Heater Fault heater 1 will not reset.

akrogolf

I have 3 machines, all duet 3 mini 5. Running mag+. About a week ago i heard a spark after recently setting up slice engineering pt1000 sensors and 50 watt heaters. Ran for ~50 hours with that. The other machines run 40wat e3d heaters and thermisters.

Anyways, i heard a small sparky pop at the end of a print as it was running the post script and since have not been about to reset the fault. I changed heaters adn pt1000s, went back to old heaters and thermisters firmware change... Inspect the board and dont see any black or damage anywhere. I changed both the fuses on the board. Machine homes, works as it should other than the heater fault. Fan is working - thermisters work identical to others... Just can't get the heater fault to clear. Any ideas?

I also just noticed that i do not get an MCU temperature reading on the faulted machine.

2/27/2023, 11:08:12 PM M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.2.2 running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: 0YDZW-3096U-D65J0-40KM2-4Z03Z-ZNPTY
Used output buffers: 3 of 40 (12 max)
=== RTOS ===
Static ram: 98732
Dynamic ram: 108152 of which 24 recycled
Never used RAM 38308, free system stack 188 words
Tasks: NETWORK(ready,204) HEAT(blocked,190) CanReceiv(blocked,947) CanSender(blocked,372) CanClock(blocked,363) TMC(blocked,106) MAIN(running,420) IDLE(ready,20) AIN(blocked,269)
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:15:17 ago, cause: reset button
Last software reset at 2023-02-27 22:35, reason: User, GCodes spinning, available RAM 38308, 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
Aux0 errors 0,0,0
Aux1 errors 0,0,0
Supply voltage: min 0.0, current 24.2, max 24.3, under voltage events: 0, over voltage events: 0, power good: yes
Driver 0: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Driver 1: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Driver 2: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Driver 3: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Driver 4: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Driver 5: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Driver 6: position 0, standstill, SG min/max 0/0, read errors 0, write errors 1, ifcnt 19, reads 52449, writes 9, timeouts 0, DMA errors 0
Date/time: 2023-02-27 23:08:13
Cache data hit count 1849901331
Slowest loop: 14.34ms; fastest: 0.12ms
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 4.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, maxWait 0ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters = 0 -1, chamberHeaters = -1 -1
Heater 0 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.
=== Network ===
Slowest loop: 14.83ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8

WiFi -
Network state is active
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.26
WiFi MAC address d8:bf:c0:14:e9:8f
WiFi Vcc 3.36, reset reason Power up
WiFi flash size 2097152, free heap 26672
WiFi IP address 192.168.68.113
WiFi signal strength -47dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0
=== CAN ===
Messages queued 8259, send timeouts 8257, received 0, lost 0, longest wait 0ms for reply type 0, free buffers 16

Phaedrux

What is the actual fault error message you are getting?

akrogolf

@Phaedrux

2/28/2023, 8:50:48 AM M562 P1
Error: Heater 1 fault: heater monitor 1 was triggered

akrogolf

@Phaedrux ;End Stops
M574 X2 S1 P"io0.in" ;Map the X endstop to io0.in
M574 Y2 S1 P"io1.in" ;May the Y endstop to io1.in

;Thermistors
M308 S0 P"temp0" Y"thermistor" T100000 B3950 A"Bed" ; configure sensor 0 as thermistor on pin temp0
M308 S1 P"temp1" Y"thermistor" A"RTemp" T100000 B4725 C7.06e-8 H0 L0 ;duet3 e3d
M308 S2 P"temp2" Y"thermistor" A"LTemp" T100000 B4725 C7.06e-8 H0 L0 ;duet3 e3d

;Heaters
M950 H0 C"out0" T0 Q11; ; create bed heater output on out5 and map it to sensor 0, lower switching frequency t
;Mosquito Magnum+ heaters
M950 H1 C"out1+out2" T1; ;2 Heaters wired to separate connectors but treated as a single logical heater
;Pid Tuning Profiles

;Safe Measures
M570 S360; ;Hot end may be a little slow to heat up so allow it 180 seconds
;Define Monitor Temperature Sensor
M143 H1 P1 S310 T2 A0;
;Mosquito Magnum+ Max Temperatures
M143 H1 S310;

;Fans
M950 F0 C"out3"; ;Layer fan
M106 P0 C"Layer Fan";
M106 P0 S0;
M950 F1 C"out4"; ;Hotend fan
M106 P1 S255 H1 T50; ;Enable thermostatic hotend fan (Fan turns on at 50C)
M950 F2 C"out5"; ;LED
M106 P2 C"LED";

;Tool definitions
M563 P0 D0 H1 S"Magnum+"; ;Define Mosquito Magnum+ Tool
G10 P0 S0 R0; ;Set tool 0 operating and standby temperatures

Phaedrux

Does the LED on the heater output turn on when you enable it?

