@droftarts Hi Ian. Thanks so much for your quick reply.
I usually keep a log of all the firmware files I've installed over time so I'm quite sure I have this issue with RRF 3.4.6 as well.
To doublecheck I'll downgrade to 3.4.6 and post the result tomorrow.

@dc42 I'm located in the Netherlands and of course I'll provide the board including SD card. Please contac met via email or other non-public way to make futher arrangements.

@dc42 In one of the earlier threads I reported having this issue on RRF 3.5.3.
I now temporarily swapped my Mini5+ WiFi for a 6HC since I have a project due.
I'd be happy to lend out my Mini WiFi if that would help you to eg. reproduce the issue and find a solution?

@dc42 I upgraded to RRF 3.5.3 today. During the 2nd print I experienced a hard reset. Please see the M122 report underneath:

=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.3 (2024-09-18 11:25:48) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: 7MPG2-K396U-D65J0-40KMQ-JQ03Z-Z0D1Q
Used output buffers: 3 of 40 (18 max)
=== RTOS ===
Static ram: 103368
Dynamic ram: 121604 of which 0 recycled
Never used RAM 16776, free system stack 198 words
Tasks: NETWORK(2,nWait 7,13.5%,217) HEAT(3,nWait 6,0.0%,350) Move(4,nWait 6,0.0%,355) CanReceiv(6,nWait 1,0.0%,939) CanSender(5,nWait 7,0.0%,336) CanClock(7,delaying,0.0%,334) TMC(4,nWait 6,0.8%,110) MAIN(1,running,84.6%,665) IDLE(0,ready,0.2%,29) AIN(4,delaying,0.8%,268), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:05:29 ago, cause: reset button
Last software reset time unknown, reason: HardFault invState, Gcodes spinning, available RAM 27292, slot 2
Software reset code 0x4863 HFSR 0x40000000 CFSR 0x00020000 ICSR 0x00000803 BFAR 0xe000ed38 SP 0x20012580 Task TMC Freestk 125 ok
Stack: 2001948c 20012334 200014e8 e000e000 00000060 00091d55 00000000 6100f000 00000000 00000000 00000000 cf410005 0041ff05 d7000000 0002ff05 3a130000 00000000 00000000 00000000 00000000 00000053 2003b5d0 20012c24 00000dae 20019494 20012e5c 2001261c
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 247196, completed 247196, timed out 0, errs 0
MCU temperature: min 31.8, current 31.8, max 34.9
Supply voltage: min 23.9, current 24.0, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 2, read errors 0, write errors 1, ifcnt 27, reads 17320, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 27, reads 17320, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 4, read errors 0, write errors 1, ifcnt 23, reads 17319, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 21, reads 17319, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 27, reads 17320, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-09-21 16:43:50
Cache data hit count 603090100
Slowest loop: 25.74ms; fastest: 0.16ms
=== Storage ===
Free file entries: 20
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 1.3ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: none, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
no step interrupt scheduled
Moves shaped first try 0, on retry 0, too short 0, wrong shape 0, maybepossible 0
=== DDARing 0 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is idle in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger is idle in state(s) 0
Queue is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000000
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 1548989
Extruder 0: no data received, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0
=== CAN ===
Messages queued 2965, received 0, lost 0, errs 1595525, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 26 (min 26), ts 1648/0/0
Tx timeouts 0,0,1647,0,0,1316 last cancelled message type 4514 dest 127
=== Network ===
Slowest loop: 28.03ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1.0
MAC address d8:bf:c0:15:0a:5c
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 42652
WiFi IP address 172.16.0.142
Signal strength -47dBm, channel 5, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

@droftarts I reverted to RRF 3.4.5, DWC 3.4.5 and WiFi 1.27 as you suggested and the results are not improving.
I dug a little deeper into the forum and found this article about similar symptoms. Although the root cause is very different (and not possible since I don't use an SSR), the direction in which @T3P3Tony was searching might suggest a hardware fault.
Could this be worth having a look at or does that seem too unlikely?

