Ormerod suddenly stops mid print

Oi oi!

I've been having trouble with my printer (528,4) suddenly -midprint- stopping any movement. During this the cooling fan stops running, the hot end cools down and so does the heated bed.
The G-Code Console on the web interface complains loudly that tools can only be driven if their heater temperatures are high. I can access the web interface during this freeze period but cannot reconnect to it (f5).
There is no visible damage on any cable.

Do any of you have experience with this?

Rebooting the printer has no effect. The cooling fan doesn't start spinning.

The cooling fan is connected directly to the 12V supply. If it is not spinning it suggests that your 12V PSU has failed (which would imply that the Duet is powered via USB or a separate 5V supply when that happens). A failed 12V would also explain why your heaters stop working.

Dave

The duet board is powered by the 5v regulator powered by the 12v power supply. Both the heated bed and the hotend does not want to power up . I don't have access to a voltmeter at the moment but i'll have a gander when i get one. I'm beginning to suspect that the board is dead.

The same thing happened to me once before. I found loose screws on the Duet's green lugs that hold the ferrule connections, even though I had tightened them properly when it was initially assembled. I tightened everything back up and it was fine, thankfully. I added these Duet screws to the ones that I periodically check on the printer. On my printer these screws seem to loosen up with use no matter how tight I get them.

Can you point at where the bad man touched you?
Is it the screw terminals where 12v is fed into the board? I just checked mine and they don't feel loose.

It's the green lugs on the Duet's 5V regulator that loosen up on my printer.

1. Tighten up the 12V power connection terminal block screws as already suggested.

2. If it happens again, then if you can get either Pronterface or the web interface or PanelDue to communicate with the printer without rebooting the Duet, send M122 and look at the "Last reset reason" and how long ago it was. That will tell you whether a reboot occurred and what the cause was.

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Large delta printer [miscsolutions.wordpress.com], E3D tool changer, Robotdigg SCARA printer, Crane Quad and Ormerod

Disclosure: I design Duet electronics and work on RepRapFirmware, [duet3d.com].

Hmm i'll try getting it up and running tomorrow. I have to deal with drunk roommates first though

Quote
improprietary
The duet board is powered by the 5v regulator powered by the 12v power supply. Both the heated bed and the hotend does not want to power up . I don't have access to a voltmeter at the moment but i'll have a gander when i get one. I'm beginning to suspect that the board is dead.

If it is only the bed and hotend not working it could be the Duet, but you said before that the hotend fan was also not spinning, which is not switched by the Duet - the 12V runs directly through the Duet board. If that was the correct description of the symptoms it indicates that the 12V is getting to the regulator board but is not being passed through to the Duet, so the Duet is getting 5V but not 12V.

As has been said, the most likely culprit is a loose connection on the 12V terminal blocks that connect the 12V from the regulator board to the Duet.

Dave

I just reassembled it and tightened the terminal screws to see if that is the cause but no power to the hot end and fan. I'll remove the duet board from its enclosure and inspect the board for any visible damage now.

If you have a voltmeter it should be easy to track where the 12V is broken without disassembly.

Dave

Edited 1 time(s). Last edit at 01/27/2016 11:08AM by dmould.

Duet board doesn't seem to have taken any damage. Also Why the hell did it jump to ninety quid?
'Twas the 5v regulator board thats the problem i think. I haven't had any voltmeter on it yet.



Well... I hope thats the issue i'm having.

Edited 1 time(s). Last edit at 01/27/2016 11:09AM by improprietary.

You can remove the regulator board altogether and use the Duet's on-board 5V regulator instead. The only reason it was disabled for the Ormerod 2 was to comply with CE EMI standards.

Dave

Wait what 5v regulator? Thats awesome i'll have a look at that! Thanks

To enable the on-board 5V, you should remove the small 5V regulator board, connect the 12V directly to the 12V input of the Duet (make sure the polarity is correct). No connection is needed to the Duet 5V input block. Remove jumper JP10 on the Duet and fit a jumper to JP9.

Dave

I could hug you right about now mate.Es funktionert!
Thanks a lot you really saved my bacon here.

Oooooh .... i hate that board! It gets hot and a nightmare to connect. I am also having mid print stops problems, i might tu that if nothing else works

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----- Making the world smarter @ www.xetal.eu
----- Helping entrepreneurs @ www.fralke.com

Quote
improprietary
Duet board doesn't seem to have taken any damage. Also Why the hell did it jump to ninety quid?