Can you check the terminals with your multimeter to see if it is switching on with voltage?

akrogolf

@Phaedrux

How would i enable it? Cannot get passed fault - it instantly triggers fault again when i reset it.

It has ~24V crossed in the "fault position"

I checked another machine which does not have a voltage crossed when heaters turned off.

Phaedrux

Do you know what may have shorted?

Can you grab a photo of the heater terminal area? Do you notice any damage to the mosfet?

Where did you hear the sparky pop from? The hotend, or the board?

deckingman

@Phaedrux This might be significant. In the first post the OP stayed " also just noticed that i do not get an MCU temperature reading on the faulted machine."

akrogolf

@Phaedrux I ended up installing a new board... the one i took off still looks brand new i really inspected it everywhere. thanks for trying to help

dc42

@akrogolf said in Heater Fault heater 1 will not reset.:

M950 H1 C"out1+out2" T1; ;2 Heaters wired to separate connectors but treated as a single logical heater
...
M143 H1 P1 S310 T2 A0;

You are using sensor 1 to control heater 1 and sensor 2 to monitor it. What reading were you getting from sensor 2? The error message suggests that sensor 2 is providing a very high reading or not providing a reading at all.

akrogolf

@dc42 Hi David, sorry for the late response and thanks for chiming in! So I've been having a hell of a time. I swapped the board and and changed the sensors and its been good.

On another machine my extruder was not working. Like an idiot, this was 100% my fault, i pulled the extruder motor cable out of the 2+ daughter board socket and the hole daughter board came with it - with the machine on (i thought it was off because i turned the switch off but i forgot this switch was just hardwired and did nothing - i needed to pull the plug to turn power off). I quickly plugged it back in it went pop and fried everything.. I know not to do that but the second i pulled it off i realized the machine was still on and i was so flustered i don't know what i was thinking - just plug it back in real quick and it will be OK. lesson learned i guess. This board will not plug in via USB, my pc does not recognize it, and nothing seems to be working - ie wifi.

Anyways, i put the old board (the one with broken thermister sensor 2 that we are talking about on this forumn) on it and just didn't use sensor 2. This worked for about 4 days and then it went pop mid print. Mind you this is on a different machine with an E3D thermister (firmware was changed) than the original machine it popped on. I think the original short may have damaged more than just sensor two and it was hanging on by a thread until it finally broke? Now both thermister sensors do not work and i cannot clear a heater fault - when i clear it it instantly faults no matter whichc sensor port is occupied. Everythign else seems to work on this board, wifi, usb pc connection.

in response to your comment, I am using magnum+ and that is the recommended config according to slice engineering. Sensor 2 gave no reading. (it said 0).

I purchased another mini5 board from fillastruder and am waiting for it to show up. in the mean time i am shielding all the thermister wires with fiberglass silicon jackets and am getting a bit more organized with my wiring.. I print about 3 kg's of plastic a day with these machines so this is something i need to get sorted out, and i want to stay with duet as i know this is most likely my fault - which is probably the case for most warranty claims.

For these two boards that i have... Is there anything i can do? I purchases from fillastruder in March 2022 but have only used them fro about 3 months. I know this is just out of warranty. I also know that i made some mistakes - the board that i pulled the dauter board out i take full responsibility but with the one with thermister sensors i am not sure what went wrong. Sounds like the pt1000 shorted and caused some issues... I am also using a metal print head where the pt1000 wire jacket was touching metal - maybe it arced? Anyways, i would really appreciated some guidance on what to do with these two boards. If there is a repair service, if can get some sort of warranty, recycling, something.. Thanks in advance. I really appreciate the documentation and community around Duet. Which is why i went those route over btt or others.

elmoret

@dc42 / @Phaedrux

Possibly a blown VSSA fuse on the board with no thermistor inputs?

https://duet3d.dozuki.com/Wiki/How_to_destroy_your_Duet_2

elmoret

@T3P3Tony ?

