@KenW, this printer IS line powered (750W 300 x 300)
I am not entirely sure what actually is happening. Before I turn on the heater, I get a nice steady temperature reading. As soon as the heater goes on, temperature jumps around and, for a few seconds, that's all it does. Then the temperature starts to go up and the temperature reading appears to be generally stable (and increasing).
I just had an interesting thought .... with the heater being line powered and the thermistor being glued to the heater, maybe I am seeing interference. This would be more of a problem when cold as the resistance is higher. I do not use a shielded cable for the thermistor and it runs together with the power lines from the bed right to the electronics compartment. It's not even a twisted line.
Funny thing is that all three of my printers are configured that way and they see to be mostly ok (although I had intermittent problems like this in the past)
Interference would explain a lot though ..... I wonder if it would make sense to stick a substantial capacitor across the sensor input pins on the Duet to absorb quick spikes? Any comments on a bandaid such as that?
I am curious though why a spike would trigger the heater error because the error has to persist for a while before a fault is triggered. I seem to recall that the time for error detection can be extended - I will give this a try first since it's just a line in config.g. I am reluctant to do this because it applies to the entire print job and not just the startup phase.
Now that I am thinking about it, maybe since the heater is hard on during startup it causes more interference than a slowly cycling heater?