Upgrading Firmware from 2.02RC3 to 3.2

sinnedwrong

@sinnedwrong
Wanting to avoid being admonished by Phaedrux again I have been attempting to convert my maestro/Ormerod 2 to firmware 3.2. Thhe machine is running succesfully on 2.5 but when I upload 3.2 the machine fails with the error below. Axes X,Y and Z all move and zero correctly. I havent tried heating up the hot end.

Error. Temperature reading fault on heater 0 unknown temperature sensor channel

subsequently the following message pops up:

Reset Heater Fault
A heater fault has occurred on heater 0. It is strongly advised to turn off your machine now and to check your wiring before you continue. If you are absolutely sure that this is not a physical problem, you can reset the heater fault ON YOUR OWN RISK. Be aware that this is NOT RECOMMENDED and can lead to further problems. How would you like to proceed?

Reinstalling version 2.5 works normally, installing 3.2 the same error occurs rectified by going back again to 2.5.

The relevent sections of config.g are:
2.5
; Heaters
M305 P0 T10000 B3988 R2200 ; set thermistor + ADC parameters for heater 0
M143 H0 S120 ; set temperature limit for heater 0 to 120C
M305 P1 T100000 B4138 R2200 ; set thermistor + ADC parameters for heater 1
M143 H1 S280 ; set temperature limit for heater 1 to 280C

3.2
; Heaters
M308 S0 P"bedtemp" Y"thermistor" T10000 B3988 ; configure sensor 0 as thermistor on pin bedtemp
M950 H0 C"bedheat" T0 ; create bed heater output on bedheat and map it to sensor 0
M307 H0 B1 S1.00 ; enable bang-bang mode for the bed heater and set PWM limit
M140 H0 ; map heated bed to heater 0
M143 H0 S120 ; set temperature limit for heater 0 to 120C
M308 S1 P"e0temp" Y"thermistor" T100000 B4138 ; configure sensor 1 as thermistor on pin e0temp
M950 H1 C"e0heat" T1 ; create nozzle heater output on e0heat and map it to sensor 1
M307 H1 B0 S1.00 ; disable bang-bang mode for heater and set PWM limit
M143 H1 S280 ; set temperature limit for heater 1 to 280C

The configuration files were created by the RRF Config Tool taking all of the default options for an Ormerod 2 (except for the X direction which should be backwards) What am I doing wrong?

dc42

Have you run M98 P"config.g" to check for errors in config.g ?

sinnedwrong

@dc42
response after uploading 3.2 and power cycling machine

M98 P"config.g"
HTTP is enabled on port 80
FTP is disabled
TELNET is disabled
Warning: M308 command is not supported
Warning: M950 command is not supported
Warning: M308 command is not supported
Warning: M950 command is not supported
Warning: M950 command is not supported

comments at start of config.g

; Configuration file for Duet Maestro (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.2.3 on Tue Mar 23 2021 17:45:18 GMT+0000 (Greenwich Mean Time)

dc42

@sinnedwrong said in Upgrading Firmware from 2.02RC3 to 2.05.1:

@dc42
response after uploading 3.2 and power cycling machine

M98 P"config.g"
HTTP is enabled on port 80
FTP is disabled
TELNET is disabled
Warning: M308 command is not supported
Warning: M950 command is not supported
Warning: M308 command is not supported
Warning: M950 command is not supported
Warning: M950 command is not supported

comments at start of config.g

; Configuration file for Duet Maestro (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.2.3 on Tue Mar 23 2021 17:45:18 GMT+0000 (Greenwich Mean Time)

Those warnings indicate that you are not running RRF3.2, you are running RRF version 2.x.

sinnedwrong

@dc42
I have just recreated firmware and specificallty ensured in the config tool to select V3.0 or later.
It provides in the zip file DuetMaestroFirmware.bin 470kb compressed size 470kb 5% ratio with a CRC 2144DF1C

sinnedwrong

@sinnedwrong and to confirm
M115
FIRMWARE_NAME: RepRapFirmware for Duet 2 Maestro FIRMWARE_VERSION: 2.05.1 ELECTRONICS: Duet Maestro 1.0 FIRMWARE_DATE: 2020-02-09b1

What's the way forward?

sinnedwrong

@sinnedwrong and just discovered this which could be the problem as I hadn't done this. Could be tomorrows challenge EXCEPT how easy is it to go from 3.x back to 2.05?

