@phaedrux Hello again! I ended up doing a complete fresh reinstall from the configurator then made sure I was using the latest stable release.

Good news is I am now connected to DWC 3.3.0, bad news is I have a new issue here.

M122 printout is being flagged as spam by Akismet. I will try and snippet the relevant.

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 3.0 running on Duet WiFi 1.02 or later + DueX5

...

Error status: 0

...

=== Network ===
Slowest loop: 15.22ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 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 1.26
WiFi MAC address 48:3f:da:75:a8:d7
WiFi Vcc 3.36, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 26024
WiFi IP address 192.168.0.74
WiFi signal strength -63dBm, reconnections 0, sleep mode unknown
Socket states: 0 0 0 0 0 0 0 0

Even better solution: I hooked up the power wires for my laser to the bed heater output and made that a GPIO that I then turn on and off via gCode.

@jay_s_uk Thanks! Now they're actually in sync that should be much easier through DWC. Back on track

@Phaedrux will do! But… I can say it does remain because my E-stop isn’t hooked up to the duet but to the mains. In an emergency I want everything to stop. Full power cycle is on my list of standard troubleshooting approaches.

I haven’t had any issues since my last post and the only thing that’s changed is that I’ve commented out the line declaring DWC needs a password.

@dc42 Thank you, and everyone. I'll put that on the To-Do after this print (took the lazy route and stuck it on an external SD via PanelDue for now).

Will mark as solved.

@T3P3Tony Thanks for the quick reply. I was hoping to avoid doing a full diagnostic on my computer as the card's somewhat difficult to get to at the moment. Will revert in due course.

Good morning!
So this 32GB card has been sat in my machine working fine for a handful of years but now I've been trying to upload a "large" file (72MB) and it keeps failing and saying the card may be full.
That didn't sound right so ran M122 and M39.
M122 reported:

=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest read time 3.0ms, write time 134.8ms, max retries 0

M39 reported:

SD card in slot 0: capacity 31.91Gb, free space 0.02Gb, speed 20.00MBytes/sec, cluster size 512 bytes

Obviously this is rather concerning, I've gone through all the files on the system and I'm probably using 2GB max all in all...
What could be up? I've reread the setup documentation and there's no mention of needing to expand the partition to fill the entire card as there is usually with RPi BOOT cards.

Any help would be appreciated, thanks!

@Phaedrux will do! But… I can say it does remain because my E-stop isn’t hooked up to the duet but to the mains. In an emergency I want everything to stop. Full power cycle is on my list of standard troubleshooting approaches.

I haven’t had any issues since my last post and the only thing that’s changed is that I’ve commented out the line declaring DWC needs a password.

@gloomyandy
Please excuse some of the comments in the config.g... I tweaked and tested a lot and reused code from another machine of mine so ought to go through and clean up the comments a bit...

Also, since posting and getting a backup copy of the SD (just in case) the machine's been running seemingly fine and is an hour or so into a laser job. In all honesty the unpredictable nature of the issue is more concerning as those usually have a more hidden solution.

@gloomyandy Apologies, yes, M552. Been slightly on autopilot.

config.g:

; Configuration file for RepRapFirmware on Duet 2 WiFi
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.5.4 on Sun Jul 28 2024 09:13:45 GMT+0100 (British Summer Time)

; General
G90 ; absolute coordinates
M83 ; relative extruder moves
M550 P"Artemis" ; set hostname

; Network
M551 P"REDACTED" ; set machine password
M552 S1 ; configure WiFi adapter
M586 P0 S1 ; configure HTTP

; Smart Drivers
M569 P0 S1 D2 ; driver 0 goes forwards (X axis)
M569 P1 S1 D2 ; driver 1 goes forwards (Y axis)
M569 P2 S0 D2 ; driver 2 goes backwards (Z axis)
M569 P3 S1 D2 ; driver 3 goes forwards (Y axis)

; Motor Idle Current Reduction
M906 I30 ; set motor current idle factor
M84 S30 ; set motor current idle timeout

; Axes
;M584 X0 Y1:3 Z2 ; set axis mapping
M584 X0 Y1:3 Z2 U3  P3 ; set drive mapping (2x Y attached Left to E1, Right to Y). Define extra axis 'U' on Y, connected to E0 driver
M350 X4 Y4 Z4 U4 I0 ; configure microstepping without interpolation (U = Y clone)
M906 X1800 Y1800 Z1800 U1800 ; set axis driver currents (U = Y clone)
M92 X160 Y160 Z100 U160 ; configure steps per mm (U = Y clone)
M208 X0:825 Y0:1245 Z0:160 U0:1245; set minimum and maximum axis limits (U = Y clone)
M566 X900 Y900:900 Z180 U900 ; set maximum instantaneous speed changes (mm/min) (U = Y clone)
M203 X3000 Y3000 Z300 U3000 ; set maximum speeds (mm/min) (U = Y clone)
M201 X50 Y50 Z20 U50; set accelerations (mm/s^2) (U = Y clone)