I presume the £90 you mention relates to the Duet 0.8.5 from T3P3. It has several improvements over the Duet 0.6, most notably it supports dual extrusion without an add on board. Also it's made in the UK instead of China.

You can get a $50 Duet 0.6 from Replikeo, although judging from reports on these forums, the QA leaves a lot to be desired. You may find RepRapPro China selling 0.6 Duets soon as well.

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Large delta printer [miscsolutions.wordpress.com], E3D tool changer, Robotdigg SCARA printer, Crane Quad and Ormerod

Disclosure: I design Duet electronics and work on RepRapFirmware, [duet3d.com].

If you buy a Replikeo board, buy two and expect them both to fail.

Also, they bumped the price of the board up to $65 recently.

Edited 1 time(s). Last edit at 01/27/2016 10:16PM by 0x0000.

Buying an additional motherboard for my printer isn't something that i desire most in this world. An upgrade would be nice but so would food on the table. Its great that we can produce niche items in europe but due to the additional price quality has to come first. I highly doubt that any board that think3dprint3d sells will be a dud because of this. We in europe cannot really compete on the global market if we do not put quality first.

But this is starting to get derailed. Its great that the duet board has an onboard switching powersupply!

Looking forward to a cheap duet from china...non listed on ebay yet though.

I have having the same problem. But heated and hot end stay hot. The print stops after few layers.
Electronics stay cool (except the small board), i get no error message.
I checked al wiring and it is ok.

I am completely in the dark

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----- Making the world smarter @ www.xetal.eu
----- Helping entrepreneurs @ www.fralke.com

Quote
Fpex
I have having the same problem. But heated and hot end stay hot. The print stops after few layers.
Electronics stay cool (except the small board), i get no error message.
I checked al wiring and it is ok.

I am completely in the dark

I thought you said in the other thread that you got an "Error reading file" message?

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Large delta printer [miscsolutions.wordpress.com], E3D tool changer, Robotdigg SCARA printer, Crane Quad and Ormerod

Disclosure: I design Duet electronics and work on RepRapFirmware, [duet3d.com].

(deleted)

Edited 1 time(s). Last edit at 01/29/2016 12:45PM by Fpex.

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----- Making the world smarter @ www.xetal.eu
----- Helping entrepreneurs @ www.fralke.com

Sorry to resuscitate an old thread.
I'm having a very similar problem:
Printing as normal in a quiet empty room, then the printer will just stop- xyz motors stop, extruder stops. Hot end fan continues. Cooling fan on Fan0 stops.
If I'm plugged into USB on my PC, I head the 'ding dong' USB unplugged noise.
Web interface reports AJAX error, then reconnects. Print status, layer statistics, head position, active temperatures are as though the printer is just switched on.
I have to bin the print and start again.

Please can anyone help? I've finally got the printer working nicely, but I'm scared to make any prints longer than about 10 minutes- this has happened on all larger prints I've tried to make.

thanks
Gwild

Diagnostics:
Ormerod 2 528.2 with addition of a 12v 0.07A cooling fan on F0 running at 100% cooling
Duet 0.6
Firmware: DC42 1.15e
Web interface: HTML: 1.11, JS: 1.11
5V from USB from my PC or smartphone charger, both fail (is it possible to power without USB?)
Printing at 185 deg C, standard Ormerod Slic3r settings
Screws on the daughter board seem tight

M122 returns:
Used output buffers: 4 of 32 (17 max)
=== Platform ===
Memory usage:
Program static ram used: 45328
Dynamic ram used: 41600
Recycled dynamic ram: 3184
Current stack ram used: 2760
Maximum stack ram used: 4392
Never used ram: 3800
Last reset 00:03:56 ago, cause: watchdog
Last software reset code & available RAM: 0x0003, 3900
Spinning module during software reset: GCodes
Error status: 0
Bed probe heights: 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Free file entries: 10
SD card 0 detected, interface speed: 21.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 72.6, current 75.7, max 78.1
Slowest main loop (seconds): 0.004578; fastest: 0.000198
=== Move ===
MaxReps: 0, StepErrors: 0, MaxWait: 0ms, Underruns: 0, 0
=== Heat ===
Bed heater = 0, chamber heater = -1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Move available? no
Stack pointer: 0 of 5
macro is idle
http is ready with "M122"
telnet is idle
serial is idle
aux is idle
file is idle
=== Network ===
Free connections: 15 of 16
Free transactions: 23 of 24
=== Webserver ===
HTTP sessions: 1 of 8
FTP connections: 0, state 0
Telnet connections: 0, state 0

Edited 3 time(s). Last edit at 11/06/2016 08:17AM by gwild.

