Pi Crashes mid-print, not power or thermal

General Discussion
1

Basic Information:

Printer Model: Prusa Mk3S
MCU / Printerboard: Einsy_Rambo (stock)
Host / SBC: RasPi 3b+ running raspberry pi os lite + KIAUH
klippy.log (604 KB)

Hello all! I am running into an issue with my printer crashing mid-print. This crash does not seem to happen at the same location in the print, and sometimes occurs within 60 seconds of printing, but almost always happens within 20 minutes of printing. This crashing does not seem to happen when the printer is left idle, as I could leave it idle for days at a time without a crash.

I set my printer up using the config template linked above, which previously worked on MainsailOS. after switching to RasPi OS and KIAUH, I have been running into these crashing issues.

Naturally, I check for errors such as uder-voltage or over-temp throttling. I replaced the USB PSU with a 5.3v 4A low noise PSU fed directly into the GPIO pins, and I moved from using a uSD card to a USB SSD in case the issues I was seeing were disk I/O. Neither seemed to resolve the issue.

I ran github / aikoncwd/rpi-benchmark (sorry, new users can’t post more than 2 hyperlinks) a few times to see if the Pi was crashing due to any non-klipper related power/heat issue and everything seemed fine. During these benchmarks was the only time I triggered an over-temp, as it just crossed 60c during the CPU bench test.

I also SSH’ed in and ran btop while printing to see if I was running against any hardware limits, but I didn’t see anything alarming. CPU usage below 25%, memory usage below 50%, and disk access below my benchmarked results and temperature below 50c.

It seems that the entire Pi crashes, because when this error happens, I cannot SSH to the Pi, nor can I access the TTY through the HDMI or with the hardware UART.

Checking journalctl -b-1 shows no error messages that trigger the crash, and checking the most current booted log, it shows that the previous journal file was not closed cleanly.

Any help would be much appreciated!

2

Really hard to tell. You already did the main steps in diagnosing such behavior.
Maybe Pi crashed 3 times mid-print, almost same place - #15 by Sineos can give you some pointers, especially regarding persistence.

Otherwise such bad crashes usually point either to:

  • Already defect or failing hardware
  • Misbehaving attached hardware, although this is very rare to drag the entire system into death
  • Kernel / Driver bugs, but these are equally rare for a standard RPi OS
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Thanks for the reply, I was really hoping I was missing something easy!

As a last resort, I pulled a pi4 2gb out of another project, and plugged the current USB SSD and printer into it, and it worked flawlessly.

So I guess in my case, the problem was either some software/hardware compatibility issues or a pi that’s failing.

Off to find something else to curse with this raspberry pi now! :smiley:

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Which specific version of Raspberry Pi OS have you imaged? I have a suspicion it’s the 64 bit.

I experienced similar behaviour when running 64 bit Bookworm on Pi 3B+. Tried numerous times. The Pi would totally hang at random times, and only a power reset would bring it back to life. Typically it would happen during printing, but once it happened during Pi reboot. I spoke with others on Klipper Discord who experienced the same issue.

BTW, 32 bit Bookworm works fine, this issue is specific to 64 bit running on Pi 3B+.

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