Possible Malfunctioning RAMBo?

[GMTH]

I'm at a loss, three out of four prints have failed unexpectedly in the last 24 hours. The first spit out a "Error:Format Error", the second tried to initiate printing from the SD card mid print without any user interaction. And now the third exhibited the same behavior as the first. Details below. I need help! This is a production environment and we can't afford to have so much downtime on this machine!

First Failure
This happened halfway through the first layer. The machine homed all axes spontaneously, and then resumed printing but broke its infill pattern before I killed it. Excerpt from the gcode here where it is running normally before and after the format error:

Code: Select all

SENT: G1 X13.087 Y-78.232 F4800
READ: ok 0
SENT: M105
SENT: G92 E0
READ: ok 0
SENT: M105
READ: ok 0
SENT: M105
SENT: G1 X13.087 Y78.318 E7.9122 F630
READ: T:234.06 B:90.93 B@:75 @:216
READ: ok 0
READ: ok 0
READ: T:233.75 B:90.90 B@:210 @:255
READ: ok 0
READ: ok 0
SENT: G1 X-13.087 Y78.318 E9.2350
READ: T:233.75 B:90.90 B@:210 @:255
READ: ok 0
SENT: G1 X-13.087 Y-78.232 E17.1472
READ: T:233.75 B:90.90 B@:210 @:255
READ: Error:Format error
READ: 
READ: Resend:1
READ: ok
SENT: G90
SENT: M82
SENT: M106 S0
SENT: M140 S90
SENT: M104 S235 T0
SENT: G28 
SENT: G92 E0
READ: Error:Format error
READ: 
READ: Resend:1
READ: ok
SENT: G90
SENT: M82
SENT: M106 S0
SENT: M140 S90
SENT: M104 S235 T0
SENT: G28 
SENT: G92 E0
READ: Error:Format error
READ: ok 0
READ: ok 0
SENT: M105
READ: Unknown command: Y78.32 E9.2350
READ: ok 0
SENT: G1 E-8.4000 F1800
READ: ok 0
SENT: M105
READ: ok 0
SENT: G1 Z0.650 F1000
SENT: T0
READ: ok 0
READ: ok 0
READ: ok 0
READ: TargetExtr0:235
READ: ok 0
SENT: G1 X17.887 Y-81.009 F4800
READ: ok 0
SENT: M105
READ: ok 0
SENT: G1 Z0.250 F1000
READ: ok 0
SENT: G1 E0.0000 F540
READ: ok 0
SENT: G92 E0
READ: ok 0
READ: ok 0
SENT: G1 X17.887 Y81.009 E8.1885 F840
READ: TargetExtr0:235
READ: ok 0
READ: ok 0
SENT: M105
READ: ok 0
SENT: G1 X15.778 Y83.118 E8.3393
SENT: G1 X-15.778 Y83.118 E9.9342
READ: ok 0
READ: T:236.25 B:91.27 B@:240 @:255
READ: ok 0

Second Failure
I don't remember exactly why I killed the print this time but it was doing something weird, perhaps standing in one spot and melting a hole in one of the top layers. I checked the log and saw that it spontaneously tried to initiate print from SD card.

Code: Select all

SENT: M105
SENT: G1 X-4.982 Y31.481 E0.3977 F1120
READ: ok 0
READ: ok 0
SENT: G1 X-4.983 Y22.308 E0.7638
READ: ok 0
SENT: G1 X4.983 Y22.308 E1.1616
READ: T:222.78 B:89.65 B@:186 @:255
READ: ok 0
SENT: G1 X4.983 Y31.481 E1.5277
READ: ok 0
SENT: G1 X4.503 Y31.001 F4800
SENT: G92 E0
READ: ok 0
READ: start
READ: Free RAM:1143
READ: X:0.00 Y:0.00 Z:0.00 E:0.00
READ: SD init fail
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
READ: wait
WARNING: Firmware unresponsive.  Attempting to force continue...
SENT: M105
SENT: G1 X-4.502 Y31.001 E0.3594 F1120
READ: ok 0
READ: T:202.37 B:88.90 B@:0 @:0
READ: ok 0
SENT: G1 X-4.503 Y22.788 E0.6872
READ: ok 0
SENT: G1 X4.503 Y22.788 E1.0466
READ: ok 0
SENT: M105
SENT: G1 X4.503 Y31.001 E1.3744
READ: ok 0
SENT: G1 X4.023 Y30.521 F4800
SENT: G92 E0
READ: ok 0
READ: T:201.02 B:88.86 B@:0 @:0
READ: ok 0
READ: ok 0
SENT: G1 X-4.022 Y30.521 E0.3211 F1120
READ: ok 0
SENT: G1 X-4.023 Y23.268 E0.6106
READ: ok 0
SENT: G1 X4.023 Y23.268 E0.9317
READ: ok 0
SENT: G1 X4.023 Y30.521 E1.2212
READ: ok 0
SENT: M105
SENT: G1 X3.543 Y30.041 F4800
SENT: G92 E0
READ: ok 0
READ: ok 0
READ: T:198.61 B:88.77 B@:0 @:0
READ: ok 0
SENT: G1 X-3.542 Y30.041 E0.2828 F1120
READ: ok 0

Third Failure
This just happened, seems to be the same problem as the first failure. I killed it immediately after it homed all axes.

Code: Select all

SENT: G1 X1.610 Y83.740 E19.0573
READ: T:235.00 B:88.90 B@:249 @:204
READ: ok 0
READ: ok 0
SENT: G1 X2.757 Y85.096 E19.1282
READ: T:235.00 B:88.90 B@:250 @:204
READ: ok 0
READ: T:235.00 B:88.90 B@:250 @:204
READ: ok 0
SENT: G1 X3.036 Y85.386 E19.1443
READ: T:235.00 B:88.90 B@:250 @:204
READ: Error:Format error
READ: 
READ: Resend:1
READ: ok
SENT: G90
SENT: M82
SENT: M106 S0
SENT: M140 S90
SENT: M104 S235 T0
SENT: G28 
SENT: G92 E0
READ: ok 0
READ: ok 0
SENT: G1 E-8.4000 F1800
READ: ok 0
READ: ok 0
SENT: G1 Z0.650 F1000
SENT: T0
READ: ok 0
READ: ok 0
READ: ok 0
SENT: G1 X14.344 Y73.505 F4800
READ: TargetExtr0:235
READ: ok 0
SENT: G1 Z0.250 F1000
READ: ok 0
SENT: M105
READ: ok 0
SENT: G1 E0.0000 F540
READ: ok 0
SENT: G92 E0
READ: ok 0
SENT: G1 X14.593 Y73.818 E0.0200 F840

Does anyone know what's happening here?! I'm stumped!

[pouncingiguana]

I'd try printing the same gcode from a fresh SD card without the usb plugged in, just to knock down some variables.

[GMTH]

Thanks for the reply! I am trying this now.

[GMTH]

So far I have been able to continue with no issue. Thanks for your help! I will update if I experience any further problems.

Cheers!