; Kinematics
M669 K0 ; configure Cartesian kinematics

; Endstops
M574 X1 P"xstop" S1 ; configure X axis endstop
;M574 Y2 P"ystop+e0stop" S1 ; configure Y axis endstop
M574 Y2 P"ystop" S1 ; Y left endstop
M574 U2 P"e0stop" S1 ; Y right endstop (U = Y clone)
M574 Z1 P"!zstop" S1 ; configure Z axis endstop

; Spindles
M453 ; CNC mode
M950 R0 C"exp.heater3" Q1000 L12000 ; configure spindle pins, heater3 via 5V PWM booster
; C = PWM pin, Q = frequenc(Hz), L = max speed
M563 P0 S"Spindle" R0 ; assign spindle 0 to tool 0
M3 P0 S0 ; ensure zero power upon wake-up

; Lasers
M452 ; Laser mode
M950 P2 C"bedheat" ; Set the heated bed output as a power switch for the laser
M42 P2 S0
;M950 P1 C"exp.heater4" Q1000 ; Dummy GPIO control of laser for testing
M98 P"/sys/laserPin.g"

; Miscellaneous
M453 ; select CNC mode

; Logging
M929 P"SysLog", S1

Morning!
Or, afternoon now, losing track of time with this issue!
So, during calibration and tweaking a few days back I had to hit my emergency stop button and then was having serious issues trying to connect.
I somehow got it stable again (serial in, M552 S0 M552 S1 M997 S1 etc) and enabled logging.

I had reason to kit my emergency stop again today and have the same issues. I've spent a couple of hours trying to connect so now turning to the forums.
When booting up DWC looks like its loading then will stall on the "connecting" bar that hovers over the GUI. The green "connection established" bar in the background shows up, times out and vanishes but the blue "connecting" bar will just sit there. This loops over and over.
I also see the orange "HTTP Timeout" warning and, more interestingly, a red "HTTP: Failed to get file list" error. I remember last time getting "ISP busy" errors but haven't had any so far this time round.
Occasionally I get a clean startup, usually after connecting via serial with main power off and Initiating M115 S0 and M115 S1.

M122 reports back good connection, hovering around -32 to -34.

=== 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 8c:aa:b5:d5:1b:1c
Module reset reason: Turned on by main processor, Vcc 3.39, flash size 4194304, free heap 46340
WiFi IP address 192.168.0.162
Signal strength -40dBm, channel 6, mode 802.11n, reconnections 0
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

I'm running RRF 1.5.2, DWC is the latest (can't remember number from when I COULD see DWC) and pretty sure wifi server is latest too as came in the RRF 1.5.2 package.

Here's the relevant from my SysLog:

