I finally have some closure on this topic. Until recently, the motor in question has been working just fine. So I assumed it was some form of user error.

Recently that same motor stumbled. Upon inspection, I found that the motor would work fine but if I touched the wires near the entry to the motor, it would stumble.

Unfortunately the leads are hard-wired into the motor so this is not something I could repair without dis-assembling the motor.

The good news is that I finally have resolution and this one was not my fault. All of that practice crimping made the replacement with the new motor uneventful.

@dc42 - since 3.4.5 is still the latest version, is it worth removing this comment from the release notes on the main github page (https://github.com/Duet3D/RepRapFirmware/releases/)?

Important! Some users have experienced issues with the printer failing to complete homing in this release. This is under investigation; in the meantime please revert to version 3.4.4 if you experience this issue.

Best
Jack

I got my first print with my Duet AM8 (thats what I call it now that my Anet A8 is an AM8 with a Duet processor). Thanks everyone for your advice and help. Especially, @nhof , your basic guide was so helpful. It may seem simplistic to you but topics of polarity are helpful to the novice.

It took me a loooooooooooonnnnnnnnnnnnnnnnnggggggg time but I took it slow as suggested. Also, I converted over to 24 volts in the process which meant new power supply, hot end, heated bed. Never thought I'd be Googling about Ohm's Law.

Learned a lot of things during the process and I hope to be able to help some others with the same conversion. Mostly, thank you all!

Jack

@phaedrux Ok. "It’s a UNIX system! I know this!". I mean, ok, between the wiring diagrams and the advice about polarity and the other guides, I think I can do this. Been costing out the AM8 as well. I'm going to take my time here and do this carefully. I'll let you all know how it goes but really blown away by you all!

@veti - ok, I have finally completed my AM8 conversion. Yes, it took me this long! But, I double and triple checked everything, printed extra parts, etc. Wow, what a huge difference. It's a different beast now - fast, quiet, stable. I've just ordered my Duet and I'll be trying out all the advice and tips you guys provided . . . hopefully within a couple of weeks (traveling at the moment). Anway, I wanted to post here because others reading may want to know how impactful the AM8 upgrade is.

@zapta and @veti - thanks guys. I'm so glad you asked :-). I can't believe this was my Anet A8 when I was first posting here.

@T3P3Tony Roger that. What a great group!

@jay_s_uk thanks - I ordered one today so will see how it goes.

@phaedrux, I really appreciate your insight.

Its a painful conclusion for me. I'm "that guy" who needed extra crimps because I find the crimping so difficult. I'm great with software, clumsy with hardware. But I thought I had turned the corner after so much practice.

At this point I'm going to assume - and probably should have from the start - that it was poor crimping (though I swear putting it on extruder seemed to work 100%) and . . if I can get it to happen again I'll re-crimp and take pictures and keep this group posted.

You all are awesome - thank you again!
Jack

@jay_s_uk I did not! I read another post and that didn't come up.

knowing there is a fuse a) makes me feel a bit dumb and b) makes me very excited. I'll check that today!

Final update (I edited above a few times). I've cut the connectors off the Mechatonics fan and I used a 9V battery to try to get the fan to operate with no luck.

I always test with a 9V battery before installing and this fan was working previously. Its has < 50 hours of usage. So, something internal to the fan but have gone wrong. But, I have no idea what triggered it. A little unsatisfying. I have a second of the same model which works fine with 9V battery. At some point I'll wire that up and put it in production.

Jack

@jay_s_uk it was the fuse - thank you so much! I never thought I would be so lucky that the thing that failed was because of a fuse. With my first duet I had experienced a failed mosfet leading to an always-on fan. But in another post I read that "If all the fans have stopped working then you have fused the via in the trace between the VIN pin of the fan jumper selection block and the +VIN power input terminal. You can add a wire on the back of the Duet to connect them together again.".

So I assumed the worst. Lesson learned.

I didn't have a spare fuse but I obtained supplies today and replaced the fuse with a 2 amp fuse because I read on the duet parts list web page that "PCB revisions 1.03 and later have a 1A mini auto blade fuse protecting the fan circuits when the fan voltage selection jumper is in the VIN position. You can increase the fuse rating to 2A or even 3A if your fans, air pumps etc. draw more than 1A in total."

