@dc42 I used a hot air station we have at work to remove the chip and the board works great now, thanks for all your help!

@fcwilt thanks, the issue come from the position of the probe relative to the nozzle (about -35X 25Y) and the travel limits of the gantry. The probe can’t physically get to those regions.

@dc42 I used a hot air station we have at work to remove the chip and the board works great now, thanks for all your help!

Thanks everyone for your help, it looks like a new SD card has fixed the problem, which is great!

@droftarts Interesting, so the SD card is the original that came with the board and the interface speed looks as expected: 22.5 MB/s

But the read write test is very slow:
SD write speed for 10.0MByte file was 0.43MBytes/sec
Testing SD card read speed...

Doesn't seem to ever finish the read test.

Not much free space either:
SD card in slot 0: capacity 7.95GB, partition size 0.26GB, free space 0.06GB, speed 22.50MBytes/sec, cluster size 512 bytes

I'm not sure where its all gone, I regularly delete all the jobs.

Could be a nice fix as I have another 32 GB SD card, once I format it as FAT 32 do I just copy all the files over? Can I reformat it using Mac OS?

@Phaedrux Yes always on curves, and only with many parts on the bed and later in the print, like there's a cashe of memory that's getting filled.

Its difficult to replicate as it requires the need to print quite a few curved parts (ovals or cylinders are the main culprits)...

I can try with the deamon off, or is there a way to decrease the frequency which it runs?

@droftarts Hi, yeah so the printer is a Zortrax M200 I've converted, I added a Duet 3 Mini 5+. I think its got Nema 16s and mechanically runs very smoothly. I took the diagnostics this morning after printing some parts that have a few stutter artefacts overnight:

=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.2 (2024-06-11 17:14:16) running on Duet 3 Mini5plus Ethernet (standalone mode)
Board ID: BM90W-YV8LU-F65J0-409NL-1903Z-HKBR7
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 103368
Dynamic ram: 117356 of which 392 recycled
Never used RAM 16300, free system stack 112 words
Tasks: NETWORK(1,ready,23.0%,155) ETHERNET(5,nWait 7,0.1%,560) HEAT(3,nWait 1,0.1%,325) Move(4,nWait 6,3.7%,253) CanReceiv(6,nWait 1,0.0%,939) CanSender(5,nWait 7,0.0%,336) CanClock(7,delaying,0.0%,334) TMC(4,nWait 6,0.8%,100) MAIN(1,running,71.5%,623) IDLE(0,ready,0.0%,29) AIN(4,delaying,0.9%,255), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 47:03:23 ago, cause: software
Last software reset at 2024-09-12 10:32, reason: User, Gcodes spinning, available RAM 17836, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00487000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 169425619, completed 169425617, timed out 0, errs 0
MCU temperature: min 21.9, current 30.8, max 32.1
Supply voltage: min 23.5, current 23.8, max 23.9, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/668/668, gc cycles 310
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 125, reads 53047, writes 4, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 0, ifcnt 53, reads 53051, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 0, ifcnt 143, reads 53044, writes 6, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 137, reads 53045, writes 6, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 0, ifcnt 138, reads 53045, writes 6, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-09-14 09:36:11
Cache data hit count 4294967295
Slowest loop: 1550.99ms; fastest: 0.10ms
=== Storage ===
Free file entries: 20
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 5.3ms, write time 215.4ms, max retries 0
=== Move ===
DMs created 84, segments created 44, maxWait 5940785ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin -0.00, ebfmax 1.00
no step interrupt scheduled
Moves shaped first try 0, on retry 0, too short 0, wrong shape 0, maybepossible 0
=== DDARing 0 ===
Scheduled moves 2526188, completed 2526188, hiccups 0, stepErrors 0, LaErrors 0, Underruns [302, 1, 1064], CDDA state -1
=== DDARing 1 ===
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 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.3
=== GCodes ===
Movement locks held by null, null
HTTP is ready with "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
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 487148590 clear 138923008
Extruder 0: pos 13756.29, errs: frame 2619 parity 10 ovrun 14317 pol 338 ovdue 0
=== CAN ===
Messages queued 458274, received 0, lost 0, errs 241814300, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 26 (min 26), ts 254597/0/0
Tx timeouts 0,0,254597,0,0,203677 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 1549.47ms; fastest: 0.04ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
= Ethernet =
Interface state: active
Error counts: 0 0 0 0 0 0
Socket states: 2 2 2 2 2 0 0 0

