Ender 3 pro serial connectrion woes (replace mainboard?)

What is the problem?

ender 3 pro, pi 3A+, custom marlin to allow ABL with bltouch.

firstly, i'm sorry, i know there are a thousand 'can't connect' posts a day, but i've been fighting this for months and have given up. i just don't use the printer at all because it takes 3 hours to get it connected.

secondly, if this is likely to be solved by replacing the mainboard on printer please tell me - i don't mind spending the money. please tell me which board to buy and which FW to use.

thirdly, maybe most useful for troubleshooting, printing from sd card and then reconnecting usb / rebooting pi seems to clear the issue most of the time. works if i abort the print after 30 seconds.

regular failures to connect to ender 3 pro by serial. not every time, but almost every time. once connected everything works perfectly until printer is powered off.

in the past i didn't understand about printer drawing power from pi usb, i suspect that the printer usb port is faulty from having been roasted, but am not sure. i now use cables with the 5v+ disconnected.

What did you already try to solve it?

6 usb cables, including with ferites, and with 5v+ cut
i strongly doubt it is a cable issue because once connected everything is fine, for as many days as i leave it on.

reboot in safe mode

various voodoo involving moving cables, grounding connectors/chassis etc (some people suggest interference on the serial connection may be to blame)

dmesg from pi shows following errors: (full output below)

[ 7.543562] brcmfmac: brcmf_fw_alloc_request: using brcm/brcmfmac43455-sdio f or chip BCM4345/6
[ 7.805296] brcmfmac: brcmf_fw_alloc_request: using brcm/brcmfmac43455-sdio f or chip BCM4345/6
[ 7.805467] brcmfmac: brcmf_fw_alloc_request: using brcm/brcmfmac43455-sdio f or chip BCM4345/6
[ 7.816489] brcmfmac: brcmf_c_preinit_dcmds: Firmware: BCM4345/6 wl0: Mar 23 2020 02:19:54 version 7.45.206 (r725000 CY) FWID 01-88ee44ea
[ 10.794857] brcmfmac: brcmf_cfg80211_set_power_mgmt: power save enabled
...
[ 4.414401] usb 1-1: device descriptor read/64, error -71
[ 4.535109] Indeed it is in host mode hprt0 = 00021501
[ 4.764427] usb 1-1: device descriptor read/64, error -71
[ 4.884538] usb usb1-port1: attempt power cycle

usb errors seem to indicate printer not receiving enough power? but it shouldn't be receiving power from pi, maybe is hardware issue on printer mainboard?
other errors are (i think) wifi related, however wifi works fine

connect to windows/ pronteface - "usb device has malfunctioned", no port in device manager

completing a print from sd card and resetting printer / pi often clears the problem

swearing, shouting, a variety of rain-dances

Have you tried running in safe mode?

yes

Did running in safe mode solve the problem?

no

Systeminfo Bundle

octoprint-systeminfo-20220502182521.zip (295.8 KB)

Additional information about your setup

OctoPrint version, OctoPi version, printer, firmware, browser, operating system, ... as much data as possible
complete dmesg

