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Intermittent extruder loss and stutters. 6HC/toolboard/RRF3.2

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  • undefined
    hamel
    last edited by hamel 3 Jan 2021, 22:36 1 Mar 2021, 22:22

    Hey all!

    I am having an issue with a new duet 6HC with toolboard. I am getting some stuttering in print moves, and extrusion not working on the extruder (toolboard). When it happens, both issues show up at the same time. I also noticed that the extruder will retract and prime again during travel, but it will never extrude. The issue is very intermittent, and I feel that it is pointing towards a slicer issue or communication issue. I do not have any communication faults. I am leaning towards that due to the fact that I can pause the print, and from DWC I can extrude without issue. Can anyone give me a little guidance on where to go from here?

    ; Configuration file for Duet 3 (firmware version 3)
    ; executed by the firmware on start-up

    ; General preferences
    G90 ; send absolute coordinates...
    M83 ; ...but relative extruder moves
    M550 P"Duet 3" ; set printer name
    M669 K1 ; select CoreXY mode

    G4 S1 ;wait for expansion boards to start

    ; Drives
    M569 P0.0 S1 ; physical drive 0.0 goes forwards
    M569 P0.1 S1 ; physical drive 0.1 goes forwards
    M569 P0.2 S1 ; physical drive 0.2 goes forwards
    M569 P0.3 S0 ; physical drive 0.2 goes forwards
    M569 P0.4 S0 ; physical drive 0.2 goes forwards
    M569 P0.5 S1 ; physical drive 0.2 goes forwards
    M569 P121.0 S0 ; physical drive 121.0 goes forwards
    M584 X0.1 Y0.0 Z0.2:0.3:0.5:0.4 E121.0 ; set drive mapping
    M350 X16 Y16 Z16 E16 I1 ; configure microstepping with interpolation
    M92 X98.00 Y98.00 Z400.00 E426.00 ; set steps per mm
    M566 X3000.00 Y3000.00 Z200.00 E200.00 ; set maximum instantaneous speed changes (mm/min)
    M203 X10000.00 Y10000.00 Z8000.00 E1000.00 ; set maximum speeds (mm/min)
    M201 X3000.00 Y3000.00 Z200.00 E200.00 ; set accelerations (mm/s^2)
    M906 X1100 Y1100 Z1000 E800 I30 ; set motor currents (mA) and motor idle factor in per cent
    M84 S30 ; Set idle timeout

    ; Axis Limits
    M208 X-200 Y-200 Z-1 S1 ; set axis minima
    M208 X200 Y200 Z400 S0 ; set axis maxima

    ; Leadscrew Locations
    M671 X-322.5:-322.5:262.5:262.5 Y-250:300:300:-250 S20 F1.2 ; Z leadscrew positions

    ; Endstops
    M574 X2 S1 P"io0.in" ; X min active low endstop switch
    M574 Y2 S1 P"io1.in" ; Y min active low endstop switch
    M574 Z1 S2

    ; Z-Probe
    M558 P8 C"^!121.io0.in" H5 F300 T16000 ; set Z probe type to unfiltered switch and the dive height + speeds
    M558 H15 ;*** Remove this line after delta calibration has been done and new delta parameters have been saved
    G31 P500 X0 Y0 Z1.5 ; set Z probe trigger value, offset and trigger height
    M556 S50 X0 Y0 Z0 ; set orthogonal axis compensation parameters
    M557 X-200:200 Y-200:200 S100 ; define mesh grid

    ; Heaters
    M308 S0 P"temp3" Y"thermistor" T100000 B4138 ; configure sensor 0 as thermistor on pin temp3
    M950 H0 C"out0" T0 ; create bed heater output on out0 and map it to sensor 0
    M307 H0 B0 S0.50 ; disable bang-bang mode for the bed heater and set PWM limit
    M140 H0 ; map heated bed to heater 0
    M143 H0 S150 ; set temperature limit for heater 0 to 120C
    M308 S1 P"121.temp0" Y"thermistor" T100000 B4138 ; configure sensor 1 as thermistor on pin 121.temp0
    M950 H1 C"121.out0" T1 ; create nozzle heater output on 121.out0 and map it to sensor 1
    M307 H1 B0 S1.00 ; disable bang-bang mode for heater and set PWM limit
    M143 H1 S350 ; set temperature limit for heater 1 to 350C