Phaedrux

Sorry for the delay. Reviewing the thread.

akrogolf

@Phaedrux Thankyou

dc42

@akrogolf I suspect you either have an intermittent short in the hot end between sensor 2 and the heater (possibly via the hot end metalwork) or you have had electrostatic discharge (ESD) between the hot end metalwork and the sensor wiring. The Duet temperature inputs can normally tolerate a short but do not always tolerate ESD.

My suggestions:

Ground the hot end metalwork to Duet ground, either directly to the VIN ground wire or indirectly through a high value resistor to any Duet ground connection. This will prevent extrusion causing a build up of static charge.
Test all three temperature inputs of the Duet 3 Mini using either a thermistor or PT1000 sensor that is not mounted in a hot end, or using a fixed resistor. They should give the same reading to within a few degrees. If the input that sensor 2 was connected to turns out to be faulty then it may be possible to rescue it by replacing the series resistor.

akrogolf

@dc42 I totally rewired everything. I did as you suggested for new wiring (ordered a new board).

I tested the temp inputs, i get no reading on 1 or 2, and 0 works. If i were to replace said resistor.... where would i find information on this?

Anything about a warranty claim?

dc42

@akrogolf if inputs 0 works but 1 and 2 don't then it could be that the series resistors for both input 1 and 2 have failed because of ESD or a short on the hot end. The series resistors are R60, R61 and R62 for inputs 0, 1, 2 respectively. They are 2.2K 0.1% tolerance 0402 size resistors. You could replace the faulty ones with 2.2K 1% tolerance resistors, at the cost of slightly less accuracy when using PT100 sensors.

These resistors are located close to the temperature connectors. Here is an extract from the PCB layout:

I suggest that you test the resistors with a multimeter before removing them. Bear in mind that lead-free solder tends to develop a tin oxide coating, so it can be hard to get a good contact between the multimeter probes and the resistors.

I find that the easiest way to remove 0402 components is to use a soldering iron with a bit that is just large enough to cover both ends of the component. Preferably, place the Duet on a hot plate heated to between 100C and 125C and allow it to heat up. Put some fresh flux-cored solder on the soldering iron bit and immediately apply it to the component. When the solder melts, surface tension will usually cause the component to stick to the bit and it will lift off when you remove the soldering iron.

To solder a new 0402 component in place, I normally clean the solder off one of the pads using solder wick and then apply no-clean flux to both pads. Using a fine-tipped soldering iron bit I heat the pad I didn't clean and with fine tweezers I push the new resistor on to that pad. Remove the soldering iron and let the solder set. Then solder the other end.

Alternatively, if the old resistors have failed open circuit, you can leave them in place and solder the new resistors on top of them.

You haven't indicated in your profile which country you are in; but if it happens to be the UK then I can do this for you. Otherwise, you may have a hackspace or makerspace local to you where you can find someone more experienced to help you.

It's also possible to use hot air soldering equipment to desolder and solder the resistors, but in this case the plastic parts of the temperature connectors must be removed first, otherwise the hot air will melt them.

akrogolf

@dc42 I don't really have time to do this type of repair. I have 2 boards that are not in use. Is there anythign duet can do as far as warranty replacments?

I have 4 boards total - all duet 5 mini - 2 of them are described in this thread. A third just started doing this:

Your Duet rejected the HTTP request: page not found
Check that the SD card is mounted and has the correct files in its /www folder

... I reformatted a new card and tried the help section in https://forum.duet3d.com/topic/6798/your-duet-rejected-the-http-request-page-not-found.

with no luck.

So now I just have the 1 board working on 1 printer..

akrogolf

@dc42 I get this error when trying to remount the SD card - it does this for 2 different cards.

WiFi module is connected to access point *********, IP address 192.168.68.107
Error: M21: Cannot initialise SD card 0: Card is unusable
ok
M21;
Error: M21: Cannot initialise SD card 0: Card is unusable
ok

Also the usb connection seems to interrupt when I power on the machine - as opposed to just being powered through the usb.