Maurits

@droftarts I downgraded succesfully to RRF 3.4.6.
The first print I ran stopped at layer 4 and the mini5+ reset itself. After trying to run about 20 more prints I notices a few things:

• during most prints the duet still resets mid-print.
• the point at which the reset occurs (print file progress) it different each time.
• only prints with a single object alway succeeed.
• prints with mutiple objects are sliced to print 'all at once'

Unfortunately it doesn't make things any clearer to me. Any suggestions?

@droftarts Hi Ian. Thanks so much for your quick reply.
I usually keep a log of all the firmware files I've installed over time so I'm quite sure I have this issue with RRF 3.4.6 as well.
To doublecheck I'll downgrade to 3.4.6 and post the result tomorrow.

I forgot to mention that the issue started while I was running firmware v3.4.6. Unfortunately upgrading to v3.5.2 did not fix it.

Since a few weeks my Duet 3 mini5+ randomly resets during a print. This happens mostly during the first layer, sometimes during the second. I've been running a series of prints using the same set of gcode files and seemingly out of the blue this problem is happening almost every print I try.

My printer is a modified Ender 5 with a Duet 3 mini5+, BLtouch clone and an E3D Hemera direct drive printhead.
I currently use a standard E3D .4mm nozzle with a generic brand PLA and I've never had any problems with it before.

Since I know the gcode files are OK I started looking for a hardware fault.
Most logical cause I thought to be the power supply, so I replaced it. The new one is much more quiet so I'll be keeping that one anyway.
Checked all the wiring & connections for faults, but couldn't find any.

I'd really appreciate any help in finding the problem here. I've got a project tot finish before christmas for the 100+ members of my sports club so I'd like to get this fixed really soon.
I've included the config.g file and the M122 diagnostics file after a reset occurs.

config.g

; Configuration file for Duet 3 Mini 5+ (firmware version 3.3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.10 on Thu Jan 06 2022 19:32:52 GMT+0100 (Midden-Europese standaardtijd)

; General preferences
M575 P1 S1 B57600                            ; enable support for PanelDue
G90                                          ; send absolute coordinates...
M83                                          ; ...but relative extruder moves
M550 P"Pluisje"                              ; 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 P0.0 S1 D3                              ; physical drive 0.0 goes forwards in driver mode stealthchop
M569 P0.1 S1 D3                              ; physical drive 0.1 goes forwards in driver mode stealthchop
M569 P0.2 S0 D3                              ; physical drive 0.2 goes backwards in driver mode stealthchop
M569 P0.4 S1 D3                              ; physical drive 0.4 goes forwards in driver mode stealthchop
M584 X0.0 Y0.1 Z0.2 E0.4                     ; set drive mapping
M350 X16 Y16 Z16 E16 I1                      ; configure microstepping with interpolation
M92 X80.00 Y80.00 Z400.00 E394.57            ; set steps per mm old value was E394.67
M566 X1200.00 Y1200.00 Z60.00 E120.00        ; set maximum instantaneous speed changes (mm/min)
M203 X30000.00 Y30000.00 Z1800.00 E1500.00   ; set maximum speeds (mm/min)
M201 X800.00 Y800.00 Z100.00 E250.00         ; set accelerations (mm/s^2)
M906 X800 Y800 Z800 E800 I30                 ; set motor currents (mA) and motor idle factor in per cent
M84 S300                                     ; Set idle timeout

;Pressure Advance
M572 D0 S0.075                               ; enable Pressure advance

; Axis Limits
M208 X0 Y0 Z0 S1                             ; set axis minima
M208 X220 Y200 Z300 S0                       ; set axis maxima

; Endstops
M574 X1 S1 P"io5.in"                         ; configure switch-type (e.g. microswitch) endstop for low end on X via pin io5.in
M574 Y1 S1 P"io6.in"                         ; configure switch-type (e.g. microswitch) endstop for low end on Y via pin io6.in
M574 Z1 S2                                   ; configure Z-probe endstop for low end on Z

; Z-Probe
M950 S0 C"io3.out"                           ; create servo pin 0 for BLTouch
M558 P9 C"io3.in" H5 F120 T6000              ; set Z probe type to bltouch and the dive height + speeds
G31 P500 X45 Y-4 Z3.460                      ; set Z probe trigger value, offset and trigger height
M557 X45:215 Y5:195 S27                      ; define mesh grid