That's the first time I've seen a watchdog timeout for many months, maybe more than a year. Either you have hit a very rare firmware bug that nobody else has, or some sort of transient has upset the microcontroller.

My money would be on a ground transient via your USB power supply. I guess the external 5V regulator supplied with the Ormerod 2 must have failed if you are using a USB PSU instead. Why not enable the on-board switching regulator? You need to put a jumper across the pins labelled 5V_EN. You can remove the one across the 5V_ATX_EN pins if you still have it, so you can use the same jumper. After enabling the on-board regulator, I suggest you measure the voltage between pins 1 and 2 on the expansion connector with a multimeter, to check that it is close to 5V.

Edited 1 time(s). Last edit at 11/06/2016 11:35AM by dc42.

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Large delta printer [miscsolutions.wordpress.com], E3D tool changer, Robotdigg SCARA printer, Crane Quad and Ormerod

Disclosure: I design Duet electronics and work on RepRapFirmware, [duet3d.com].

I moved the jumper from 5V_ATX_EN to 5V_EN, I was able to unplug my USB cable without the Duet powering off, and I was able to print for a whole 30 minutes I thought that solved the problem.
But just as I was writing my thanks just now, it's just happened again! Disaster.
The printer has reset itself mid-print.

DC42, I'm not sure what you were guessing about USB power-
I initially used USB from my PC to connect to pronterface, and then started to use the web interface so used my phone charger so I could unplug from the PC. Was/ is there another way of powering the board? In both cases, I found that if I unplugged the USB cable, everything stopped. The jumper was on 5V_ATX_EN.

Here's M112 again, any thoughts?

M122
=== Diagnostics ===
Used output buffers: 4 of 32 (8 max)
=== Platform ===
Memory usage:
Program static ram used: 45328
Dynamic ram used: 41600
Recycled dynamic ram: 3184
Current stack ram used: 2760
Maximum stack ram used: 4304
Never used ram: 3888
Last reset 00:00:27 ago, cause: watchdog
Last software reset code & available RAM: 0x0003, 2716
Spinning module during software reset: GCodes
Error status: 0
Bed probe heights: 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000
Free file entries: 10
SD card 0 detected, interface speed: 21.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 72.9, current 74.4, max 78.1
Slowest main loop (seconds): 0.005852; fastest: 0.000118
=== Move ===
MaxReps: 0, StepErrors: 0, MaxWait: 0ms, Underruns: 0, 0
=== Heat ===
Bed heater = 0, chamber heater = -1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Move available? no
Stack pointer: 0 of 5
macro is idle
http is ready with "M122"
telnet is idle
serial is idle
aux is idle
file is idle
=== Network ===
Free connections: 15 of 16
Free transactions: 23 of 24
=== Webserver ===
HTTP sessions: 1 of 8
FTP connections: 0, state 0
Telnet connections: 0, state 0

Many firmware versions ago, you needed to use M111 S0 at the start of config.g to prevent the printer stopping when you disconnected the USB cable.

It's better to not have the USB cable connected during printing because it usually creates a ground loop. The Ethernet cable does not.

What power supply are you using? Can you confirm that the printer reset doesn't always happen at the same point in the print?

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Large delta printer [miscsolutions.wordpress.com], E3D tool changer, Robotdigg SCARA printer, Crane Quad and Ormerod

Disclosure: I design Duet electronics and work on RepRapFirmware, [duet3d.com].

There is also an issue if you switch anything that is on the same power plug. For example when I first used my Ormerod it was plugged into an extension lead - if I plugged a soldering iron into another socket on the same extension lead, the Duet would crash. So ensure that your Ormerod is the only device connected to the wall socket. Maybe try using an extension lead that has surge protection in case it is cause by something else in your home (e.g. fridge or washing machine cycling). e.g. [www.amazon.co.uk]

Dave