; Configuration file for Duet 3 Mini 5+ (firmware version 3.3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.10 on Mon May 23 2022 00:42:46 GMT+0100 (BST)

; General preferences
M575 P1 S1 B57600                                  ; enable support for PanelDue
G90                                                ; send absolute coordinates...
M83                                                ; ...but relative extruder moves
M550 P"Zortrax M200"                               ; set printer name

; Network
M551 P"reprap"                                     ; set password
M552 P0.0.0.0 S1                                   ; enable network and acquire dynamic address via DHCP
M586 P0 S1                                         ; enable HTTP
M586 P1 S0                                         ; disable FTP
M586 P2 S0                                         ; disable Telnet

; Drives
M569 P0.4 S0 D3 V0                                 ; physical drive 0.3 goes backwards
M569 P0.3 S1 D3 V0                                 ; physical drive 0.2 goes backwards
M569 P0.2 S0 D3 V0                                 ; physical drive 0.1 goes forwards
M569 P0.0 S1 D3 V0                                 ; physical drive 0.0 goes forwards
M584 X0.4 Y0.3 Z0.2 E0.0                           ; set drive mapping
M350 X16 Y16 Z16 E16 I1                            ; configure microstepping with interpolation
M92 X80.00 Y80.00 Z800.00 E120                     ; set steps per mm
M566 X600.00 Y600.00 Z120 E10000 P1              ; set maximum instantaneous speed changes (mm/min)
M203 X9000.00 Y9000.00 Z900.00 E10000             ; set maximum speeds (mm/min)
M201 X1000.00 Y1000.00 Z400.00 E20000.00           ; set accelerations (mm/s^2)
M906 X800 Y800 Z800 E450 I10                       ; set motor currents (mA)
M84 S3                                             ; Disable motor idle current reduction

; Axis Limits
M208 X0 Y0 Z0 S1                                   ; set axis minima
M208 X200 Y188 Z180 S0                             ; set axis maxima

; Endstops
M574 X1 S1 P"io6.in"                               ; configure switch-type (e.g. microswitch) endstop for low end on X via pin io6.in
M574 Y1 S1 P"io5.in"                               ; configure switch-type (e.g. microswitch) endstop for low end on Y via pin io5.in
M574 Z1 S2                                         ; configure Z-probe endstop for low end on Z

; Z-Probe
M950 S0 C"io3.out"                                 ; create servo pin 0 for BLTouch
M558 P9 C"io3.in" H5 F200 A02 T6000                ; set Z probe type to bltouch and the dive height + speeds
G31 P500 X0 Y-20 z0.37                             ; set Z probe trigger value, offset and trigger height - decrease to raise nozzel
M557 X0:200 Y0:188 P20:20						   ; define mesh grid
M671 X40:100:160 Y213:-13:213 P0.5                 ; define adjusting screw positions 

; Filament Monitor
M591 D0 P3 C"io2.in" L25.87 S1                     ; filament monitor connected to io2.in calibrated with 25.87
;M591 D0                                           ; display filament sensor parameters for extruder drive 0

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4138       ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0                                 ; create bed heater output on out0 and map it to sensor 0
M307 H0 B0 S1.00                                   ; disable 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"temp1" Y"pt1000"                         ; configure sensor 1 as thermistor on pin temp1
M950 H1 C"out1" T1                                 ; create nozzle heater output on out1 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

; Fans
M950 F0 C"out3" Q500                               ; create fan 0 on pin out3 and set its frequency
M106 P0 S0 H-1                                     ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"out4" Q500                               ; create fan 1 on pin !out4 and set its frequency
M106 P1 S1 H1 T45                                  ; set fan 1 value. Thermostatic control is turned on
M950 F2 C"out5" Q500                               ; create fan 2 on pin out5 and set its frequency
M106 P2 S0.5 H1:0 T45                              ; set fan 2 value. Thermostatic control is turned on
M950 F3 C"out6" Q500                               ; create fan 3 on pin out6 and set its frequency
M106 P3 S0.5 H1:0 T45                              ; set fan 3 value. Thermostatic control is turned on

