Duet mini 5+ freezes and shuts off heaters

jay_s_uk

@michael-hathaway Is the M122 output you posted from directly after the freeze?

Michael Hathaway

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.4.1 (2022-06-01 21:06:56) running on Duet 3 Mini5plus Ethernet (standalone mode)
Board ID: 6G14B-Z096U-D65J0-40KMD-2113Z-7JZ07
Used output buffers: 1 of 40 (22 max)
=== RTOS ===
Static ram: 103684
Dynamic ram: 105204 of which 0 recycled
Never used RAM 32824, free system stack 204 words
Tasks: NETWORK(ready,26.4%,238) ETHERNET(notifyWait,0.3%,568) HEAT(notifyWait,0.0%,358) Move(notifyWait,0.0%,363) CanReceiv(notifyWait,0.0%,942) CanSender(notifyWait,0.0%,372) CanClock(delaying,0.0%,339) TMC(notifyWait,0.7%,105) MAIN(running,71.7%,422) IDLE(ready,0.1%,29) AIN(delaying,0.8%,264), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:03:26 ago, cause: reset button
Last software reset at 2022-09-06 10:42, reason: User, GCodes spinning, available RAM 32536, slot 1
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
MCU revision 3, ADC conversions started 206480, completed 206480, timed out 0, errs 0
Step timer max interval 751
MCU temperature: min 48.7, current 48.7, max 51.8
Supply voltage: min 24.0, 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 0, read errors 0, write errors 1, ifcnt 27, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 29, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 2, read errors 0, write errors 1, ifcnt 33, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 54, read errors 0, write errors 1, ifcnt 21, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 19, reads 10837, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2022-09-07 02:37:14
Cache data hit count 353060786
Slowest loop: 8.73ms; fastest: 0.13ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 5.2ms, write time 44.1ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: mesh, comp offset 0.000
=== MainDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
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
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Movement lock held by 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
Code queue is empty
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 1856, received 0, lost 0, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 18 (min 18), ts 1032/0/0
Tx timeouts 0,0,1031,0,0,823 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 12.40ms; fastest: 0.03ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 2 of 8
- Ethernet -
State: active
Error counts: 0 0 0 0 0
Socket states: 2 2 2 2 2 0 0 0

Michael Hathaway

This one is directly after freeze

jay_s_uk

@michael-hathaway said in Duet mini 5+ freezes and shuts off heaters:

Last reset 00:03:26 ago, cause: reset button

this is the reason for the "freezes". now its just understanding why this is happening.
Might be a good idea to post a high res picture of the reset button area

Michael Hathaway

@jay_s_uk So the reset button on the board is being triggered?

jay_s_uk

@michael-hathaway yep

Michael Hathaway

Michael Hathaway

Michael Hathaway

Is there anyway of resetting besides pressing that button?

jay_s_uk

@michael-hathaway i suppose the question is when and where did you purchase?
one for @Phaedrux or maybe @droftarts

jay_s_uk

@michael-hathaway said in Duet mini 5+ freezes and shuts off heaters:

Is there anyway of resetting besides pressing that button?

not that i'm aware of

Michael Hathaway

My old board just started doing this recently after 1.5 years use. And my new board does the same exact thing. I purchased from Filastruder 1.5 years ago.

droftarts

@michael-hathaway I just did a quick test on my Mini 5+ to see what a power cycle, M999 (reset) and reset button press reports on restart in M122.
M999:

=== Platform ===
Last reset 00:00:12 ago, cause: software
Last software reset at 2022-09-07 11:54, reason: User, GCodes spinning, available RAM 27680, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00

Reset button:

=== Platform ===
Last reset 00:00:13 ago, cause: reset button
Last software reset at 2022-09-07 11:54, reason: User, GCodes spinning, available RAM 27680, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00

Power cycle:

=== Platform ===
Last reset 00:00:22 ago, cause: power up
Last software reset at 2022-09-07 11:54, reason: User, GCodes spinning, available RAM 27680, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00

I did the M999 first, and that is what the subsequent M122 'Last software reset...' is reporting. I notice that your M122 also reports the same time for 'Last software reset...' so I don't think the reset is coming from the firmware or gcode file.

