Background Info:

I've have the Duet Ethernet Duex 5 setup running for many months. This on my bigger printer, so I don't run it a bunch, but enough to know it was functioning fine. I was cleaning up the electrical panel a few days ago (adding some cooling fans to the boards because I was getting temp warning from the drivers and removing some unused hardware). In cleaning up the panel, I removed the Duet and Duex to remount them on some tall standoffs to get better airflow underneath the boards. I had also intermittently had issues with the ethernet module not starting (very intermittently maybe once or twice in the last few months, usually a power cycle or two would resolve the issue.

Once I restarted after cleaning up the panel, I have had some really flakey results from the system. I struggled for about 2 hours trying to get the ethernet working, I finally pulled the module and re-seated it and that seams to have done the trick. The only mistake I made was I connected a thermistor to the always on fan, thinking it was a fan. I blew the thermistor. After it was replaced, no issue, temp reads fine.

The Problem:

• Sometimes the board powers up and does not recognize the Duex. Under the settings screen, it does not say Duet Ethernet + Duex 5, just Duet Ethernet. A power cycle or two and unit will detect the Duex again. I cannot seem to get it to reliably detect the Duex. I have replaced the ribbon cable with a new one. Seemingly no change to the problem. Sometimes it is detected, sometimes not.
• The endstop for E2_Stop is not changing state. Although the lights on the board are changing state, the settings screen is not showing the endstop as changing state. This is when the Duex is being detected. The drivers on the Duex are functioning and the temp inputs on the Duex are working properly.
• I was having issues with my V and W Axis homing as the drives were not moving, but I think this was because the Duex was not being detected properly.
• The thermostatic control on the extruders is no longer working reliably. The fans on the 2 extruders on the main board (Duet Ethernet) are set to run once the hotend gets above 45deg C. This keeps the unit from making a bunch of noise in my office when it is not actively printing. Now, once the temp gets above 45 degrees, they turn on, but only for a few minutes and then cut out even though the temp is 245 deg. I have checked the meter going back to the board and no power from the board.

I am concerned that I have damaged the electronics in some way. I have ordered a new Duet and Duex5 last night. I have another printer that I would like to convert to these electronics. So, not a waste if the issue on the current ones can be resolved.

I have replaced the Duex5 and the unit fired up the first time.

See below for reset details from M122.

Software reset code 0x4033 HFSR 0x40000000 CFSR 0x00008200 ICSR 0x0041f803 BFAR 0x43910046 SP 0x2000464c Task 0x4e49414d
Stack: 00420831 00421220 21000000 20000168 200001c8 20004954 00000000 0000008d 20013da0 a5a5a5a5 00452ff7 200001c8 00000000 0000000a 00000035 2000ac10 004236cf 2000ac10 20004954 00000000 2000ac10 20009aa8 2000ac10

Update: I rebooted and the unit would not restart. The red Diag light just blinked. It took me 10 power cycles before the controller would boot properly and I could re-connect to the web interface.

Note that all the power leds come on but no interface lights on the rJ45 connector.

I have received a new Duet Wifi and I am going to pull this board off the machine and set it up on the bench until I can figure out what is wrong.

Update:

I have removed the Duet Ethernet and put in a brand new Duet Wifi. Everything seems to go fine, until I put in my config file. I could not get the web interface to start, similar to the previous board after I copied my old config files over. So, I wiped the config file down to basics and added line by line the config file items and traced the problem down to the chamber heater.

If I leave the code below out, the system boots up just fine every time. If it is included, it fails to boot. This doesn't seem like it should be an issue, but I have confirmed the problem about a dozen times. I can't see what about the chamber heater code could be the problem. Note: my chamber heater is a little underpowered, hence the long D value for the M307 settings. This was not previously a problem on prior firmware versions.

This new wifi board is 2.02 (RTOS) out of the box I had recently upgraded the Ethernet board to 2.02 (RC2) and I am wondering if this explains some of the booting problems on both boards (granted, I might still have an I2C problem on either the old ethernet board/old duex5 board).

By omitting the offending code below, everything seems to be running just fine. I've got the new unit powered up, homing and doing a small test print.

What are your thoughts? I do need to get the chamber heater running again.

; Chamber Heater
M141 H5                        ; heater 5 is the chamber heater
M305 P5 R4700 T100000 B3950    ;heater 5 is monitored by a 100K thermistor with B=3950 and a 4.7K series resistor
M307 H5 A21.5 C171.8  D60     ; Setup Heater PID Settings
M307 H5 B1                    ; setup bang-bang control]

Cool. Thanks.

That's just what I was looking for. I knew I was overlooking something basic.

I know M106 will trigger the fan. But I want to tell the fan to just run for a period of, say, 300 seconds after the print finishes.