[    0.000000] Booting Linux on physical CPU 0x0
[    0.000000] Linux version 5.10.103-v7+ (dom@buildbot) (arm-linux-gnueabihf-gcc-8 (Ubuntu/Linaro 8.4.0-3ubuntu1) 8.4.0, GNU ld (GNU Binutils for Ubuntu) 2.34) #1529 SMP Tue Mar 8 12:21:37 GMT 2022
[    0.000000] CPU: ARMv7 Processor [410fd034] revision 4 (ARMv7), cr=10c5383d
[    0.000000] CPU: div instructions available: patching division code
[    0.000000] CPU: PIPT / VIPT nonaliasing data cache, VIPT aliasing instruction cache
[    0.000000] OF: fdt: Machine model: Raspberry Pi 3 Model A Plus Rev 1.0
[    0.000000] random: fast init done
[    0.000000] Memory policy: Data cache writealloc
[    0.000000] Reserved memory: created CMA memory pool at 0x13c00000, size 64 MiB
[    0.000000] OF: reserved mem: initialized node linux,cma, compatible id shared-dma-pool
[    0.000000] Zone ranges:
[    0.000000]   DMA      [mem 0x0000000000000000-0x0000000017ffffff]
[    0.000000]   Normal   empty
[    0.000000] Movable zone start for each node
[    0.000000] Early memory node ranges
[    0.000000]   node   0: [mem 0x0000000000000000-0x0000000017ffffff]
[    0.000000] Initmem setup node 0 [mem 0x0000000000000000-0x0000000017ffffff]
[    0.000000] On node 0 totalpages: 98304
[    0.000000]   DMA zone: 864 pages used for memmap
[    0.000000]   DMA zone: 0 pages reserved
[    0.000000]   DMA zone: 98304 pages, LIFO batch:31
[    0.000000] percpu: Embedded 20 pages/cpu s50828 r8192 d22900 u81920
[    0.000000] pcpu-alloc: s50828 r8192 d22900 u81920 alloc=20*4096
[    0.000000] pcpu-alloc: [0] 0 [0] 1 [0] 2 [0] 3
[    0.000000] Built 1 zonelists, mobility grouping on.  Total pages: 97440
[    0.000000] Kernel command line: coherent_pool=1M 8250.nr_uarts=0 snd_bcm2835.enable_compat_alsa=0 snd_bcm2835.enable_hdmi=1 bcm2708_fb.fbwidth=656 bcm2708_fb.fbheight=416 bcm2708_fb.fbswap=1 vc_mem.mem_base=0x1ec00000 vc_mem.mem_size=0x20000000  console=ttyS0,115200 console=tty1 root=PARTUUID=8757bb3e-02 rootfstype=ext4 elevator=deadline fsck.repair=yes rootwait
[    0.000000] Kernel parameter elevator= does not have any effect anymore.
               Please use sysfs to set IO scheduler for individual devices.
[    0.000000] Dentry cache hash table entries: 65536 (order: 6, 262144 bytes, linear)
[    0.000000] Inode-cache hash table entries: 32768 (order: 5, 131072 bytes, linear)
[    0.000000] mem auto-init: stack:off, heap alloc:off, heap free:off
[    0.000000] Memory: 306728K/393216K available (10240K kernel code, 1312K rwdata, 2952K rodata, 1024K init, 862K bss, 20952K reserved, 65536K cma-reserved)
[    0.000000] SLUB: HWalign=64, Order=0-3, MinObjects=0, CPUs=4, Nodes=1
[    0.000000] ftrace: allocating 32081 entries in 95 pages
[    0.000000] ftrace: allocated 94 pages with 5 groups
[    0.000000] rcu: Hierarchical RCU implementation.
[    0.000000]  Rude variant of Tasks RCU enabled.
[    0.000000]  Tracing variant of Tasks RCU enabled.
[    0.000000] rcu: RCU calculated value of scheduler-enlistment delay is 10 jiffies.
[    0.000000] NR_IRQS: 16, nr_irqs: 16, preallocated irqs: 16
[    0.000000] random: get_random_bytes called from start_kernel+0x3ac/0x580 with crng_init=1
[    0.000000] arch_timer: cp15 timer(s) running at 19.20MHz (phys).
[    0.000000] clocksource: arch_sys_counter: mask: 0xffffffffffffff max_cycles: 0x46d987e47, max_idle_ns: 440795202767 ns
[    0.000007] sched_clock: 56 bits at 19MHz, resolution 52ns, wraps every 4398046511078ns
[    0.000024] Switching to timer-based delay loop, resolution 52ns
[    0.000311] Console: colour dummy device 80x30
[    0.001172] printk: console [tty1] enabled
[    0.001241] Calibrating delay loop (skipped), value calculated using timer frequency.. 38.40 BogoMIPS (lpj=192000)
[    0.001299] pid_max: default: 32768 minimum: 301
[    0.001516] LSM: Security Framework initializing
[    0.001775] Mount-cache hash table entries: 1024 (order: 0, 4096 bytes, linear)
[    0.001821] Mountpoint-cache hash table entries: 1024 (order: 0, 4096 bytes, linear)
[    0.003288] cgroup: Disabling memory control group subsystem
[    0.003576] CPU: Testing write buffer coherency: ok
[    0.004094] CPU0: thread -1, cpu 0, socket 0, mpidr 80000000
[    0.005356] Setting up static identity map for 0x100000 - 0x10003c
[    0.005564] rcu: Hierarchical SRCU implementation.
[    0.006509] smp: Bringing up secondary CPUs ...
[    0.007690] CPU1: thread -1, cpu 1, socket 0, mpidr 80000001
[    0.008973] CPU2: thread -1, cpu 2, socket 0, mpidr 80000002
[    0.010296] CPU3: thread -1, cpu 3, socket 0, mpidr 80000003
[    0.010454] smp: Brought up 1 node, 4 CPUs
[    0.010509] SMP: Total of 4 processors activated (153.60 BogoMIPS).
[    0.010540] CPU: All CPU(s) started in HYP mode.
[    0.010567] CPU: Virtualization extensions available.