    ; Fans
    M950 F0 C"nil"
    M950 F0 C"121.out2" Q500 ; create fan 0 on pin 121.out1 and set its frequency
    M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off
    M950 F1 C"121.out1" Q500 ; create fan 1 on pin 121.out2 and set its frequency
    M106 P1 S1 H1 T45 ; set fan 1 value. Thermostatic control is turned on

    ; Tools
    M563 P0 D0 H1 F0 ; define tool 0
    G10 P0 X0 Y0 Z0 ; set tool 0 axis offsets
    G10 P0 R0 S0 ; set initial tool 0 active and standby temperatures to 0C

    ; Custom settings are not defined

    ; Miscellaneous
    M501 ; load saved parameters from non-volatile memory
    T0 ; select first tool

    ;FLAVOR:RepRap
    ;TIME:14241
    ;Filament used: 19.0959m
    ;Layer height: 0.2
    ;MINX:-29.257
    ;MINY:-39.222
    ;MINZ:0.2
    ;MAXX:115.616
    ;MAXY:95.857
    ;MAXZ:115
    ;Generated with Cura_SteamEngine 4.5.0
    T0
    M190 S60
    M104 S200
    M109 S200
    M82 ;absolute extrusion mode
    T0
    G28

    M83 ;relative extrusion mode
    G1 F4800 E-1.5
    ;LAYER_COUNT:575
    ;LAYER:0
    M107
    G1 F600 Z0.7
    G0 F7200 X10.941 Y31.13 Z0.7
    ;TYPE:SKIRT
    G1 F600 Z0.2
    G1 F1920 E1.5
    G1 F1800 X13.485 Y30.22 E0.1011
    G1 X16.018 Y29.233 E0.10172
    G1 X18.546 Y28.164 E0.1027
    G1 X21.015 Y27.035 E0.10158
    G1 X23.467 Y25.831 E0.10221
    G1 X25.871 Y24.564 E0.10168
    G1 X28.246 Y23.226 E0.102
    G1 X30.605 Y21.806 E0.10303
    G1 X32.863 Y20.36 E0.10033
    G1 X35.117 Y18.824 E0.10206
    G1 X37.354 Y17.205 E0.10333
    G1 X39.47 Y15.581 E0.09981
    G1 X42.768 Y12.855 E0.1601
    G1 X43.316 Y12.391 E0.02687
    G1 X45.162 Y10.855 E0.08986
    G1 X45.585 Y10.494 E0.02081
    G1 X45.986 Y10.168 E0.01934
    G1 X47.358 Y9.043 E0.06639
    G1 X48.097 Y8.428 E0.03597
    G1 X49.464 Y7.312 E0.06603
    G1 X51.466 Y5.627 E0.09791
    G1 X52.566 Y4.691 E0.05404
    G1 X54.923 Y2.751 E0.11423
    G1 X55.766 Y2.048 E0.04107
    G1 X56.17 Y1.7 E0.01995
    G1 X57.122 Y0.911 E0.04627
    G1 X59.162 Y-.85 E0.10084
    G1 X61.17 Y-2.685 E0.10178
    G1 X63.145 Y-4.595 E0.1028
    G1 X65.053 Y-6.545 E0.10208
    G1 X66.896 Y-8.543 E0.10171
    G1 X68.377 Y-10.232 E0.08405
    G1 X68.664 Y-10.567 E0.01651
    G1 X69.579 Y-11.621 E0.05223
    G1 X70.619 Y-12.843 E0.06004
    G1 X71.075 Y-13.387 E0.02656
    G1 X73.462 Y-16.222 E0.13867
    G1 X75.793 Y-18.969 E0.13481
    G1 X76.504 Y-19.829 E0.04175
    G1 X79.49 Y-23.372 E0.17337
    G1 X80.507 Y-24.593 E0.05946