Here is my Config File. I am not using the bed leveling in home all. For now I just call G32 manually when I want to perform the function. I will automate this in home all later.

My Z axis are connected to separate drivers

; Configuration file for Duet WiFi (firmware version 2.03)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v2.0.4 on Sat Sep 21 2019 11:21:20 GMT+0100 (British Summer Time)

; General preferences
G90                                             ; send absolute coordinates...
M83                                             ; ...but relative extruder moves
M550 P"Small Printer"                           ; set printer name

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

; Drives
M569 P0 S1                                      ; physical drive 0 goes forwards
M569 P1 S0                                      ; physical drive 1 goes backwards
M569 P2 S1                                      ; physical drive 2 goes forwards
M569 P3 S1                                      ; physical drive 3 goes forwards
M569 P4 S1                                      ; physical drive 4 goes forwards
M569 P5 S0                                      ; physical drive 5 goes backwards
M584 X0 Y1 Z2:6 U5 E3:4                         ; set drive mapping
M350 X16 Y16 Z16 U16 E16:16 I1                  ; configure microstepping with interpolation
M92 X100 Y100 Z400.0 U100 E418.00:418.00        ; set steps per mm
M566 X600.00 Y600.00 Z12.00 U600.00 E120.00:120.00      ; set maximum instantaneous speed changes (mm/min)
M203 X6000.00 Y6000.00 Z500.00 U6000.00 E1200.00:1200.00 ; set maximum speeds (mm/min) (was 6000)
M201 X500.00 Y500.00 Z20.00 U500.00 E250.00:250.00      ; set accelerations (mm/s^2)
M906 X800 Y800 Z800 U800 E800:800 I30                ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                         ; Set idle timeout

; Dual Z Axis
M671 X-116:322 Y100:100 S4                      ; define 2 leadscrews location & max correction

; Axis Limits
M208 X-88 Y0 Z0 U-5 S1                                ; set axis minima
M208 X230 Y210 Z200 U318 S0                          ; set axis maxima

; Endstops
M574 X1 Y1 Z1 U2 S1                                ; set active low and disabled endstops

; Z-Probe
M558 P1 H5 F120 T6000                           ; set Z probe type to unmodulated and the dive height + speeds
G31 P500 X-33.5 Y0 Z1.35                             ; set Z probe trigger value, offset and trigger height
M557 X15:195 Y15:195 S45                        ; define mesh grid

; Heaters
M305 P0 T100000 B4138 R4700                     ; set thermistor + ADC parameters for heater 0
M143 H0 S150                                    ; set temperature limit for heater 0 to 120C
M305 P1 T100000 B4138 R4700                     ; set thermistor + ADC parameters for heater 1
M143 H1 S280                                    ; set temperature limit for heater 1 to 280C
M305 P2 T100000 B4138 R4700                     ; set thermistor + ADC parameters for heater 2
M143 H2 S280                                    ; set temperature limit for heater 2 to 280C

; Chamber Heater
M141 H7 ; heater 3 is the chamber heater
M305 P7 R4700 T100000 B3950 ; heater 3 is monitored by a 100K thermistor with B=3950 and a 4.7K series resistor
M301 H7 B1 ; use bang-bang control for the chamber heater
M307 H7 A50 C600 D300

; Fans
M106 P0 H1 T45                       ; set fan 0 value. Thermostatic control is turned on Heater 1
M106 P1 H2 T45                       ; set fan 1 value. Thermostatic control is turned on Heater 2

; Tools
M563 P0 S"Extruder 1" D0 H1 X0 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
M563 P1 S"Extruder 2" D1 H2 X3 F1                  ; define tool 1
G10 P1 X-.4 Y.4 Z-.1                                 ; set tool 1 axis offsets
G10 P1 R0 S0                                    ; set initial tool 1 active and standby temperatures to 0C

; Custom settings are not defined

I have 2 Z axis motors and that are leveling the gantry when I run a G32. I am leveling the z axis then re-homing and repeating to check. Then I mesh level. The problem is that I am very consistently getting a slope (left side higher than the right side) when the plot shows up.

Do I have to use G30 to level the bed from 2 points or can I level the bed from the mesh leveled points?

I seem to be pretty consistantly off about .3mm every time I run the G30 lines of code. It says it corrects to 0, but if I run it again I am off by about .3mm.

i figured that if I run it a bunch of times in a row, it might gradually get better, but no dice. It will correct to about .3mm and never really get any better. Is this normal?

