Something's Gone Haywire!



  • I turned my printer on today after a probably a couple months of no use because I needed to print a part for a project with a short deadline (of course…). The first attempt to print the part went as expected until the part came lose from the bed. When the print started, I recognized that the first layer wasn't as close as is ideal so I somewhat expected this... To try and quickly fix the calibration, I went into the Duet web control and edited the config file and changed...

    G31 X0 Y10 Z1.65 P500 ; Set the zprobe height and threshold

    to...

    G31 X0 Y10 Z1.75 P500 ; Set the zprobe height and threshold

    as I've done countless times in the past. I saved the changes through the web interface and it wanted to reboot so I let it. Oddly, the reboot seemed to hang and after a couple minutes I manually powered off the printer and turned it back on. Everything seemed to be as expected. However, I then noticed that the temperature and fans were acting very erratic. See the video below.

    https://goo.gl/photos/HYH2GmjiFSDF7HWU8

    I was running Duet Wifi Firmware v1.15e. My initial thought was that the firmware somehow got corrupted. So, I pulled down the latest bits from GitHub and uploaded v1.17rc1. No change. Next, I'm going to try wiping everything and re-flashing the firmware using bossac but I wanted to report this and see if anyone else has experienced this problem or has any other ideas.

    I've experienced similar behavior in the past on temp sensors when a wire breaks but this seems to be effecting both temp sensors at once and the fans. So, I feel like there's a bigger problem this time.

    Thanks,

    Ian



  • Check to see if the config got corrupted, somehow.



  • @StephenRC:

    Check to see if the config got corrupted, somehow.

    I did that and no change.

    Unfortunately, I didn't have time to reload everything via Bossa yet. Is there any chance this is going to actually yield different results from uploading a new .bin over the web interface?

    Anyone seen anything like this before? I really need to get this printer working again ASAP.

    Thanks!
    Ian


  • administrators

    It does sound like a problem with SD card corruption to me. Have you checked it in a PC for errors? Or try reformatting it and then copy the files back on. Or a new SD card.


  • administrators

    It does sound like a problem with SD card corruption to me. Have you checked it in a PC for errors? Or try reformatting it and then copy the files back on. Or a new SD card.



  • @dc42:

    It does sound like a problem with SD card corruption to me. Have you checked it in a PC for errors? Or try reformatting it and then copy the files back on. Or a new SD card.

    Funny you should suggest that… I was just talking to one my local printer building pals and he suggested the same. I'll be trying a new card tonight.

    Thanks!
    Ian



  • @dc42:

    It does sound like a problem with SD card corruption to me. Have you checked it in a PC for errors? Or try reformatting it and then copy the files back on. Or a new SD card.

    The SD card checked out OK. I reformatted it and copied everything new to it. No change. Next I'm erasing the firmware manually and trying to re-apply but ran into problems acquiring SAM-BA last night. I've got a copy now and will try again tonight. Still open to other theories if anyone has any.



  • I got SAM-BA 2.16 installed tonight then erased the firmware and re-flashed the board. That didn't change anything. So, next steps were to unplug everything from the board and see if thermistors would work by themselves. This revealed something interesting. If only one of the thermistors (hotend & bed) is connected then the Duet doesn't report any reading at all for either thermistors. However, when I connect the second thermistor then I start getting the erratic values for both thermistors. I've tested both thermistors with a meter and tried connecting new thermistors and the behavior is the same. I now think there's something wrong with this board.

    You can see my tests in this video.

    Any ideas? Next, I'm going to start ripping my other Duet WiFi board out of my other printer (that's not working because of other issues….) and swap it out. I'm really hesitant to do this w/o knowing why this board is not working, though. I've examined all the obvious locations where there could be wiring problems and so far have found nothing that looks like a problem. The only thing that happened between working & not working was a config change & restart. I'm puzzled...



  • Well, after swapping out the board, I'm back to printing. No idea what's up with the that board. I still need to try and get it working so I can put it back in my other printer. Any ideas I can test from here? If we don't find anything, can I send it in for examination and possible RMA or repair?



  • @ianlee74:

    Any ideas I can test from here? If we don't find anything, can I send it in for examination and possible RMA or repair?

    @dc42 - any thoughts? I don't mind attempting a repair on my end if you have some ideas on where I should be lookinging. I'm not excited about purchasing a 4th Duet WiFi board this year, though, without first having some idea what went wrong with this one.

    Thanks!
    Ian


  • administrators

    Are you certain that it was reading config.g correctly? The only hardware fault I can think of that would change the behaviour in the ways you describe would be a failure to read and process config.g, perhaps because of a hardware fault in the SD card interface.



  • @dc42:

    Are you certain that it was reading config.g correctly? The only hardware fault I can think of that would change the behaviour in the ways you describe would be a failure to read and process config.g, perhaps because of a hardware fault in the SD card interface.

    How can I know for sure? The controller board that I'm using now is running off the same SD card that I was using on the board that doesn't work. Because the new board hadn't been fired up in many months, all I did was upload all the latest .bin files and it works as expected. Is there some way I can test if the SD card interface is working as expected? FYI, my controller board is totally enclosed and the SD card wasn't touched at the time that it stopped working.


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