DuetWiFi V1.01 doesn't boot reliably (firmware not loading?)

JeroenZvZ

Hi,

I've an older DuetWiFi that I have trouble to get working again after I shut down it's power supply during a failing print.

Over the years that I've been using the DuetWiFi it sometimes didn't boot up well (no WiFi blue led, don't remember if Diag led was on) but with a couple of tries it always started working again.

Last week, restarting didn't work (Diag led was red) so I tried Fallback procedure #2 and #3 numerous times on different PC's with different USB cables and different Transcend SD cards (present performing Fallback procedure #2, 16gb, formatted using the official SD-tool).

I've tried the procedures numerous times because, after flashing the firmware (tried 3.2 , 3.4.5, 3.5beta1. WifiServer 1.25, 1.27, 2.1beta2) and and reconnecting it to the printer and power supply (tried 12v and 24v, no usb connected), it only boots up fully (WiFi blue led on) maybe once in a hundred tries. The 3.3v and 5v (and VIN) light up. Processor, WiFi and SD-card don't get hot)

Fallback #3 / BOSSA: only connected to my PC, the serial port (reset) doesn't come up reliably most of the times but the BOSSA port (erase, reset) does. Flashing firmware using BOSSA failed lots of times because the tool (windows and cmdline) often couldn't unlock the flash regions. Switching cables, PC's, usb-ports, resetting COM ports helps but I didn't find a stable way to perform Fallback procedure #3. I've tried to erase/unlock it by using the button (doesn't seem stuck) and by connecting the soldering joints with a screwdriver. It seems that the erase-procedure doesn't work reliably anymore on my board. Most of the times the Diag led stays lit but when it doesn't that doesn't change it's behaviour with Fallback procedure #2 and #3.
Fallback #2 / YAT: after flashing with BOSSA I've to switch to another PC to get the serial port to show up (trail and error, unreliable) before I can use YAT (sometimes restarting PC and clearing COM ports helped).
With YAT I can configure WiFi and start a connection (tried as part of wifi-network and as access point, WiFi blue led comes on. Webpages load). But:
after putting it back on only the power supply the Duet can't be reached/wifi doesn't start.
connecting it again to the PC and reset doesn't bring back the serial port. Takes trial and error.
reflashing it with YAT works, reflashing it through the webpages works. Multiple reflashes after eachother makes the Duet nonresponsive.
multiple M999 restarts (say, five times) makes the Duet nonresponsive.
the Diag led stays lit most of the times after flashing/restarts. But when it doesn't, it makes no difference when I put it back in the printer and doesn't boot up to WiFi.

Does anyone have any experience with this behaviour? I don't see any damage to the board, processor, SD and wifi don't get hot, 3.3v and 5v leds light up. It seems that it has trouble to load the firmware at boot but why? Any ideas?

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 3.4.5 (2022-11-30 19:36:12) running on Duet WiFi 1.0 or 1.01
Board ID: 08DAM-999TL-MQ4SD-6JKDG-3SN6J-TP9HW
Used output buffers: 1 of 26 (14 max)
=== RTOS ===
Static ram: 23836
Dynamic ram: 73384 of which 0 recycled
Never used RAM 14860, free system stack 184 words
Tasks: NETWORK(ready,13.5%,384) HEAT(notifyWait,0.0%,388) Move(notifyWait,0.0%,363) MAIN(running,86.2%,428) IDLE(ready,0.2%,30), total 100.0%
Owned mutexes: WiFi(NETWORK) USB(MAIN)
=== Platform ===
Last reset 00:25:03 ago, cause: power up
Last software reset at 2025-04-16 19:07, reason: deliberate User, GCodes spinning, available RAM -2050144, slot 2
Software reset code 0x8003 HFSR 0xffffffff CFSR 0xffffffff ICSR 0xffffffff BFAR 0xffffffff SP 0xffffffff Task [Warning: "FFh EDh" is a byte sequence outside the Unicode basic multilingual plane (plane 0)! Only Unicode plane 0 is supported by .NET Framework and thus YAT (yet).]Y[Warning: "FFh 20h" is a byte sequence outside the Unicode basic multilingual plane (plane 0)! Only Unicode plane 0 is supported by .NET Framework and thus YAT (yet).]Freestk 4294967287 ok
Stack: ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff ffffffff
Error status: 0x00
Step timer max interval 0
MCU temperature: min 23.3, current 25.8, max 26.3
Supply voltage: min 2.0, current 2.1, max 2.1, under voltage events: 0, over voltage events: 0, power good: no
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: ok, SG min n/a
Driver 1: ok, SG min n/a
Driver 2: ok, SG min n/a
Driver 3: ok, SG min n/a
Driver 4: ok, SG min n/a
Driver 5: 
Driver 6: 
Driver 7: 
Driver 8: 
Driver 9: 
Driver 10: 
Driver 11: 
Date/time: 1970-01-01 00:00:00
Cache data hit count 4294967295
Slowest loop: 165.15ms; fastest: 0.13ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest read time 1.0ms, write time 8.9ms, max retries 0
=== Move ===
DMs created 83, segments created 0, maxWait 0ms, bed compensation in use: none, 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 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 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 ready with "M122" 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
Daemon is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty
=== Network ===
Slowest loop: 99.94ms; fastest: 0.07ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 0 of 8
= WiFi =
Network state is active
WiFi module is connected to access point 
Failed messages: pending 0, notready 0, noresp 2
WiFi firmware version 1.27
WiFi MAC address 5c:cf:7f:2c:24:ba
WiFi Vcc 3.40, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 25160
WiFi IP address 192.168.2.20
WiFi signal strength -67dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0
ok

dc42

@JeroenZvZ if you boot it up without the SD card inserted, does it normally respond to commands sent to it over USB such as M115 and M122?

JeroenZvZ

@dc42 If I get it to be recognised as USB Serial COM-port, and connect to it with YAT then it responds to M115 and M122 (booted up without a SD card present).

Just now, I tested this by connecting the board without SD only to USB and pressed reset: no port was shown, diag LED stayed on. Then, while typing my reply, a 3 or 4 minutes after reset I see that de Diag LED turns off and a USB serial COM-port appears in Windows. Never seen that before that it took so long.

I tried again with the SD Card present resetted and waited ten minutes, Diag LED stays on. I tried again without SD card, waited and now the led stays on.
So I find it's behaviour unpredictable and don't know which component could broken.