Random board/driver resets during printing.

[Gleb-blocksdev]

Did you test the latest bugfix-2.1.x code?

No, but I will test it now!

Bug Description

I have been having random resets on various printers while printing large files for long amounts of time. I have only now started with some real testing closer to the final build. And have made many attempts at finding the source and correcting it. Simply put, there were two problems:

• The printers would reset their TMC2209 through UART and change their micro steps from 16 to 8 which would make the printer go crazy with its travels.

• The board would just reset itself in a random move after a random amount of time printing.

  Through some research and help in the Discord Server I think the source of both resets is probably connected. Seems like some kind of electrostatic discharge that sometimes resets the drivers and sometimes affects the USB/SD shields and confuses the Media reading code. Seems very related to the issue #24158 . Sometimes after trying to resume from powerloss, the sdpos would be a crazy high value and the printer would just stand still in the printing screen.

  I have tested with drivers TMC2209 (UART and Standalone), TMC2226, TMC2100 and Polulu A4988. Tested with the boards MKS ROBIN NANO V3.1, BTT GTR V1.0 and BTT SKR 2. By advice of the discord server I have grounded everything that I can, because I found some parasitic voltages. I have swapped almost every cable and jumper and even power sources. Tested Marlin versions 2.0.9.4 and 2.1.2 both with my custom code in it and the bare minimum version with just configuration and configuration_adv files changed. The printers have a DGUS LCD, but when using the bare minimum versions of marlin a MKS_MINI_12864 LCD was used. This happens whether the printers are printing through USB or Onboard SD Card. I have tried different USB flashdrives and SD cards, good and bad ones.

  The driver resets never happened with the standalone configurations as expected and have not happened for some days after grounding everything. But the board resets still happen. The only few tests where it never happened were when printing through Pronterface. Not even with Postmortem debugging and Marlin dev mode I got insightful logs of why it is resetting. Through logging I could only assert drivers had different micro steps when they reset.

  I am at a loss of what I can do here... Attached in this issue will be a spreadsheet with some of the tests and configurations. Thank you all in advance.

Bug Timeline

This has been happening for a month and a half.

Expected behavior

I expect the prints to finish without resets.

Actual behavior

The printer either resets stepper micro steps or resets midprint.

Steps to Reproduce

1. Start printing through USB or Onboard SD card.
2. Wait.

Version of Marlin Firmware

V2.0.9.4 and V2.1.2

Printer model

Custom model.

Electronics

MKS ROBIN NANO V3.1, BTT GTR V1.0, BTT SKR 2.

Add-ons

Banana pi m3

Bed Leveling

ABL Bilinear mesh

Your Slicer

Cura

Host Software

OctoPrint

Don't forget to include

• [X] A ZIP file containing your Configuration.h and Configuration_adv.h.

Additional information & file uploads

Both versions were tested with heavy custom code and with just the bare minimum changes to configuration and configuration_adv files. So no custom code should be influencing the issue. Conf_files_and_Spreadsheet.zip

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