I think if the firmware is reporting a reset button press, it probably actually is a reset button press or short. Is the printed case you have the Duet in new? My guess is that, as the board heats up, it's flexing slightly and somehow shorting out on the case. Maybe add some nylon washers under your mounting screws (ideally the board should be mounted using nylon washers), to lift the board up a little?

Ian

Michael Hathaway

@droftarts Thank you, I will try that. I will also order a new board just in case I have fried this one.

droftarts

@michael-hathaway Looking at the Mini 5+ schematic (https://raw.githubusercontent.com/Duet3D/Duet3-Mini5plus/main/v1.01/Duet3_5%2B_Wifi_schematic_v1.01.pdf), there are also reset pins on the 12864_EXP2 connector, SWD connector (just behind the reset button, but as it is unpopulated with a header, this shouldn't be a problem) and there's also a test point (on the back of the board, by the SWD connector pins, I think). I don't think you have anything plugged into the 12864 connector, but again check that it is not shorting out to anything, top or bottom.

Ian

Michael Hathaway

I ordered a new Duet mini 5 plus board with overnight postage, should have it tomorrow. I also ordered nylon washers as recommended.

This time when mounting in the petg enclosure, I will allow to board to float and not be fastened down so well.

I have found new Samsung endurance sdcards, which are designed to be powered on continuously. I am hopeful this increases reliability.

I appreciate everyone's help I have received and I will update with my progress as I proceed.

Michael Hathaway

Brand new Duet mini 5+ board, mounted loose on nylon washers.

Reset tripped, frozen mid print.

9/10/2022, 1:42:33 AM 	m122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.4.1 (2022-06-01 21:06:56) running on Duet 3 Mini5plus Ethernet (standalone mode)
Board ID: 6MFQS-V096U-D65J0-40KMJ-JS03Z-R72JU
Used output buffers: 1 of 40 (15 max)
=== RTOS ===
Static ram: 103684
Dynamic ram: 105204 of which 0 recycled
Never used RAM 32824, free system stack 204 words
Tasks: NETWORK(ready,26.2%,246) ETHERNET(notifyWait,0.2%,568) HEAT(notifyWait,0.0%,358) Move(notifyWait,0.0%,363) CanReceiv(notifyWait,0.0%,942) CanSender(notifyWait,0.0%,372) CanClock(delaying,0.0%,339) TMC(notifyWait,0.7%,114) MAIN(running,71.9%,422) IDLE(ready,0.2%,29) AIN(delaying,0.8%,264), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:01:26 ago, cause: reset button
Last software reset details not available
Error status: 0x00
MCU revision 3, ADC conversions started 87093, completed 87092, timed out 0, errs 0
Step timer max interval 752
MCU temperature: min 60.2, current 60.2, max 62.8
Supply voltage: min 24.1, current 24.1, 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 39, reads 4560, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 4, read errors 0, write errors 1, ifcnt 39, reads 4560, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 39, reads 4559, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 2, read errors 0, write errors 1, ifcnt 33, reads 4559, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 29, reads 4560, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2022-09-10 01:42:33
Cache data hit count 148434782
Slowest loop: 8.24ms; fastest: 0.13ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 1.0ms, write time 3.8ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: mesh, comp offset 0.000
=== MainDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
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
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Movement lock held by 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
Code queue is empty
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 783, received 0, lost 0, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 18 (min 18), ts 436/0/0
Tx timeouts 0,0,435,0,0,346 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 4.93ms; fastest: 0.03ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 2 of 8
- Ethernet -
State: active
Error counts: 0 0 0 0 0
Socket states: 2 2 2 2 2 0 0 0

Michael Hathaway

I have 3 boards now that do the same thing. One board ran great for 1.5 years and this happened.

droftarts

@michael-hathaway is it the same print, same Gcode file and stopping in the exact same place? I still don’t think anything else would cause M122 to report a manual reset except for a reset button press, or short on on of the other reset pins I mentioned in my earlier post.

Did you change anything just before this started happening? I can’t think that you’d have three Duets that have the same problem!

Ian

Michael Hathaway

@droftarts I didn't change anything else. I will try a few different prints and report back. I don't know the electronics well enough to know what would trigger a reset other than the button and those contacts which are not being touched. If a stepper was getting too hot, would that trigger a reset? Would a broken wire trigger a reset?