[    0.011465] devtmpfs: initialized
[    0.029166] VFP support v0.3: implementor 41 architecture 3 part 40 variant 3 rev 4
[    0.029466] clocksource: jiffies: mask: 0xffffffff max_cycles: 0xffffffff, max_idle_ns: 19112604462750000 ns
[    0.029528] futex hash table entries: 1024 (order: 4, 65536 bytes, linear)
[    0.032591] pinctrl core: initialized pinctrl subsystem
[    0.033808] NET: Registered protocol family 16
[    0.038031] DMA: preallocated 1024 KiB pool for atomic coherent allocations
[    0.043782] audit: initializing netlink subsys (disabled)
[    0.044701] thermal_sys: Registered thermal governor 'step_wise'
[    0.045570] audit: type=2000 audit(0.040:1): state=initialized audit_enabled=0 res=1
[    0.045798] hw-breakpoint: found 5 (+1 reserved) breakpoint and 4 watchpoint registers.
[    0.045839] hw-breakpoint: maximum watchpoint size is 8 bytes.
[    0.046160] Serial: AMBA PL011 UART driver
[    0.064407] bcm2835-mbox 3f00b880.mailbox: mailbox enabled
[    0.080154] raspberrypi-firmware soc:firmware: Attached to firmware from 2021-12-01T15:08:00, variant start_x
[    0.090166] raspberrypi-firmware soc:firmware: Firmware hash is 71bd3109023a0c8575585ba87cbb374d2eeb038f
[    0.134472] Kprobes globally optimized
[    0.139486] bcm2835-dma 3f007000.dma: DMA legacy API manager, dmachans=0x1
[    0.141839] SCSI subsystem initialized
[    0.142124] usbcore: registered new interface driver usbfs
[    0.142211] usbcore: registered new interface driver hub
[    0.142303] usbcore: registered new device driver usb
[    0.144338] clocksource: Switched to clocksource arch_sys_counter
[    1.862160] VFS: Disk quotas dquot_6.6.0
[    1.862306] VFS: Dquot-cache hash table entries: 1024 (order 0, 4096 bytes)
[    1.862533] FS-Cache: Loaded
[    1.862789] CacheFiles: Loaded
[    1.872852] NET: Registered protocol family 2
[    1.873089] IP idents hash table entries: 8192 (order: 4, 65536 bytes, linear)
[    1.874755] tcp_listen_portaddr_hash hash table entries: 512 (order: 0, 6144 bytes, linear)
[    1.874854] TCP established hash table entries: 4096 (order: 2, 16384 bytes, linear)
[    1.874952] TCP bind hash table entries: 4096 (order: 3, 32768 bytes, linear)
[    1.875076] TCP: Hash tables configured (established 4096 bind 4096)
[    1.875253] UDP hash table entries: 256 (order: 1, 8192 bytes, linear)
[    1.875315] UDP-Lite hash table entries: 256 (order: 1, 8192 bytes, linear)
[    1.875619] NET: Registered protocol family 1
[    1.876427] RPC: Registered named UNIX socket transport module.
[    1.876462] RPC: Registered udp transport module.
[    1.876491] RPC: Registered tcp transport module.
[    1.876520] RPC: Registered tcp NFSv4.1 backchannel transport module.
[    1.878235] hw perfevents: enabled with armv7_cortex_a7 PMU driver, 7 counters available
[    1.881992] Initialise system trusted keyrings
[    1.882278] workingset: timestamp_bits=14 max_order=17 bucket_order=3
[    1.891848] zbud: loaded
[    1.893958] FS-Cache: Netfs 'nfs' registered for caching
[    1.894995] NFS: Registering the id_resolver key type
[    1.895078] Key type id_resolver registered
[    1.895108] Key type id_legacy registered
[    1.895277] nfs4filelayout_init: NFSv4 File Layout Driver Registering...
[    1.895314] nfs4flexfilelayout_init: NFSv4 Flexfile Layout Driver Registering...
[    1.896528] Key type asymmetric registered
[    1.896562] Asymmetric key parser 'x509' registered
[    1.896635] Block layer SCSI generic (bsg) driver version 0.4 loaded (major 249)
[    1.896675] io scheduler mq-deadline registered
[    1.896706] io scheduler kyber registered
[    1.900211] bcm2708_fb soc:fb: FB found 1 display(s)
[    1.912442] Console: switching to colour frame buffer device 82x26
[    1.919739] bcm2708_fb soc:fb: Registered framebuffer for display 0, size 656x416
[    1.930369] bcm2835-rng 3f104000.rng: hwrng registered
[    1.933352] vc-mem: phys_addr:0x00000000 mem_base=0x1ec00000 mem_size:0x20000000(512 MiB)
[    1.939314] gpiomem-bcm2835 3f200000.gpiomem: Initialised: Registers at 0x3f200000
[    1.956843] brd: module loaded
[    1.971680] loop: module loaded
[    1.976190] Loading iSCSI transport class v2.0-870.
[    1.980750] usbcore: registered new interface driver lan78xx
[    1.983483] usbcore: registered new interface driver smsc95xx
[    1.986113] dwc_otg: version 3.00a 10-AUG-2012 (platform bus)
[    2.716920] Core Release: 2.80a
[    2.719451] Setting default values for core params
[    2.721975] Finished setting default values for core params
[    2.924866] Using Buffer DMA mode
[    2.927298] Periodic Transfer Interrupt Enhancement - disabled
[    2.929846] Multiprocessor Interrupt Enhancement - disabled
[    2.932405] OTG VER PARAM: 0, OTG VER FLAG: 0
[    2.934952] Dedicated Tx FIFOs mode