I turned on the system and my hot-end fan came on - great!!! Then I enabled my cooling fans and within say 5 seconds, the fuse blew. This is actually also great - because now I get to find the real root of the problem.

I replaced the fuse again and removed the Mechatronics fan. I've left the system up with fans on for about 5 minutes. It seems like this is the culprit because removing the other fan but leaving the Mechatronics will also blow the fuse. I put a multi-meter on the connectors to the Mechatronics fan (the terminals that plug into the duet so that I'm checking the full fan and wiring) and checked the resistance and I see about 16 Ohms of resistance. What I read said that this is a typical expected range. I would really like to find the root cause of the root cause so that this doesn't happen again. Any suggestions are welcome.

Thank you all for the help @jay_s_uk and @oliof and have a wonderful weekend.

@jay_s_uk I did not! I read another post and that didn't come up.

knowing there is a fuse a) makes me feel a bit dumb and b) makes me very excited. I'll check that today!

Hi @oliof

I purchased a Sunon Maglev 5015 which is 24V and a Mechatronics B5015E24B-BSR also 24V. All of my fines are wired up 2-pin to the FAN headers using the Duet-provided connectors. So the hotend fan is always-on, others are as-needed.
It is an open frame design with a heated bed. Spare fans don't work either.

Here is my config.g.

; Configuration file for Duet WiFi (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.1.4 on Mon Oct 05 2020 07:16:08 GMT-0700 (Pacific Daylight Time)

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

; Network
M552 S1 ; enable network
M586 P0 S1 ; enable HTTP
M586 P1 S0 ; disable FTP
M586 P2 S0 ; disable Telnet

; Drives
M569 P0 S0 ; physical drive 0 controlx X motor and goes backwards with new motor and wiring
M569 P1 S0 ; physical drive 1 controls Y motor and goes backwards with new motor and wiring
M569 P2 S0 ; physical drive 2 controls both Z motors and goes backwards
M569 P3 S1 ; physical drive 3 goes forwards with new motor and wiring
M569 P4 S1 ; physical drive 4 goes forwards because no longer using an interted Titan
M584 X0 Y1 Z2 E3:4 ; set drive mapping, including second extruder
M350 X16 Y16 Z16 E16:16 I1 ; configure microstepping with interpolation, including second extruder
;M92 X100.00 Y100.00 Z400.00 E418.59:418.59 ; set steps per mm including second extruder. E values calculated by JW
;M92 X100.00 Y100.05 Z405.41 E418.59:418.59 ; set steps per mm including second extruder. E values calculated by JW ; Z value was coming up short - calibrated to 405.41 ; Y was short calibrated to 100.05
M92 X101.00 Y101.00 Z411.58 E418.59:415 ; BMG Extruder says use 415
M566 X600.00 Y600.00 Z18.00 E300.00:300.00 ; set maximum instantaneous speed changes (mm/min), including second extruder
M203 X7200.00 Y7200.00 Z180.00 E1200.00:1200.00 ; set maximum speeds (mm/min) including second extruder. 7200=120 mm/sec. 180=3 mm/sec. 1200=20 mm/sec
M201 X1500.00 Y1500.00 Z100.00 E10000.00:10000.00 ; set accelerations (mm/s^2) including second extruder
;M906 X800 Y800 Z800 E800:800 I30 ; set motor currents (mA) and motor idle factor in per cent, including 2nd extruder. Nema 17 rated 900mA. Configurator recently used X500 Y500 Z500
; M906 X1800 Y1800 Z800 E1800:800 I30 ; New motors are rated 2.0 Amps
M906 X1200 Y1200 Z800 E1200:800 I30 ; New motors are rated 2.0 Amps but X getting hot - try 1200 for the new ones
M84 S30 ; Set idle timeout