**Updating from RRF 2.x to 3.x
Upgrading ANY Duet 2 from 2.x to 3.0 or later requires installing 3.0 first.

The version 3.01 and later binaries are too large to be installed by the IAP program supported by version 1.x and 2.x firmware. Therefore you cannot upgrade directly from version 1.x or 2.x firmware to 3.01 or later firmware. This is the procedure:

Download file Duet2and3Firmware-3.0.zip from https://github.com/Duet3D/RepRapFirmware...
Upload and install that file on the Duet through Duet Web Control
Send M115 and check the response to confirm that you are running version 3.0 firmware
You can then upgrade to version 3.01 or later firmware.
Important! When upgrading from 1.x or 2.x firmware to 3.x you will need to make substantial changes to your config.g file. See RepRapFirmware 3 overview.**

Phaedrux

If you still have access to DWC. Upload these 3 zip files, one at a time in the system tab. Don't extract them. Reboot after each. Use M115 to verify the firmware has been applied.
https://github.com/Duet3D/RepRapFirmware/releases/download/2.05.1/Duet2Firmware-2.05.1.zip
https://github.com/Duet3D/RepRapFirmware/releases/download/3.0/Duet2and3Firmware-3.0.zip
https://github.com/Duet3D/RepRapFirmware/releases/download/3.2.2/Duet2and3Firmware-3.2.2.zip
That will get your firmware and DWC up to date.

You can see the change logs here:
https://github.com/Duet3D/RepRapFirmware/wiki/Changelog-RRF-3.x

For your config, might be a good idea to run through the configurator tool and generate a fresh set for RRF3.
https://configtool.reprapfirmware.org/Start

Backup your existing config files in the sys folder in case you want to switch back to RRF3. IT’s easy to switch back and forth, just upload the zip file for the version you want and then upload your config files.

These documents will come in handy during the conversion.
https://duet3d.dozuki.com/Wiki/RepRapFirmware_3_overview
https://duet3d.dozuki.com/Wiki/Gcode

sinnedwrong

@phaedrux I finally got brave enough to attempt the firmware upgrade which was straightforward as I guess you are not surprised. I now have an issue in my config files. The bed which was working perfectly under 2.05 so isn't a wiring fault is coming up with the message "Heater fault rising more slowly than expected 1.8C/sec"
Settings in the RRF config tool:
tick for heated bed, bang bang,
values 120, 100, 10000,3988, 0
which are the defaults after specifying an Ormerod 2 in the initial screen. M115 gives Firmware 3.2.2 X&Y axes zero OK. That's as far as I've tested.
Ideas?

dc42

@sinnedwrong, I suggest you run heater tuning on the bed header. This will fix the fault message, also running the bed heater in bang-bang mode may cause Z banding.

sinnedwrong

@dc42 Clearly more reading and research to do however the RRF config tool was what specified bang/bang and I went with the default recommendation. Clearly I will now have to read https://duet3d.dozuki.com/Wiki/Tuning_the_heater_temperature_control and discover how to use heater tuning. Out of interest what is Z banding and should the config tool be updated?

Thanks

Phaedrux

Well the config tool can't do the tuning for you, so even if you didn't select bang-bang there it wouldn't have any tuned PID values to use until you did a tuning cycle.

sinnedwrong

@phaedrux Just a quick reply to thank everybody, the TOY is now working successfully on 3.2.

A couple of points:
I didn't find in the change log for version 3.2 that BANG-BANG wouldn't work only that there was a new heating algorithm.
Removing the BANG-BANG option in the configuration tool might be a good idea to avoid confusion
Also for completeness it might be a good idea to change the title of this thread by adding the phrase "to 3.2". I don't think I'm allowed to do this, I suspect an admin or moderator needs to do this.

Thanks again for all the help

Dennis

dc42

@sinnedwrong said in Upgrading Firmware from 2.02RC3 to 3.2:

I didn't find in the change log for version 3.2 that BANG-BANG wouldn't work only that there was a new heating algorithm.

Bang-bang can still be used. However, if you don't run heater tuning, then RRF knows nothing about your heater; so its heating rate may be lower than RRF expects, leading to a heater fault being raised.