F/W Version: 2.02(RTOS)

; bed.g
; called to perform automatic bed compensation via G32
;


M561 ; clear any bed transform
G28  ; Home

G30 P0 X10 Y100 Z-99999 ; probe near leadscrew 1 
G30 P1 X210 Y100 Z-99999 S2 ; probe near leadscrew 2 and calibrate 2 motors
G28  ; Re-Home

G30 P0 X10 Y100 Z-99999 ; probe near leadscrew 1 
G30 P1 X210 Y100 Z-99999 S2 ; probe near leadscrew 2 and calibrate 2 motors
G28  ; Re-Home

G30 P0 X10 Y100 Z-99999 ; probe near leadscrew 1 
G30 P1 X210 Y100 Z-99999 S2 ; probe near leadscrew 2 and calibrate 2 motors
G28  ; Re-Home

G29  ; probe the bed and enable compensation

From Config File

; Dual Z Axis
M671 X-116:322 Y100:100 S4                      ; define 2 leadscrews location & max correction

I'd like to run one of my auxiliary fans (an exhaust fan) at full speed for a few minutes to remove as much of the VOC as possible when a print is complete.

I currently turn it on just a little bit at slow speed to create an ever-so-slightly negative environment. This helps to keep any of the smelly garbage out of my office and it dumps a couple cfm (or maybe cfh) outside through a window adapter.

When a part is finished. I'd like to run the fan full blast for a few minutes to further remove anything still in the chamber.

Side note: I've ordered a chamber scrubber from Alvero3D. I like this option because I can recirculate the air inside the chamber without dumping all the heat. It also uses and H13 HEPA filter and a good size amount of activated carbon and the replacement filters don't cost too much at €19. I am also trying to buy a unit from SYNE, but they are in Poland and I cannot find a reseller.

I'd like to know if anyone has had good luck with scrubbers/filters for their printer.

-Doug

Update:

I have removed the Duet Ethernet and put in a brand new Duet Wifi. Everything seems to go fine, until I put in my config file. I could not get the web interface to start, similar to the previous board after I copied my old config files over. So, I wiped the config file down to basics and added line by line the config file items and traced the problem down to the chamber heater.

If I leave the code below out, the system boots up just fine every time. If it is included, it fails to boot. This doesn't seem like it should be an issue, but I have confirmed the problem about a dozen times. I can't see what about the chamber heater code could be the problem. Note: my chamber heater is a little underpowered, hence the long D value for the M307 settings. This was not previously a problem on prior firmware versions.

This new wifi board is 2.02 (RTOS) out of the box I had recently upgraded the Ethernet board to 2.02 (RC2) and I am wondering if this explains some of the booting problems on both boards (granted, I might still have an I2C problem on either the old ethernet board/old duex5 board).

By omitting the offending code below, everything seems to be running just fine. I've got the new unit powered up, homing and doing a small test print.

What are your thoughts? I do need to get the chamber heater running again.

; Chamber Heater
M141 H5                        ; heater 5 is the chamber heater
M305 P5 R4700 T100000 B3950    ;heater 5 is monitored by a 100K thermistor with B=3950 and a 4.7K series resistor
M307 H5 A21.5 C171.8  D60     ; Setup Heater PID Settings
M307 H5 B1                    ; setup bang-bang control]

Update: I rebooted and the unit would not restart. The red Diag light just blinked. It took me 10 power cycles before the controller would boot properly and I could re-connect to the web interface.

Note that all the power leds come on but no interface lights on the rJ45 connector.

I have received a new Duet Wifi and I am going to pull this board off the machine and set it up on the bench until I can figure out what is wrong.

I have replaced the Duex5 and the unit fired up the first time.

See below for reset details from M122.

Software reset code 0x4033 HFSR 0x40000000 CFSR 0x00008200 ICSR 0x0041f803 BFAR 0x43910046 SP 0x2000464c Task 0x4e49414d
Stack: 00420831 00421220 21000000 20000168 200001c8 20004954 00000000 0000008d 20013da0 a5a5a5a5 00452ff7 200001c8 00000000 0000000a 00000035 2000ac10 004236cf 2000ac10 20004954 00000000 2000ac10 20009aa8 2000ac10

I cannot seem to get the Duet to reliably start. Meaning, the red diag led by the ethernet just blinks and I cannot connect to the web interface.

When it does start sometimes it finds the duex 5 board and sometimes not.

When the board is found it almost never shows the endstops changing state.

That said, after a whole lot of screwing around tonight, removing and re-seating connectors, checking contacts and replacing cables. I got it to all connect properly and the drivers were working, endstops functioning, I even homed the machine. I re-taught my z-probe height (un-related by i had removed my bracket and needed to reset zero position).

Everything was grand, decided to power cycle the machine again and double-check to make sure I had fixed it. And nope, same set of problems, won't detect Duex or devices on Duex won't respond.

I checked M122 and am getting nak errors. No other IIC errors reported.

When it does connect, This is happening.

The stepper drivers appear to work thermister inputs work. The Endstops and Fan outputs do not seem to be working.