[    2.937845] WARN::dwc_otg_hcd_init:1074: FIQ DMA bounce buffers: virt = 93d14000 dma = 0xd3d14000 len=9024
[    2.944955] FIQ FSM acceleration enabled for :
               Non-periodic Split Transactions
               Periodic Split Transactions
               High-Speed Isochronous Endpoints
               Interrupt/Control Split Transaction hack enabled
[    2.955965] dwc_otg: Microframe scheduler enabled

[    2.956046] WARN::hcd_init_fiq:457: FIQ on core 1

[    2.960362] WARN::hcd_init_fiq:458: FIQ ASM at 807cb8b8 length 36

[    2.964802] WARN::hcd_init_fiq:497: MPHI regs_base at 98810000
[    2.969264] dwc_otg 3f980000.usb: DWC OTG Controller
[    2.971582] dwc_otg 3f980000.usb: new USB bus registered, assigned bus number 1
[    2.973958] dwc_otg 3f980000.usb: irq 89, io mem 0x00000000
[    2.976301] Init: Port Power? op_state=1
[    2.978535] Init: Power Port (0)
[    2.981045] usb usb1: New USB device found, idVendor=1d6b, idProduct=0002, bcdDevice= 5.10
[    2.985661] usb usb1: New USB device strings: Mfr=3, Product=2, SerialNumber=1
[    2.988124] usb usb1: Product: DWC OTG Controller
[    2.990479] usb usb1: Manufacturer: Linux 5.10.103-v7+ dwc_otg_hcd
[    2.992876] usb usb1: SerialNumber: 3f980000.usb
[    2.996044] hub 1-0:1.0: USB hub found
[    2.998480] hub 1-0:1.0: 1 port detected
[    3.002074] dwc_otg: FIQ enabled
[    3.002087] dwc_otg: NAK holdoff enabled
[    3.002099] dwc_otg: FIQ split-transaction FSM enabled
[    3.002116] Module dwc_common_port init
[    3.002429] usbcore: registered new interface driver usb-storage
[    3.005175] mousedev: PS/2 mouse device common for all mice
[    3.008816] bcm2835-wdt bcm2835-wdt: Broadcom BCM2835 watchdog timer
[    3.014024] sdhci: Secure Digital Host Controller Interface driver
[    3.016617] sdhci: Copyright(c) Pierre Ossman
[    3.019868] mmc-bcm2835 3f300000.mmcnr: could not get clk, deferring probe
[    3.023142] sdhost-bcm2835 3f202000.mmc: could not get clk, deferring probe
[    3.025992] sdhci-pltfm: SDHCI platform and OF driver helper
[    3.030462] ledtrig-cpu: registered to indicate activity on CPUs
[    3.033479] hid: raw HID events driver (C) Jiri Kosina
[    3.036273] usbcore: registered new interface driver usbhid
[    3.038878] usbhid: USB HID core driver
[    3.046688] Initializing XFRM netlink socket
[    3.049301] NET: Registered protocol family 17
[    3.051939] Key type dns_resolver registered
[    3.054997] Registering SWP/SWPB emulation handler
[    3.057508] registered taskstats version 1
[    3.059848] Loading compiled-in X.509 certificates
[    3.063028] Key type ._fscrypt registered
[    3.065383] Key type .fscrypt registered
[    3.067709] Key type fscrypt-provisioning registered
[    3.081685] uart-pl011 3f201000.serial: cts_event_workaround enabled
[    3.084164] 3f201000.serial: ttyAMA0 at MMIO 0x3f201000 (irq = 114, base_baud = 0) is a PL011 rev2
[    3.091295] bcm2835-power bcm2835-power: Broadcom BCM2835 power domains driver
[    3.095522] mmc-bcm2835 3f300000.mmcnr: mmc_debug:0 mmc_debug2:0
[    3.097995] mmc-bcm2835 3f300000.mmcnr: DMA channel allocated
[    3.125819] Indeed it is in host mode hprt0 = 00021501
[    3.188341] sdhost: log_buf @ (ptrval) (d3d13000)
[    3.226382] mmc1: queuing unknown CIS tuple 0x80 (2 bytes)
[    3.230423] mmc1: queuing unknown CIS tuple 0x80 (3 bytes)
[    3.234339] mmc1: queuing unknown CIS tuple 0x80 (3 bytes)
[    3.239471] mmc1: queuing unknown CIS tuple 0x80 (7 bytes)
[    3.242738] mmc0: sdhost-bcm2835 loaded - DMA enabled (>1)
[    3.247834] of_cfs_init
[    3.250135] of_cfs_init: OK
[    3.253303] Waiting for root device PARTUUID=8757bb3e-02...
[    3.305149] mmc0: host does not support reading read-only switch, assuming write-enable
