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Description
Here is an MWE that shows this:
using DifferentialEquations, ModelingToolkit
using ModelingToolkitStandardLibrary: Thermal
@variables t
@named temp = Thermal.FixedTemperature(; T=300)
@named heatflow = Thermal.FixedHeatFlow(; Q_flow=-1.0)
@named wall = Thermal.ThermalResistor(; R=1)
eqs = [
    connect(temp.port, wall.port_a),
    connect(wall.port_b, heatflow.port),
]
@named test_model = compose(ODESystem(eqs, t; name=:_test), [temp, heatflow, wall])
sys = structural_simplify(test_model)
sol = solve(ODAEProblem(sys, [], (0, 1.0)))
sol[wall.Q_flow]The last line gives the following error:
ERROR: The nonlinear solver failed with the return code MaxIters.
...
The problem stems from the temperature dependence of the heat flow implemented in Thermal.FixedHeatFlow. observed(sys) gives the following list for the observed variables.
julia> observed(sys)
9-element Vector{Equation}:
 temp₊port₊T(t) ~ temp₊T
 heatflow₊port₊Q_flow(t) ~ wall₊Q_flow(t)
 wall₊port_a₊Q_flow(t) ~ wall₊Q_flow(t)
 wall₊port_b₊Q_flow(t) ~ -wall₊Q_flow(t)
 temp₊port₊Q_flow(t) ~ -wall₊Q_flow(t)
 wall₊port_a₊T(t) ~ temp₊port₊T(t)
 heatflow₊port₊T(t) ~ (-heatflow₊port₊Q_flow(t) + heatflow₊Q_flow*(-1 + heatflow₊T_ref*heatflow₊alpha)) / (heatflow₊Q_flow*heatflow₊alpha)
 wall₊dT(t) ~ temp₊port₊T(t) - heatflow₊port₊T(t)
 wall₊port_b₊T(t) ~ heatflow₊port₊T(t)
The culprit is the 7th equation in which alpha is in denominator and for constant heat source is zero. Also if the source is modeling an insulated point where Q_flow = 0, the same symptom occurs regardless of the value of alpha.
The remedy is to correctly define the Thermal.FixedHeatFlow equation as port.Q_flow ~ -Q_flow and ditch the temperature dependence, which is meaningless for a fixed heat flow source anyway. Note that the same argument applies to Thermal.PrescribedHeatFlow for which the correct equation should be port.Q_flow ~ -Q_flow.u.
PS. I know that Modelica Standard Library defines the above sources the same way that they are currently implemented in ModelingToolkit Standard Library, but I think the correct way to define them is as discussed above. When a temperature dependent heat flow source is desired, it can be achieved by combining Thermal.PrescribedHeatFlow, Thermal.TemperatureSensor and some function block.