; Axis Limits

M208 X-7 Y-19 Z0 S1 ; set axis minima for V6 hotend
;Maxima is same for V6 or Chimera+ hotend.
M208 X220 Y220 Z240 S0 ; set axis maxima - tested this. I can go to z=245 and still issue home which moves carriage up to z=250

; Endstops
M574 X1 S1 P"xstop" ; Rewired endstop and moved it back to X pins - also made it active-high (normally closed) at the same time.
M574 Y1 S1 P"!ystop" ; configure active-low endstop for low end on Y via pin ystop - at some point in future will re-wire this to be active-high
M574 Z1 S2 ; configure Z-probe endstop for low end on Z. probe position (Z=1) is activated at the low end of the bed (like microswitch being at bottom) but S2 defines Z sensor as a probe

; Z-Probe
; My BlTouch has two pins wired to zprobe.in and ground which are on the "Z Probe" header.
; The first is green and that is connected to the white z_min on the BLTouch.
; The second is yellow and that is connected to the black ground on the BLTouch.
;
; The other wires are connected on the expansion header using pins 1 and 2 which are 5V and ground.
; Those power pins are Red (Pin 1 +5V) and Brown (Pin 2 GND) and connect to BLTouch wires of the same color.
; The last wire is Orange at Duet and is connected to the expansion header using pin 8 which is heater3.
; The Orange wire connects to the BLTouch orange wire with is software PLM or the control channel.
;
M307 H3 A-1 C-1 D-1 ; unbind that heater 3 pin
M950 S0 C"exp.heater3" ; create servo pin 0 for BLTouch
M558 P9 C"^zprobe.in" H5 F120 T6000 ; set Z probe type to bltouch and the dive height + speeds
;M558 P9 C"^zprobe.in" H5 F100 T6000 R0.2 A5 B1 ; set Z probe type to bltouch and the dive height + speeds

; Decreasing the Z value is equivalent to saying the probe is that closer to the bed and
; this results in loosening the print.
; Hence, decrease the Z value to loosen things.
;

G31 P25 X29.45 Y-10.4 Z1.417 ; ?

; define mesh grid

M557 X30:210 Y15:210 S40 ; This probes points of 30, 70, 110, 150, 190

; Heaters
; Now using a silicon pad by a company called Polisi. The specifications state "With 1meter NTC 100K 3950 thermistor for temperature Control. Power consumption: 300W"
M308 S0 P"bedtemp" Y"thermistor" T100000 B3950 ; configure sensor 0 as thermistor on pin bedtemp. My pad uses NTC3950 thermister which has Beta of 3950. Trying default C=0
; I think this is Marlin type 11 which is "100k beta 3950 1% thermistor (4.7k pull-up)"
M950 H0 C"bedheat" T0 ; create bed heater output on bedheat and map it to sensor 0. heater 0 uses the bed_heat pin, sensor 0
M307 H0 B0 S.90 ; disable bang-bang mode for the bed heater and set PWM limit to 90% based on doing M303 H0 S110 P1
M140 H0 ; map heated bed to heater 0
M143 H0 S130 ; set temperature limit for heater 0 to 130C

M308 S1 P"e0temp" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin e0temp - Even though datasheet says B=4267, E3d recommends T100000 B4725 C7.06e-8
M950 H1 C"e0heat" T1 ; create nozzle heater output on e0heat and map it to sensor 1
M307 H1 B0 S1.00 ; disable bang-bang mode for heater and set PWM limit
M143 H1 S262 ; set temperature limit for heater 1 to 262 Celcius which is also the Duet default
;M143 H1 S288 ; set temperature limit for heater 1 to 285 Celcius for nozzle tightening only. Seems to force temp to be < this, not <=. Also needs buffer to overshoot.

M308 S2 P"e1temp" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 2 as thermistor on pin e1temp - Even though datasheet says B=4267, E3d recommends T100000 B4725 C7.06e-8
M950 H2 C"e1heat" T2 ; create nozzle heater output on e1heat and map it to sensor 2
M307 H2 B0 S1.00 ; disable bang-bang mode for heater and set PWM limit
M143 H2 S262 ; set temperature limit for heater 1 to 262 Celcius which is also the Duet default
;M143 H2 S288 ; set temperature limit for heater 2 to 285 Celcius for nozzle tightening only. Seems to force temp to be < this, not <=. Also needs buffer to overshoot.

