I just started a long print (6+ hours) and approximately 2.5 hours into the print, the job failed with the "Error: Movement halted because a step timing error occurred (code 3). Please reset the controller." error. This is with the 3.6.0-alpha.5+1 firmware.

Here is the output of M112 right after the error:

M122 === Diagnostics === RepRapFirmware for Duet 2 WiFi/Ethernet version 3.6.0-alpha.5+1 (2024-08-31 17:50:58) running on Duet WiFi 1.0 or 1.01 Board ID: 08DAM-999TL-MQ4SD-6JTDL-3SS6N-968BX Used output buffers: 13 of 26 (21 max) === RTOS === Static ram: 23360 Dynamic ram: 67504 of which 12 recycled Never used RAM 11864, free system stack 102 words Tasks: NETWORK(2,nWait 6,15.3%,195) HEAT(3,nWait 5,0.1%,309) Move(4,invalid,5.2%,266) MAIN(1,running,79.4%,752) IDLE(0,ready,0.0%,29), total 100.0% Owned mutexes: WiFi(NETWORK) === Platform === Last reset 02:31:01 ago, cause: software Last software reset at 2024-09-16 11:25, reason: User, Gcodes spinning, available RAM 28192, slot 2 Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00400000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a Error status: 0x00 Aux0 errors 0,0,0 MCU temperature: min 27.7, current 48.5, max 49.4 Supply voltage: min 23.5, current 24.2, max 24.6, under voltage events: 0, over voltage events: 0, power good: yes Heap OK, handles allocated/used 99/2, heap memory allocated/used/recyclable 2048/1132/1072, gc cycles 1 Events: 0 queued, 0 completed Date/time: 2024-09-16 13:56:21 Slowest loop: 218.04ms; fastest: 0.13ms I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0 === Storage === Free file entries: 8 SD card 0 detected, interface speed: 20.0MBytes/sec SD card longest read time 9.4ms, write time 3.1ms, max retries 0 === Move === Segments created 639, maxWait 442509ms, bed comp in use: none, height map offset 0.000, hiccups added 5 (0.15ms), max steps late 1, ebfmin 0.00, ebfmax 0.00 Pos req/act/dcf: 68366.00/68371/-0.79 66822.00/66848/-0.92 76754.00/76740/0.84 no step interrupt scheduled Driver 0: standstill, SG min 0 Driver 1: standstill, SG min 0 Driver 2: standstill, SG min 0 Driver 3: standstill, SG min 0 Driver 4: standstill, SG min n/a Driver 5: Driver 6: Driver 7: Driver 8: Driver 9: Driver 10: Driver 11: === DDARing 0 === Scheduled moves 912010, completed 912008, LaErrors 0, Underruns [17, 0, 0] === Heat === Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0 Heater 0 is on, I-accum = 0.1 Heater 1 is on, I-accum = 0.2 === GCodes === Movement locks held by null HTTP is idle in state(s) 0 Telnet is idle in state(s) 0 File is doing "G1 X-6.539 Y47.848" in state(s) 0 USB is idle in state(s) 0 Aux is idle in state(s) 0 Trigger is idle in state(s) 0 Queue is idle in state(s) 0 LCD is idle in state(s) 0 Daemon is idle in state(s) 0 Autopause is idle in state(s) 0 Q0 segments left 1 Code queue 0 is empty === Network === Slowest loop: 195.01ms; fastest: 0.00ms Responder states: HTTP(0) HTTP(4) HTTP(0) FTP(0) Telnet(0) HTTP sessions: 1 of 8 === WiFi === Interface state: active Module is connected to access point Failed messages: pending 0, notrdy 0, noresp 0 Firmware version 2.1.0 MAC address 5c:cf:7f:2c:25:00 Module reset reason: Turned on by main processor, Vcc 3.40, flash size 4194304, free heap 40984 WiFi IP address 192.168.1.61 Signal strength -28dBm, channel 6, mode 802.11n, reconnections 0 Clock register 00002002 Socket states: 0 0 0 0 0 0 0 0