[    3.312806] mmc0: new high speed SDHC card at address 5048
[    3.316303] mmcblk0: mmc0:5048 SD32G 28.9 GiB
[    3.321704]  mmcblk0: p1 p2
[    3.334405] usb 1-1: new full-speed USB device number 2 using dwc_otg
[    3.337166] Indeed it is in host mode hprt0 = 00021501
[    3.367582] EXT4-fs (mmcblk0p2): mounted filesystem with ordered data mode. Opts: (null)
[    3.371996] VFS: Mounted root (ext4 filesystem) readonly on device 179:2.
[    3.382580] devtmpfs: mounted
[    3.401241] Freeing unused kernel memory: 1024K
[    3.408921] mmc1: new high speed SDIO card at address 0001
[    3.454872] Run /sbin/init as init process
[    3.457238]   with arguments:
[    3.457250]     /sbin/init
[    3.457260]   with environment:
[    3.457272]     HOME=/
[    3.457282]     TERM=linux
[    3.544475] usb 1-1: device descriptor read/64, error -71
[    3.664883] Indeed it is in host mode hprt0 = 00021501
[    3.874406] usb 1-1: device descriptor read/64, error -71
[    3.994556] Indeed it is in host mode hprt0 = 00021501
[    4.064822] systemd[1]: System time before build time, advancing clock.
[    4.204430] usb 1-1: new full-speed USB device number 3 using dwc_otg
[    4.207777] Indeed it is in host mode hprt0 = 00021501
[    4.214665] NET: Registered protocol family 10
[    4.218738] Segment Routing with IPv6
[    4.300813] systemd[1]: systemd 241 running in system mode. (+PAM +AUDIT +SELINUX +IMA +APPARMOR +SMACK +SYSVINIT +UTMP +LIBCRYPTSETUP +GCRYPT +GNUTLS +ACL +XZ +LZ4 +SECCOMP +BLKID +ELFUTILS +KMOD -IDN2 +IDN -PCRE2 default-hierarchy=hybrid)
[    4.310459] systemd[1]: Detected architecture arm.
[    4.414230] systemd[1]: Set hostname to <octopi>.
[    4.414401] usb 1-1: device descriptor read/64, error -71
[    4.535109] Indeed it is in host mode hprt0 = 00021501
[    4.764427] usb 1-1: device descriptor read/64, error -71
[    4.884538] usb usb1-port1: attempt power cycle
[    5.297593] random: systemd: uninitialized urandom read (16 bytes read)
[    5.314963] random: systemd: uninitialized urandom read (16 bytes read)
[    5.318346] systemd[1]: Started Forward Password Requests to Wall Directory Watch.
[    5.327050] random: systemd: uninitialized urandom read (16 bytes read)
[    5.330162] systemd[1]: Listening on initctl Compatibility Named Pipe.
[    5.337115] systemd[1]: Listening on Journal Socket (/dev/log).
[    5.343180] systemd[1]: Reached target Swap.
[    5.352424] systemd[1]: Created slice system-systemd\x2dfsck.slice.
[    5.358912] systemd[1]: Started Dispatch Password Requests to Console Directory Watch.
[    5.368008] systemd[1]: Reached target Paths.
[    6.149632] EXT4-fs (mmcblk0p2): re-mounted. Opts: (null)
[    6.257477] systemd-journald[116]: Received request to flush runtime journal from PID 1
[    6.859375] mc: Linux media interface: v0.10
[    6.862658] vc_sm_cma: module is from the staging directory, the quality is unknown, you have been warned.
[    6.867174] bcm2835_vc_sm_cma_probe: Videocore shared memory driver
[    6.867204] [vc_sm_connected_init]: start
[    6.868300] [vc_sm_connected_init]: installed successfully
[    6.902719] videodev: Linux video capture interface: v2.00
[    6.946861] bcm2835_mmal_vchiq: module is from the staging directory, the quality is unknown, you have been warned.
[    6.947729] bcm2835_mmal_vchiq: module is from the staging directory, the quality is unknown, you have been warned.
[    6.950907] bcm2835_mmal_vchiq: module is from the staging directory, the quality is unknown, you have been warned.
[    6.962531] bcm2835_isp: module is from the staging directory, the quality is unknown, you have been warned.
[    6.968814] bcm2835_codec: module is from the staging directory, the quality is unknown, you have been warned.
