[BUG] FW Crash when SD card is removed

[sethtroisi]

Printer model

MK3S

MMU model

No-MMU

Firmware versions

3.14.0-8066

Upgrades and modifications

None

Printing from...

SD Card

Describe the bug

"FW crash detected" each time SD card is removed.

How to reproduce

1. Have SD card inserted (inserting SD card works fine)
2. Remove SD card

Expected behavior

No response

Files

crash.webm

[3d-gussner]

@sethtroisi I see that you selected in the issue printer model the MK3 without a S, but in your video your printer has MK3S firmware installed. Which printer do you have?

I can't reproduce your issue. I had to use the MK404 Simulator as I don't have a real MK3 at the moment.
See
https://github.com/user-attachments/assets/66deb3f3-7615-4597-8356-f0c625395367

Did it work with FW 3.14.0 and suddenly it started to crash?

Did you have the issue before FW 3.14.0?

[sethtroisi]

It's an MK3S. I recently upgraded to FW 3.14.0 and immediately started having crashes which I had never had before.

I flashed back to prusa3d_fw_MK3S_MK3S+_3_13_3_7094 and the crashes stop happening.
I flashed MK3S_MK3S+_FW_3.14.0_MULTILANG again and crashes resume.

[3d-gussner]

It's an MK3S. I recently upgraded to FW 3.14.0 and immediately started having crashes which I had never had before.

I flashed back to prusa3d_fw_MK3S_MK3S+_3_13_3_7094 and the crashes stop happening. I flashed MK3S_MK3S+_FW_3.14.0_MULTILANG again and crashes resume.

I tried to reproduce this issue also on real printer and it works.

Can you please:

1. Use a different fresh formatted FAT32 SDCard
2. Connect via USB and use a serial monitor like Putty or https://www.serialterminal.com/ to capture the serial output.
3. Please provide also the CRASH DUMP see https://help.prusa3d.com/article/crash-dump_364959
4. Contact LiveChat support and ask them to forward your logfiles to me.

[sethtroisi]

With a different freshly formatted FAT32 2GB SDCard with one partition and only a single file (benchy.gcode)

With 3.13.3, no crash

# Insert SD Card
echo:SD card released
LCD status changed
Sending 0xFF
echo:SD card ok
LCD status changed

# Removing SD Card
echo:SD card released
LCD status changed
echo:SD init fail
LCD status changed

On 3.14.0

start                                                                                                                                                            
echo: 3.14.0-8066_b97131bd2                                                                                                                                 
MMU is Off                                                                                                                                                       
SpoolJoin is Off                                                                                                                                                 
echo: Last Updated: 2024-05-22 05:21:06 | Author: prusa3d                                                                                                        
echo: Free Memory: 2511  PlannerBufferBytes: 1760                                                                                                                
echo:Stored settings retrieved                                                                                                                                   
adc_init                                                                                                                                                         
Hotend fan type: NOCTUA                                                                                                                                          
CrashDetect DISABLED                                                                                                                                             
echo:SD init fail                                                                                                                                                
//action:dump_available                                                                                                                                          
echo:SD init fail

# Insert SD Card
echo:SD card released
LCD status changed
Sending 0xFF
echo:SD card ok
LCD status changed

# Remove SD Card
echo:SD card released
LCD status changed
Sending 0xFF
Error:volume.init failed
LCD status changed
start
echo: 3.14.0-8066_b97131bd2

It looks like the printer is believes that an SD card is present when it's not.
This matches the physical experience with the printer where I occasionally have to use a little extra pressure or re-seat the SD card to get it to notice it's inserted.

This still looks like a regression in 3.14 to crash when 3.13.3 didn't.

I sent a crashdump to live support and asked them to send it to you.

[3d-gussner]

@sethtroisi Thanks for the update and I got the dump file from chat support.

It looks like the printer is believes that an SD card is present when it's not.
This matches the physical experience with the printer where I occasionally have to use a little extra pressure or re-seat the SD card to get it to notice it's inserted.

This looks like a hardware issue where your SD card slot does thing it shouldn't.