; Fans
;M950 F0 C"fan0" Q500 ; create fan 0 on pin fan0 and set its frequency
M950 F0 C"fan0" Q3000 L128 ; create fan 0 on pin fan0 and set its frequency. Minimum 50% power as doesn't blow much below that.
M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"fan1" Q500 L128 ; create fan 1 on pin fan1 and set its frequency
M106 P1 S0 H-1 ; set fan 1 value. Thermostatic control is turned off

; Tools
M563 P0 D0 H1 F0:1 ; define tool 0 - assign two fans: Fan0 and Fan1

;Define bed screws - well close enough to bed screws that can be reached by my probe
; Bed adjustment screws are at (110,0), (0,220), (220,220). In general I want 20 mm margin to bed edge
; so I would ideally target (110, 20), (20, 200), (200,200).
; With MGN mod and new BLTouch placement, my new probe position is 29 mm to the right and
; 7 mm in front of printhead. So, I can reach Y=0 or Y=20. Can I reach X=20? Well, my X minima
; from above is -4 and my BLTouch is 29 mm to the right of that so the smallest X value
; that my sensor can reach is 25 mm
M671 X110:25:200 Y20:200:200 ; With MGN mod and new BLTouch placement, (110,20), (25,200), and (200,200).

; Miscellaneous
M575 P1 S1 B57600 ; enable support for PanelDue
M501 ; load saved parameters from non-volatile memory
T0 ; select first tool

; G29 S2 ; Not using any height maps right now
G29 S1 ; Load height map

In January of last year I moved over to higher end parts-cooling fans (based on recommendations here https://forum.duet3d.com/category/5/duet-hardware-and-wiring).

Once I had my new fans, I purchased a new Duet2 WiFi in April and I haven't had any issues since then.

Last night during perhaps the last hour of a print, apparently all of my fans went out. I say apparently because

1. The filament was melted at the bottom of my bowden tube.
2. None of the fans work today - hotend fan and both parts fans.

I saw a thread where someone had been doing maintenance and shorted something (https://forum.duet3d.com/topic/4018/my-fans-have-stopped-working) but nothing like that happened. Everything has been working fine for the last 8 months.

Is there anything that might have triggered this? Is there any chance this would be covered under Warranty?

Thanks
Jack

@dc42 - since 3.4.5 is still the latest version, is it worth removing this comment from the release notes on the main github page (https://github.com/Duet3D/RepRapFirmware/releases/)?

Important! Some users have experienced issues with the printer failing to complete homing in this release. This is under investigation; in the meantime please revert to version 3.4.4 if you experience this issue.

Best
Jack

I finally have some closure on this topic. Until recently, the motor in question has been working just fine. So I assumed it was some form of user error.

Recently that same motor stumbled. Upon inspection, I found that the motor would work fine but if I touched the wires near the entry to the motor, it would stumble.

Unfortunately the leads are hard-wired into the motor so this is not something I could repair without dis-assembling the motor.

The good news is that I finally have resolution and this one was not my fault. All of that practice crimping made the replacement with the new motor uneventful.

@jay_s_uk thanks - I ordered one today so will see how it goes.

@jay_s_uk that is extremely helpful - thank you! Most 24v Sunon's are out of stock. I did find one from Mellow on Ali Express that claims to be a genuine Sunon and even has information on how to tell a genuine from a fake. Its the same price as from DigiKey but they have in stock

https://www.aliexpress.us/item/2255800678887752.html?spm=a2g0o.cart.0.0.7ecd38daMmPAYm&mp=1&gatewayAdapt=glo2usa&_randl_shipto=US

I was going to order from someone like DigiKey or Filastruder or Matter Hackers but that doesn't seem to be an option at the moment.

Interestingly, the Mellow one states "Upgrade: New fan support voltage to adjust wind speed"

@Phaedrux and @mrehorstdmd this is part of what I love about 3d printing. There is as much devil and as much detail as you could ever want . . .