@chrishamm Sigh.... So I replaced my Pi 4 with a 3B+, ensured the voltage was fine (5.21V again) with no throttling events. But it just died again with literally 30 seconds to go on a 25 hour print. Please see logs and diagnostics captured right after it happened below.
Maybe I do need to replace the ribbon cable? Where can I find a replacement?
#DuetControlServer log when it stopped Jun 20 12:11:39 Rancor DuetControlServer[397]: [info] Starting macro file M800.g on channel File Jun 20 12:11:39 Rancor DuetControlServer[397]: [warn] Lost connection to Duet (Board is not available (no header)) Jun 20 12:11:39 Rancor DuetControlServer[397]: [info] Connection to Duet established Jun 20 12:11:39 Rancor DuetControlServer[397]: [info] Starting macro file config.g on channel Trigger Jun 20 12:11:39 Rancor DuetControlServer[397]: [info] Starting macro file globals.g on channel Trigger Jun 20 12:11:40 Rancor DuetControlServer[397]: [info] Finished macro file globals.g Jun 20 12:11:42 Rancor DuetControlServer[397]: [error] M584: Driver 1.0 does not exist Jun 20 12:11:42 Rancor DuetControlServer[397]: Driver 1.1 does not exist Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Starting macro file tools/t0.g on channel Trigger Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Finished macro file tools/t0.g Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Starting macro file tools/t1.g on channel Trigger Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Finished macro file tools/t1.g Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Starting macro file tools/bed.g on channel Trigger Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Finished macro file tools/bed.g Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Starting macro file tools/setup.g on channel Trigger Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Starting macro file tools/revo_a_0.4/config.g on channel Trigger Jun 20 12:11:43 Rancor DuetControlServer[397]: [warn] M307: Heater 1 predicted maximum temperature at full power is 497°C Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Finished macro file tools/revo_a_0.4/config.g Jun 20 12:11:43 Rancor DuetControlServer[397]: [info] Starting macro file tools/revo_b_0.4/config.g on channel Trigger Jun 20 12:11:44 Rancor DuetControlServer[397]: [warn] M307: Heater 2 predicted maximum temperature at full power is 497°C Jun 20 12:11:44 Rancor DuetControlServer[397]: [info] Finished macro file tools/revo_b_0.4/config.g Jun 20 12:11:44 Rancor DuetControlServer[397]: [info] Starting macro file tools/bed_offsets.g on channel Trigger Jun 20 12:11:44 Rancor DuetControlServer[397]: [info] Finished macro file tools/bed_offsets.g Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Finished macro file tools/setup.g Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Starting macro file soft_load_tool.g on channel Trigger Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Starting macro file 0:/filaments/PLA/config.g on channel Trigger Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Starting macro file tools/revo_a_0.4/filament.g on channel Trigger Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Finished macro file tools/revo_a_0.4/filament.g Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Finished macro file 0:/filaments/PLA/config.g Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Finished macro file soft_load_tool.g Jun 20 12:11:45 Rancor DuetControlServer[397]: [info] Finished macro file config.g M122 B0 === Diagnostics === RepRapFirmware for Duet 3 MB6HC version 3.4.1 (2022-06-01 21:09:01) running on Duet 3 MB6HC v1.01 or later (SBC mode) Board ID: 08DJM-9P63L-DJ3S0-7JTD0-3SN6R-TUMBA Used output buffers: 1 of 40 (14 max) === RTOS === Static ram: 151000 Dynamic ram: 69072 of which 0 recycled Never used RAM 127672, free system stack 180 words Tasks: SBC(ready,0.6%,454) HEAT(notifyWait,0.0%,321) Move(notifyWait,0.0%,267) CanReceiv(notifyWait,0.0%,797) CanSender(notifyWait,0.0%,374) CanClock(delaying,0.0%,339) TMC(notifyWait,7.7%,58) MAIN(running,91.1%,1205) IDLE(ready,0.5%,30), total 100.0% Owned mutexes: HTTP(MAIN) === Platform === Last reset 00:02:24 ago, cause: software Last software reset at 2022-06-20 12:11, reason: OutOfMemory, GCodes spinning, available RAM 672, slot 0 Software reset code 0x41c3 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0440f000 BFAR 0x00000000 SP 0x204341b0 Task SBC Freestk 629 ok Stack: 20435bac 00418801 00000000 204366d0 20419894 0040c457 00000006 204341f0 204341f8 0040c5a3 20434559 20434558 00000065 204341f8 204342e8 00451913 204341f8 00000065 6579616c 40240072 00000000 43300000 00000000 2043611a 00000006 00483de7 00000001 Error status: 0x00 Aux0 errors 0,0,0 Aux1 errors 0,0,0 Step timer max interval 168 MCU temperature: min 46.1, current 46.2, max 47.0 Supply voltage: min 23.8, current 23.9, max 23.9, under voltage events: 0, over voltage events: 0, power good: yes 12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0 Heap OK, handles allocated/used 99/54, heap memory allocated/used/recyclable 