[    6.972650] bcm2835_v4l2: module is from the staging directory, the quality is unknown, you have been warned.
[    6.978362] bcm2835-isp bcm2835-isp: Device node output[0] registered as /dev/video13
[    6.978506] bcm2835-codec bcm2835-codec: Device registered as /dev/video10
[    6.978561] bcm2835-codec bcm2835-codec: Loaded V4L2 decode
[    6.979463] bcm2835-isp bcm2835-isp: Device node capture[0] registered as /dev/video14
[    6.981003] bcm2835-isp bcm2835-isp: Device node capture[1] registered as /dev/video15
[    6.981572] bcm2835-isp bcm2835-isp: Device node stats[2] registered as /dev/video16
[    6.981615] bcm2835-isp bcm2835-isp: Register output node 0 with media controller
[    6.981644] bcm2835-isp bcm2835-isp: Register capture node 1 with media controller
[    6.981666] bcm2835-isp bcm2835-isp: Register capture node 2 with media controller
[    6.981687] bcm2835-isp bcm2835-isp: Register capture node 3 with media controller
[    6.981993] bcm2835-isp bcm2835-isp: Loaded V4L2 bcm2835-isp
[    7.006132] snd_bcm2835: module is from the staging directory, the quality is unknown, you have been warned.
[    7.045716] bcm2835_audio bcm2835_audio: card created with 8 channels
[    7.310725] cfg80211: Loading compiled-in X.509 certificates for regulatory database
[    7.417535] cfg80211: Loaded X.509 cert 'sforshee: 00b28ddf47aef9cea7'
[    7.534758] brcmfmac: F1 signature read @0x18000000=0x15264345
[    7.543562] brcmfmac: brcmf_fw_alloc_request: using brcm/brcmfmac43455-sdio for chip BCM4345/6
[    7.551737] usbcore: registered new interface driver brcmfmac
[    7.602978] bcm2835-codec bcm2835-codec: Device registered as /dev/video11
[    7.603034] bcm2835-codec bcm2835-codec: Loaded V4L2 encode
[    7.621623] bcm2835-v4l2-0: scene mode selected 0, was 0
[    7.622124] bcm2835-v4l2-0: V4L2 device registered as video0 - stills mode > 1280x720
[    7.622349] bcm2835-codec bcm2835-codec: Device registered as /dev/video12
[    7.622399] bcm2835-codec bcm2835-codec: Loaded V4L2 isp
[    7.627575] bcm2835-v4l2-0: Broadcom 2835 MMAL video capture ver 0.0.2 loaded.
[    7.630816] bcm2835-codec bcm2835-codec: Device registered as /dev/video18
[    7.630871] bcm2835-codec bcm2835-codec: Loaded V4L2 image_fx
[    7.805296] brcmfmac: brcmf_fw_alloc_request: using brcm/brcmfmac43455-sdio for chip BCM4345/6
[    7.805467] brcmfmac: brcmf_fw_alloc_request: using brcm/brcmfmac43455-sdio for chip BCM4345/6
[    7.816489] brcmfmac: brcmf_c_preinit_dcmds: Firmware: BCM4345/6 wl0: Mar 23 2020 02:19:54 version 7.45.206 (r725000 CY) FWID 01-88ee44ea
[   10.330052] random: crng init done
[   10.330069] random: 7 urandom warning(s) missed due to ratelimiting
[   10.431188] uart-pl011 3f201000.serial: no DMA platform data
[   10.584392] Adding 102396k swap on /var/swap.  Priority:-2 extents:3 across:214420k SSFS
[   10.598936] 8021q: 802.1Q VLAN Support v1.8
[   10.794857] brcmfmac: brcmf_cfg80211_set_power_mgmt: power save enabled
[   16.256640] IPv6: ADDRCONF(NETDEV_CHANGE): wlan0: link becomes ready
[   17.416377] Bluetooth: Core ver 2.22
[   17.416532] NET: Registered protocol family 31
[   17.416545] Bluetooth: HCI device and connection manager initialized
[   17.416582] Bluetooth: HCI socket layer initialized
[   17.416602] Bluetooth: L2CAP socket layer initialized
[   17.416641] Bluetooth: SCO socket layer initialized
[   17.430076] Bluetooth: HCI UART driver ver 2.3
[   17.430088] Bluetooth: HCI UART protocol H4 registered
[   17.430152] Bluetooth: HCI UART protocol Three-wire (H5) registered
[   17.430300] Bluetooth: HCI UART protocol Broadcom registered
[   17.656906] Bluetooth: BNEP (Ethernet Emulation) ver 1.3
[   17.656920] Bluetooth: BNEP filters: protocol multicast
[   17.656938] Bluetooth: BNEP socket layer initialized