Here is config.g:

; Setup some global variables global power_fail_retract = 2 ; Retract 2mm when power fails ; Communication and general M550 P"BigDelta" ; Machine name and Netbios name (can be anything you like) M551 Preprap ; Machine password (used for FTP) M552 S1 ; Enable WiFi. Disabled for setup and testing. Enable once set up on your network. ; Enable telnet M586 S1 P2 ; Debugging M111 S0 ; Debug off M929 P"eventlog.txt" S1 ; Start logging to file eventlog.txt M555 P2 ; Set output to look like Marlin G21 ; Work in millimetres G90 ; Send absolute coordinates... M83 ; ...but relative extruder moves ; Axis and motor configuration M569 P0 S0 ; Drive 0 goes backwards M569 P1 S0 ; Drive 1 goes backwards M569 P2 S0 ; Drive 2 goes backwards M569 P3 S0 ; Drive 3 goes backwards ; Assign extruder drive M584 E3 ; Set homing switch config M574 X2 S1 P"!xstop" ; Set homing switch configuration on S1 = high-end, active-low M574 Y2 S1 P"!ystop" ; Set homing switch configuration on S1 = high-end, active-low M574 Z2 S1 P"!zstop" ; Set homing switch configuration on S1 = high-end, active-low ; Set it as a linear delta M669 K3 ; Setup paneldue 5i M575 P1 S1 B57600 M665 R215.062 L395.317:395.475:395.433 B160 H374.050 ; set delta radius, diagonal rod length, printable radius and homed height M666 X0 Y0 Z0 ; put your endstop adjustments here, or let auto calibration find them M350 X16 Y16 Z16 E16 I1 ; Set 16x microstepping with interpolation M92 X200 Y200 Z200 ; Set axis steps/mm M906 X1400 Y1400 Z1400 E1400 I60 ; Set motor currents (mA) and increase idle current to 60% M84 S60 ; Set idle timeout M201 X12000 Y12000 Z2000 E10000 ; Accelerations (mm/s^2) M203 X30000 Y30000 Z5000 E3600 ; Maximum speeds (mm/min) ;M566 X900 Y900 Z300 E1200 P1 ; Maximum instant speed changes mm/minute ;M566 X300 Y300 Z300 E450 P1 ; Maximum instant speed changes mm/minute M566 X600 Y600 Z300 E900 P1 ; Maximum instant speed changes mm/minute M204 P9000 T9000 ; Set acceleration for print and travel moves ; Configure Input shaping M593 P"zvdd" F45 ; Thermistors M308 S0 P"bed_temp" Y"thermistor" T100000 B3950 R4700 H30 L0 ; Put your own H and/or L values here to set the bed thermistor ADC correction M308 S1 P"e0_temp" Y"thermistor" T100000 B3950 R4700 H30 L0 ; 100K NTC ;M308 S1 P"e0_temp" Y"thermistor" T100000 B4658 C6.5338987554e-08 ; 104-NT Aliexpress thermistor M950 H0 C"bed_heat" T0 ; Set up H0 as the bed heater using T0 as the sensor M950 H1 C"e0_heat" T1 ; Set up H1 as the extruder heater using T1 as the sensor M140 H0 ; Map H0 as the bed heater ; Set temperature excursion warnings M570 H0 P20 M570 H1 P20 M308 S3 Y"mcu-temp" A"MCU" ; configure sensor 3 as thermistor on pin e1temp for left stepper M308 S4 Y"drivers" A"Drivers" ; configure sensor 4 as temperature warning and overheat flags on the TMC2660 on Duet M912 P0 S-3.5 ; Calibrate MCU temp ; Fan definitions M950 F0 C"fan0" M950 F1 C"fan1" M950 F2 C"fan2" ; Thermostatic fan on 1 for cooling the hotend M106 P1 T50 H1 ; Thermostatic fan on 2 for cooling the board M106 P2 H3:4 L.3 X1 B0.3 T35:70 ; set fan 2 value ; Tool definitions M563 P0 D0 H1 ; Define tool 0 G10 P0 S0 R0 ; Set tool 0 operating and standby temperatures ;M92 E1392 ; Based on https://www.thingiverse.com/thing:1359717; 2023/01/06 M92 E1077.1646 ; This is the new value for the hobb-goblin extruder. 03/07/2023 ;M92 E319.2005 ; Set extruder steps per mm. This is for the MK8 gear ; Z probe and compensation definition M558 P8 C"^!zprobe.in" R0.4 H4 F1200 T6000 A5 S0.01 ; Z probe is a piezo sensor G31 X0 Y0 Z-0.08 P100 ; Set the zprobe height and threshold M557 R150 S20 ; Probe within a radius of 150mm and mesh spacing of 20 M376 H5 ; Taper off bed compensation after 5mm ; Configure power failure and resume M911 S21.0 R23.0 P"G91 M83 G1 Z3 E{-global.power_fail_retract} F1000" ; Relative movement and extrusion. Move head up and retract 2mm filament. M208 S1 Z-0.5 ; set minimum Z T0 ; select first hot end M501 ; Load any config overrides