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4138 ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0                           ; create bed heater output on out0 and map it to sensor 0
M307 H0 R0.343 K0.363:0.000 D3.36 E1.35 S1.00 B0 ;disable bang-bang mode for the bed heater and set PWM limit
M140 H0                                      ; map heated bed to heater 0
M143 H0 S110                                 ; set temperature limit for heater 0 to 110C
M308 S1 P"temp1" Y"thermistor" T100000 B4138 ; configure sensor 1 as thermistor on pin temp1
M950 H1 C"out1" T1                           ; create nozzle heater output on out1 and map it to sensor 1
M307 H1 R2.032 K0.592:0.000 D4.83 E1.35 S1.00 B0 V23.7 ; disable ban-bang mode for heater and set PWM limit
M143 H1 S285                                 ; set temperature limit for heater 1 to 285C

; Fans
M950 F0 C"out5" Q500                         ; create fan 0 on out5 with and set its frequency
;M106 P0 C"FAN0" S0.6 H1 T45                  ; set fan 0 name and value. Thermostatic control is turned on
M950 F1 C"!out4+out4.tach" Q500              ; create fan 1 on out4 with tacho and set its frequency
M106 P1 C"FAN1" S1 H1 T45                    ; set fan 1 name and value. Thermostatic control is turned on

; Tools
M563 P0 D0 H1 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

; Filament Monitor
;M591 D0 P3 C"io1.in" S0                      ; Duet3D magnetic filament monitor connected to io1.in

config.g

M122

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.2 (2024-06-11 17:14:16) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: 7MPG2-K396U-D65J0-40KMQ-JQ03Z-Z0D1Q
Used output buffers: 14 of 40 (28 max)
=== RTOS ===
Static ram: 103368
Dynamic ram: 121568 of which 0 recycled
Never used RAM 16480, free system stack 198 words
Tasks: NETWORK(2,nWait 7,10.5%,217) HEAT(3,nWait 1,0.0%,355) Move(4,nWait 6,0.0%,355) CanReceiv(6,nWait 1,0.0%,939) CanSender(5,nWait 7,0.0%,336) CanClock(7,delaying,0.0%,334) TMC(4,nWait 6,0.8%,110) MAIN(1,running,86.8%,665) IDLE(0,ready,1.0%,29) AIN(4,delaying,0.9%,265), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:00:24 ago, cause: reset button
Last software reset time unknown, reason: HardFault invState, Gcodes spinning, available RAM 27292, slot 2
Software reset code 0x4863 HFSR 0x40000000 CFSR 0x00020000 ICSR 0x00000803 BFAR 0xe000ed38 SP 0x20012580 Task TMC Freestk 125 ok
Stack: 2001948c 20012334 200014e8 e000e000 00000060 00091d55 00000000 6100f000 00000000 00000000 00000000 cf410005 0041ff05 d7000000 0002ff05 3a130000 00000000 00000000 00000000 00000000 00000053 2003b5d0 20012c24 00000dae 20019494 20012e5c 2001261c
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 24848, completed 24847, timed out 0, errs 0
MCU temperature: min 31.6, current 31.8, max 32.2
Supply voltage: min 23.9, current 24.0, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 2, read errors 0, write errors 1, ifcnt 43, reads 1284, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 16, read errors 0, write errors 1, ifcnt 43, reads 1284, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 4, read errors 0, write errors 1, ifcnt 40, reads 1284, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 32, reads 1283, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 43, reads 1284, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-09-17 16:15:14
Cache data hit count 47397715
Slowest loop: 14.86ms; fastest: 0.16ms
=== Storage ===
Free file entries: 20
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 1.7ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: none, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
no step interrupt scheduled
Moves shaped first try 0, on retry 0, too short 0, wrong shape 0, maybepossible 0
=== DDARing 0 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is idle in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger is idle in state(s) 0
Queue is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000000
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 119043
Extruder 0: no data received, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0
=== CAN ===
Messages queued 223, received 0, lost 0, errs 118088, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 26 (min 26), ts 125/0/0
Tx timeouts 0,0,124,0,0,97 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 26.64ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 2 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1.0
MAC address d8:bf:c0:15:0a:5c
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 42956
WiFi IP address 172.16.0.142
Signal strength -40dBm, channel 5, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

M122.txt