I searched on that and the first result read:

More often than not, those errors are due to a weedy power supply or a cruddy cable between the power supply and your RPi along with too many USB devices pulling too much current.

https://forums.raspberrypi.com/viewtopic.php?t=182297

As your description shows you really tried a lot of things but - unless I oversaw it - the pi's powersupply was not on your list.

That said, I have an Ender 3 and replaced the mainboard with a BTT SKR MINI E3 V1.2 and a pi 3B on the other side and I never had usb connection issues. The power supply is labled 5V/2,4A, 'Rydges Speed Power', a dedicated raspberry power supply (as opposed to a charger).

(BTW, long listings like the dmesg output above gain readability when codefencing them with tripple backtics on a line before and after the listing. You could even edit your post and do it retroactively)

thanks, have added backticks!

my psu is a dedicated pi one, 5v 3000ma from. i haven't tried replacing it.

i suppose the psu could be faulty although it seems unlikely as once connected everything works fine with no errors, and printing from SD usually clears the issue. any ideas how to test the psu? i'm fairly handy, happy to solder some kind of jig if necessary. got boxes full of resistors and capacitors etc and i think there's a scope at work...

were you having any usb issues before upgrading the mainboard?

Seems like most PSU related problems are voltage rather than current capacity. The stock raspberry supply is 5.1V. If you have a multi-meter you could check your PSU?

no, prev board was a melzi 8 bit and firmware upgrades were painfull, I changed the board to get 32 bit performance.

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