; Tools
M563 P0 S"Extruder1" D0 H1 F0                      ; define tool 0
G10 P0 X0 Y0 Z0                                    ; set tool 0 axis offsets
G10 P0 R0 S0                                       ; set initial tool 0 active and standby temperatures to 0C
;M572 D0 S0.1                					   ; set pressure advance to 0.1s

; Custom settings are not defined

; Miscellaneous
M950 E0 C"led"                                     ; LED strip settings
M912 P0 S-6.7
M501                                               ; load saved parameters from non-volatile memory
M911 S0 R11 P"M913 X0 Y0 G91 M83 G1 Z3 E-5 F1000"  ; set voltage thresholds and actions to run on power loss

; LED control
if {state.status} == "paused"
  M150 R255 U150 B070 P255 S21 F1  ; white
  M150 R255 U160 B000 P255 S21     ; yellow
  M300 S4000 P50 G4 P300 M300 S4000 P50 ; double beep
elif {state.status} == "processing" || {state.status} == "busy"
  M150 R255 U150 B070 P255 S42    ; white
elif {heat.heaters[0].current} > 32 || {heat.heaters[1].current} > 32
  M150 R255 U000 B000 P255 S04 F1 ; red
  M150 R255 U150 B070 P255 S13 F1 ; white
  M150 R255 U000 B000 P255 S08 F1 ; red
  M150 R255 U150 B070 P255 S13 F1 ; white
  M150 R255 U000 B000 P255 S04 F1 ; red
  M150 R255 U150 B070 P255 S03    ; white
elif {state.status} == "idle"
  M150 R000 U255 B000 P255 S04 F1 ; green
  M150 R255 U150 B070 P255 S13 F1 ; white
  M150 R000 U255 B000 P255 S08 F1 ; green
  M150 R255 U150 B070 P255 S13 F1 ; white
  M150 R000 U255 B000 P255 S04 F1 ; green
  M150 R255 U150 B070 P255 S03    ; white
else
  M150 R255 U150 B070 P255 S21 F1 ; white
  M150 R150 U0 B150 P255 S21      ; purple

@cosmowave Yes so changing the resolution from 0.012 to 0.05, making it coarser.

Interesting, I hadn't considered the daemon file. There isn't too much in there, just some code to control the LEDs based on printer status. Do you think this could cause a problem?

I've had a long standing issue where if I fill the bed with multiple round parts the printer seems to struggle to keep up and stutters causing blobs on the print surface. I don't have the problem if I print one single part, but multiple of that same part causes the issue.

The other thing I notice it it gets worse later in the print, the first 30 mm is usually ok, then pauses start to happen over the next 40 mm getting worst near the end.

My question is; am I really reaching the limits of the board's processor? I thought it was quite powerful.

I can mitigate it by decreasing the slicer resolution (0.05 from 0.012), and arc fitting post processing also helps, but then I start to notice the curves becoming faceted and am still limited on how many copies I can print at once.

Is there a solution such as using a SBC to process the commands, or is there anything else I can try?

Some extra info: printing from the SD card, micro stepping 16x with interpolation, debug mode turned off for everything, jerk is relatively high at 600 mm/min, slicer is OrcaSlicer but happened previously on PS and SS

@dc42 that’s a good option, thanks! Do you think it’s possible to remove the driver chip with just a soldering iron (I have chip quick flux and some low melt solder)? I think the big ground pad could be a challenge.

And would it be advisable to remove any of the other components in that damaged area or could that potentially cause more problems?

@oliof thanks for your help, yeah that’s what I was afraid of. No errors on startup, just seems like there’s no power to any of the driver circuits, as I can move the print head freely which I usually can’t when the printer is powered up.

Here’s a photo of the back of the board showing some more damage:

This is a Duet 3 Mini 5+. I was trouble shooting getting some LEDs to work on the tool head when a screwdriver bit made contact with the board on the Driver 1 circuit. Looks pretty fried but I was hoping I could use the spare driver as a replacement, however none seem to be communicating anymore.

I've updated the config to represent the new mapping but any attempt to home the axis results in the an error with no movement. Is there a fuse perhaps that could have gone too? I can't see any other damage to the board other than the driver circuits the rest of the board seems to be working fine.