@droftarts said in Duet 3 mini5+ nightly restarts 3.5.2:

@Chriss Fair enough, and thank you for you help and feedback so far!

You are more than welcome, I like to test early versions and give feedback if possible but this alpha was a bit to much for me. 😉 There are to many projects at my table at the moment and I have to many printers which do work as they should.

@Exerqtor please try again using 3.6.0-alpha.5. There is a bug fix since alpha 4 that may well be relevant.

Hey @jay_s_uk, awesome, it worked, thanks for your help!

@rechrtb I don't think the disconnects are running out of memory. They happen even when nothing is happening on the printer, and that out of memory only happens when a job fails in the middle and doesn't reclaim memory. While I've been debugging new code, that happens occasionally but not frequently like teh WiFi disconnects. A restart fixes it, and I don't have it happen too much any more, while the WiFi disconnects continue to happen. I just was assuming there's RF pollution around.

Also I've watched it happen spontaneously, the reconnect, with no reset, and there was no error. Often I'm actually just editing a macro when it happens, and I may not have even run a print job in days.

@droftarts @chrishamm Would be nice to have a permanent fix. rm .config/chromium/SingletonLock worked for me to

All those running 3.6.0alpha builds, please see my announcement at https://forum.duet3d.com/topic/36421/reprapfirmware-3-6-0-alpha-4-3-available-for-testing/1 and upgrade to that version. If you find any issues, please continue in that thread. I shall lock this one shortly.

Been printing on and off for several prints and knock on wood haven't had any tramming issues. Print quality is also very much improved over 3.52. Looking forward to further improvements.

@gloomyandy Ah ok, that actually makes a lot of sense. I'll keep that in mind in the future.

@droftarts SOLVED!

@droftarts

I actually ended up reimaging the original sd card and doing the same manual recreation of the config files and it's been fine so far. I think more permissions or something when doing the image/sftp backup/restore originally.

@charliedrums One other thing to try, I think you said that once it gets into this "over extrusion mode" then it stays in it even when starting a new print? If that is the case can you try checking the extruder calibration when in this state see: https://docs.duet3d.com/en/How_to_guides/Calibration#h-3-calibrating-extruder-e-steps-per-mm and then do a reboot and perform the same task again and see if there is any difference.

This appears to be fixed with v3.5.2. I'm no longer getting the error message using the above steps. Additionally the 3 macros in the upper right corner of the 'Control' page have returned.

Marking as solved.

@chrishamm I discovered the solution. After loading all of the projects, then do a full clean and then quit Eclipse. Restart Eclipse and now the board build options should be available under the Hammer icon.

@Aurimas next time this happens, please run M122 B# where # is the CAN address of tool board, and post the output here.

@dc42 : Heater fault in my case was due to some interference from BLtouch wire., not due to RRF 3.5.1.. There was a change in wiring in addition to RR3.5.1 upgrade, but when I debugged further, the root cause was as stated.