22 AMM122
=== Diagnostics ===
Used output buffers: 3 of 32 (14 max)
=== Platform ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 1.21 running on Duet WiFi 1.02 or later
Board ID: 08DDM-9FAM2-LW4S4-6JKFL-3SJ6J-KJVBY
Static ram used: 16152
Dynamic ram used: 100632
Recycled dynamic ram: 2000
Stack ram used: 1224 current, 6480 maximum
Never used ram: 5808
Last reset 00:41:01 ago, cause: power up
Last software reset at 2018-04-25 03:54, reason: User, spinning module GCodes, available RAM 4564 bytes (slot 0)
Software reset code 0x0003 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x0441f000, 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: 527.8ms
MCU temperature: min 41.1, current 44.5, max 44.8
Supply voltage: min 23.9, current 24.1, max 24.4, under voltage events: 0, over voltage events: 0
Driver 0: standstill, SG min/max 0/1023
Driver 1: standstill, SG min/max 0/386
Driver 2: standstill, SG min/max 0/553
Driver 3: standstill, SG min/max 0/160
Driver 4: standstill, SG min/max not available
Date/time: 2018-04-29 15:43:19
Slowest main loop (seconds): 0.610332; fastest: 0.000111
=== Move ===
MaxReps: 5, StepErrors: 0, LaErrors: 0, FreeDm: 240, MinFreeDm 120, MaxWait: 831704ms, Underruns: 0, 0
Scheduled moves: 15346, completed moves: 15346
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = -1 -1 -1 -1, chamberHeaters = -1 -1
Heater 1 is on, I-accum = 0.5
=== GCodes ===
Segments left: 0
Stack records: 3 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 idle 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: 2 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 60:01:94:73:5a:b6
WiFi Vcc 3.36, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 16944
WiFi IP address 192.168.1.32
WiFi signal strength -67dBm, reconnections 0, sleep mode modem
Socket states: 2 0 0 0 0 0 0 0
=== Expansion ===

Mysta

Heater 1 model: gain 375.6, time constant 138.5, dead time 5.7, max PWM 1.00, calibration voltage 24.1, mode PID, inverted no, frequency default
Computed PID parameters for setpoint change: P11.6, I0.415, D46.1
Computed PID parameters for load change: P11

dc42

Did you make sure that your M307 H1 parameters are set to those values in config.g? Send M307 H1 with no additional parameters to check.

Could it be that you have either a poor crimp connection in the heater wiring, or a loose terminal block screw on the Duet?

The gain figure of 375 is quite low and suggests to me that you don't have a silicone sock on the heater block.

Mysta

@dc42 Yeah I have silicon on it, I think something shook loose or something I'm taking it apart. I have always been a little weary that I used cat6e cables for the hotend because I combined 2 for each heater lead and even though it's copper strand it just didn't seem to fit right so I may remake that whole connector.

What gauge is ideal for the 6 pin connector on the smart effector? I bought a lot of silicon wiring I think I'll use for the connector.

Edit: Specify smart effector