2048/1028/340, gc cycles 0 Events: 0 queued, 0 completed Driver 0: standstill, SG min 0, mspos 408, reads 21308, writes 14 timeouts 0 Driver 1: standstill, SG min 0, mspos 536, reads 21308, writes 14 timeouts 0 Driver 2: standstill, SG min 0, mspos 472, reads 21309, writes 14 timeouts 0 Driver 3: standstill, SG min 0, mspos 776, reads 21304, writes 19 timeouts 0 Driver 4: standstill, SG min 0, mspos 360, reads 21304, writes 19 timeouts 0 Driver 5: standstill, SG min 0, mspos 584, reads 21304, writes 19 timeouts 0 Date/time: 2022-06-20 12:14:03 Slowest loop: 30.80ms; fastest: 0.05ms === Storage === Free file entries: 10 SD card 0 not detected, interface speed: 37.5MBytes/sec SD card longest read time 0.0ms, write time 0.0ms, max retries 0 === Move === DMs created 125, segments created 3, maxWait 75628ms, bed compensation in use: none, comp offset 0.000 === MainDDARing === Scheduled moves 2, completed 2, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 2], 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 -1 -1 -1 -1 -1 -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 doing "M122 B0" 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 Extruder 1 sensor: no filament === CAN === Messages queued 1312, received 2994, lost 0, boc 0 Longest wait 1ms for reply type 6018, peak Tx sync delay 230, free buffers 50 (min 49), ts 724/723/0 Tx timeouts 0,0,0,0,0,0 === SBC interface === Transfer state: 5, failed transfers: 0, checksum errors: 0 RX/TX seq numbers: 47574/6777 SPI underruns 0, overruns 0 State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x2b880 Buffer RX/TX: 0/0-0, open files: 0 === Duet Control Server === Duet Control Server v3.4.1 File /opt/dsf/sd/gcodes/DualLightSaber_T0-PLA_T1-PLA.gcode is selected, processing File: Executing macro M800.g, started by M800 F"layer" > Next stack level Suspended code: G1 X54.614 Y175.558 Suspended code: G11 ; unretract Suspended code: M204 P800 Suspended code: ;HEIGHT:0.15 Suspended code: G1 F900 Suspended code: G1 X57.334 Y175.561 E.06804 Suspended code: G1 X57.725 Y175.6 E.00983 Suspended code: G1 X59.068 Y175.817 E.03402 Suspended code: G1 X60.269 Y175.984 E.03032 Suspended code: G1 X61.33 Y176.073 E.02664 Suspended code: G1 X62.097 Y176.092 E.01919 Suspended code: G1 X62.863 Y176.073 E.01917 Suspended code: G1 X63.928 Y175.986 E.02672 Suspended code: G1 X66.729 Y175.57 E.07083 Suspended code: G1 X69.581 Y175.557 E.07134 Suspended code: G1 X69.344 Y175.697 E.00689 Suspended code: G1 X68.524 Y176.069 E.02252 Suspended code: G1 X67.765 Y176.362 E.02034 Suspended code: G1 X66.972 Y176.624 E.02089 Suspended code: G1 X66.161 Y176.847 E.02105 Suspended code: G1 X65.388 Y177.021 E.01981 Suspended code: G1 X64.579 Y177.162 E.02053 Suspended code: G1 X63.663 Y177.272 E.02308 Suspended code: G1 X62.945 Y177.324 E.01801 Suspended code: G1 X62.166 Y177.345 E.0195 Suspended code: G1 X61.187 Y177.32 E.02449 Suspended code: G1 X60.424 Y177.262 E.01913 Suspended code: G1 X59.638 Y177.165 E.01982 Suspended code: G1 X58.806 Y177.021 E.02112 Code buffer space: 4096 Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0 Full transfers per second: 37.60, max time between full transfers: 226.0ms, max pin wait times: 108.3ms/17.1ms Codes per second: 17.30 Maximum length of RX/TX data transfers: 3968/1592 M122 B1 Diagnostics for board 1: Duet EXP3HC rev 1.01 or earlier firmware version 3.4.1 (2022-06-01 21:15:27) Bootloader ID: SAME5x bootloader version 2.3 (2021-01-26b1) All averaging filters OK Never used RAM 158400, free system stack 167 words Tasks: Move(notifyWait,1.5%,92) HEAT(notifyWait,0.7%,50) CanAsync(notifyWait,0.1%,64) CanRecv(notifyWait,0.7%,80) CanClock(notifyWait,0.1%,71) TMC(notifyWait,33.3%,65) MAIN(running,41.1%,344) IDLE(ready,0.0%,40) AIN(delaying,22.5%,263), total 100.0% Last reset 25:24:51 ago, cause: power up Last software reset data not available Driver 0: pos -258009, 160.0 steps/mm,standstill, SG min 0, mspos 744, reads 9620, writes 29 timeouts 0, steps req 185814711 done 185537164 Driver 1: pos 257123, 160.0 steps/mm,standstill, SG min 0, mspos 744, reads 9620, writes 29 timeouts 0, steps req 232322253 done 232005820 Driver 2: pos 13558906, 397.0 steps/mm,standstill, SG min 0, mspos 776, reads 9625, writes 26 timeouts 0, steps req 22606666 done 22606666 Moves scheduled 1382523, completed 1382523, in progress 0, hiccups 193, step errors 0, maxPrep 214, maxOverdue 7319, maxInc 7313, mcErrs 0, gcmErrs 0 Peak sync jitter -5/5, peak Rx sync delay 187, resyncs 0/1, no step interrupt scheduled VIN voltage: min 24.0, current 24.1, max 24.2 V12 voltage: min 12.1, current 12.1, max 12.2 MCU temperature: min 31.2C, current 46.9C, max 49.2C Last sensors broadcast 0x00000004 found 1 181 ticks ago, 0 ordering errs, loop time 0 CAN messages queued 1881188, send timeouts 0, received 2211077, lost 0, free buffers 37, min 37, error reg 110000 dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 424, adv 34892/95319 === Filament sensors === Interrupt 5726621 to 0us, poll 1 to 576us Driver 2: ok