power up + 00:00:00 [info] Event logging started at level warn
power up + 00:00:01 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:12 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:00:00 [info] Event logging started at level warn
power up + 00:00:01 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:13 [warn] Error: WiFi module reported: Authentication failed
power up + 00:00:13 [warn] WiFi module is idle
power up + 00:00:18 [warn] Error: WiFi module reported: Authentication failed
power up + 00:00:18 [warn] WiFi module is idle
power up + 00:00:23 [warn] Error: WiFi module reported: Authentication failed
power up + 00:00:23 [warn] WiFi module is idle
power up + 00:00:29 [warn] Error: WiFi module reported: Authentication failed
power up + 00:00:29 [warn] WiFi module is idle
power up + 00:00:37 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:00:01 [info] Event logging started at level warn
power up + 00:00:01 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:16 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:00:00 [info] Event logging started at level warn
power up + 00:00:00 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:08 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:00:00 [info] Event logging started at level warn
power up + 00:00:00 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:08 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:00:42 [warn] HTTP client 192.168.0.115 attempted login with incorrect password
power up + 00:00:51 [warn] WiFi module is idle
power up + 00:01:04 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:01:16 [warn] HTTP client 192.168.0.115 login succeeded (session key 467032916)
2024-08-03 11:23:47 [warn] Date and time set at power up + 00:01:16
2024-08-03 11:24:27 [warn] HTTP client 192.168.0.115 login succeeded (session key 369489427)
2024-08-03 11:24:33 [warn] HTTP client 192.168.0.115 login succeeded (session key 1633576112)
2024-08-03 11:25:53 [warn] HTTP client 192.168.0.115 login succeeded (session key 2082771136)
2024-08-03 11:25:58 [warn] HTTP client 192.168.0.115 login succeeded (session key 1151036652)
2024-08-03 11:26:09 [warn] HTTP client 192.168.0.115 login succeeded (session key 940317988)
2024-08-03 11:26:22 [warn] HTTP client 192.168.0.115 login succeeded (session key 592266043)
2024-08-03 11:26:53 [warn] HTTP client 192.168.0.115 login succeeded (session key 628680856)
2024-08-03 11:27:12 [warn] HTTP client 192.168.0.115 login succeeded (session key 619603552)
2024-08-03 11:27:36 [warn] HTTP client 192.168.0.115 login succeeded (session key 528694161)
2024-08-03 11:27:48 [warn] HTTP client 192.168.0.115 login succeeded (session key 1622916288)
2024-08-03 11:27:51 [warn] HTTP client 192.168.0.115 login succeeded (session key 1164251869)
power up + 00:00:00 [info] Event logging started at level warn
power up + 00:00:00 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:08 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:01:42 [warn] WiFi module started
power up + 00:01:48 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:02:06 [warn] HTTP client 192.168.0.115 attempted login with incorrect password
power up + 00:02:15 [warn] HTTP client 192.168.0.115 login succeeded (session key 536479440)
2024-08-03 11:31:39 [warn] Date and time set at power up + 00:02:15
2024-08-03 11:38:21 [warn] HTTP client 192.168.0.115 login succeeded (session key 1473597974)
2024-08-03 11:42:02 [warn] Error: G1: target position outside machine limits
2024-08-03 11:42:07 [warn] HTTP client 192.168.0.115 login succeeded (session key 1979731814)
2024-08-03 11:43:04 [warn] HTTP client 192.168.0.115 login succeeded (session key 240971280)
2024-08-03 11:43:13 [warn] HTTP client 192.168.0.115 login succeeded (session key 1997628365)
2024-08-03 11:43:31 [warn] HTTP client 192.168.0.115 login succeeded (session key 380593357)
2024-08-03 11:43:51 [warn] HTTP client 192.168.0.115 login succeeded (session key 1426250333)
2024-08-03 11:45:31 [warn] HTTP client 192.168.0.115 login succeeded (session key 776878917)
2024-08-03 11:45:44 [warn] HTTP client 192.168.0.115 login succeeded (session key 303384259)
2024-08-03 11:45:54 [warn] HTTP client 192.168.0.115 login succeeded (session key 853063035)
power up + 00:00:01 [info] Event logging started at level warn
power up + 00:00:01 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:08 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162
power up + 00:00:09 [warn] HTTP client 192.168.0.115 login succeeded (session key 1663640895)
2024-08-03 11:46:34 [warn] Date and time set at power up + 00:00:09
2024-08-03 11:50:28 [warn] HTTP client 192.168.0.115 login succeeded (session key 575438325)
2024-08-03 11:50:34 [warn] HTTP client 192.168.0.115 login succeeded (session key 1273065834)
2024-08-03 11:50:40 [warn] HTTP client 192.168.0.115 login succeeded (session key 1037896977)
2024-08-03 11:50:54 [warn] HTTP client 192.168.0.115 login succeeded (session key 2072311505)
2024-08-03 11:50:59 [warn] HTTP client 192.168.0.115 login succeeded (session key 1449677489)
2024-08-03 11:51:06 [warn] HTTP client 192.168.0.115 login succeeded (session key 1527582408)
2024-08-03 11:51:31 [warn] HTTP client 192.168.0.115 login succeeded (session key 910531371)
2024-08-03 11:51:34 [warn] HTTP client 192.168.0.115 login succeeded (session key 332283875)
2024-08-03 11:51:50 [warn] HTTP client 192.168.0.115 login succeeded (session key 1237604925)
2024-08-03 11:52:10 [warn] HTTP client 192.168.0.115 login succeeded (session key 2046853280)
2024-08-03 11:52:20 [warn] HTTP client 192.168.0.115 login succeeded (session key 922535667)
2024-08-03 11:52:26 [warn] HTTP client 192.168.0.115 login succeeded (session key 225023929)
2024-08-03 11:52:34 [warn] HTTP client 192.168.0.115 login succeeded (session key 258472336)
2024-08-03 11:52:39 [warn] HTTP client 192.168.0.115 login succeeded (session key 1932616918)
2024-08-03 11:52:45 [warn] HTTP client 192.168.0.115 login succeeded (session key 802379951)
2024-08-03 11:52:51 [warn] HTTP client 192.168.0.115 login succeeded (session key 1550016944)
2024-08-03 11:52:57 [warn] HTTP client 192.168.0.115 login succeeded (session key 10656051)
2024-08-03 11:53:08 [warn] HTTP client 192.168.0.115 login succeeded (session key 855106456)
2024-08-03 11:53:13 [warn] HTTP client 192.168.0.115 login succeeded (session key 813640268)
2024-08-03 11:53:24 [warn] HTTP client 192.168.0.115 login succeeded (session key 1823603827)
2024-08-03 11:53:29 [warn] HTTP client 192.168.0.115 login succeeded (session key 422910405)
2024-08-03 11:53:35 [warn] HTTP client 192.168.0.115 login succeeded (session key 1831788912)
2024-08-03 11:53:50 [warn] HTTP client 192.168.0.115 login succeeded (session key 550680592)
2024-08-03 11:54:04 [warn] HTTP client 192.168.0.115 login succeeded (session key 1781674821)
2024-08-03 11:54:16 [warn] HTTP client 192.168.0.115 login succeeded (session key 96742779)
2024-08-03 11:54:20 [warn] HTTP client 192.168.0.115 login succeeded (session key 310765874)
2024-08-03 11:54:30 [warn] HTTP client 192.168.0.115 login succeeded (session key 361814814)
2024-08-03 11:54:44 [warn] HTTP client 192.168.0.115 login succeeded (session key 1495374241)
2024-08-03 11:54:48 [warn] HTTP client 192.168.0.115 login succeeded (session key 753747646)
2024-08-03 11:54:54 [warn] HTTP client 192.168.0.115 login succeeded (session key 230652669)
2024-08-03 11:55:07 [warn] HTTP client 192.168.0.115 login succeeded (session key 371425048)
2024-08-03 11:55:11 [warn] HTTP client 192.168.0.115 login succeeded (session key 1953303554)
2024-08-03 11:55:39 [warn] HTTP client 192.168.0.115 login succeeded (session key 590320389)
2024-08-03 11:55:56 [warn] HTTP client 192.168.0.115 login succeeded (session key 140328783)
2024-08-03 11:56:43 [warn] HTTP client 192.168.0.115 login succeeded (session key 568811475)
2024-08-03 11:56:50 [warn] HTTP client 192.168.0.115 login succeeded (session key 1564747528)
2024-08-03 11:57:00 [warn] HTTP client 192.168.0.115 login succeeded (session key 626961934)
2024-08-03 11:57:11 [warn] HTTP client 192.168.0.115 login succeeded (session key 1794452556)
2024-08-03 11:57:20 [warn] HTTP client 192.168.0.115 login succeeded (session key 103770224)
power up + 00:00:01 [info] Event logging started at level warn
power up + 00:00:01 [info] Running: Duet WiFi 1.02 or later: 3.5.2 (2024-06-11 17:13:43)
power up + 00:00:01 [warn] WiFi module started
power up + 00:00:13 [warn] Error: WiFi module reported: Authentication failed
power up + 00:00:13 [warn] WiFi module is idle
power up + 00:00:42 [warn] WiFi module is connected to access point Home Sweet Home, IP address 192.168.0.162

Look at how many "login succeeded" messages there are for my computer's local IP. Something's up and I don't know what or what more to try, at this point I can't really use my machine.
If anyone has any advice or pointers I'd be very grateful, thanks!

@o_lampe it wasn’t, as it happens. I redid the firmware from scratch using the RRF configuration tool which gave a slightly different setup to the one I was working on when I asked the spindle question.
Ironically having fixed the issues I’m back to essentially my original spindle config.
What I’ve ended up doing to solve that original issue is break out heater3 (and 4 for the laser) and use those to PWM drive an external MOS chip that level shifts the PWM to a breakout from the fan 5V… which is then the right level and “side” of the spindle controller to control it properly!

It seemed to work when I tried it at 9:00 last night but that’s my cutoff time for trusting my brain not to do something stupid so I’ll be doing more tests and checks this afternoon.

@dc42 Sorry, got there myself with some playing around when it got more verbose and pointed me towards config.g and now sorting my config properly. That's irrelevant to this topic so I'll mark it as solved ◡̈

@dc42 Good afternoon and thanks!
I deleted out the current IAP and uploaded the one linked (thanks). M997 took longer to execute this time and upon running M115 I am happy to report she's now on RRF 3.5.2!

EDIT: I am however getting the following error:

Error in macro line 47 while starting up: exactly one of EFHJPSR must be given

I can't seem to find reference to this anywhere.