    Cancelled printing file 0:/gcodes/VC_2020SpoolHolderRedu.gcode, print time was 0h 1m
    3/1/2021, 5:20:37 PM M25
    Printing paused at X-3.7 Y91.5 Z0.2
    3/1/2021, 5:20:30 PM m122
    === Diagnostics ===
    RepRapFirmware for Duet 3 MB6HC version 3.2.2 running on Duet 3 MB6HC v0.6 or 1.0 (SBC mode)
    Board ID: 08DJM-956L2-G43S8-6JTDL-3SD6J-1S3YF
    Used output buffers: 1 of 40 (18 max)
    === RTOS ===
    Static ram: 149788
    Dynamic ram: 62544 of which 148 recycled
    Never used RAM 146352, free system stack 129 words
    Tasks: Linux(ready,101) HEAT(blocked,297) CanReceiv(blocked,832) CanSender(blocked,348) CanClock(blocked,352) TMC(blocked,17) MAIN(running,1097) IDLE(ready,19)
    Owned mutexes: Telnet(MAIN)
    === Platform ===
    Last reset 00:02:40 ago, cause: software
    Last software reset at 2021-03-01 17:17, reason: User, GCodes spinning, available RAM 146352, slot 0
    Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00400000 BFAR 0x00000000 SP 0x00000000 Task Linu Freestk 0 n/a
    Error status: 0x00
    Aux0 errors 0,0,0
    Aux1 errors 0,0,0
    MCU temperature: min 51.3, current 51.4, max 52.3
    Supply voltage: min 29.8, current 30.3, max 30.5, under voltage events: 0, over voltage events: 0, power good: yes
    12V rail voltage: min 12.1, current 12.1, max 12.2, under voltage events: 0
    Driver 0: position 8608, standstill, reads 59269, writes 3 timeouts 0, SG min/max 0/200
    Driver 1: position -9329, standstill, reads 59268, writes 3 timeouts 0, SG min/max 0/287
    Driver 2: position 80, ok, reads 59268, writes 3 timeouts 0, SG min/max 0/194
    Driver 3: position 0, ok, reads 59268, writes 3 timeouts 0, SG min/max 0/183
    Driver 4: position 0, ok, reads 59268, writes 3 timeouts 0, SG min/max 0/234
    Driver 5: position 0, ok, reads 59268, writes 3 timeouts 0, SG min/max 0/193
    Date/time: 2021-03-01 17:20:28
    Slowest loop: 155.82ms; fastest: 0.03ms
    === Storage ===
    Free file entries: 10
    SD card 0 not detected, interface speed: 37.5MBytes/sec
    SD card longest read time 0.0ms, write time 0.0ms, max retries 0
    === Move ===
    DMs created 125, maxWait 125409ms, bed compensation in use: none, comp offset 0.000
    === MainDDARing ===
    Scheduled moves 188, completed moves 186, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
    === AuxDDARing ===
    Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
    === Heat ===
    Bed heaters = 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamberHeaters = -1 -1 -1 -1
    Heater 0 is on, I-accum = 0.1
    Heater 1 is on, I-accum = 0.0
    === GCodes ===
    Segments left: 0
    Movement lock held by HTTP
    HTTP* is idle in state(s) 21
    Telnet* is doing "M122" in state(s) 0
    File* is idle 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
    SBC is idle in state(s) 0
    Daemon is idle in state(s) 0 0, running macro
    Aux2 is idle in state(s) 0
    Autopause is idle in state(s) 0
    Code queue is empty.
    === CAN ===
    Messages queued 721, send timeouts 0, received 1696, lost 0, longest wait 1ms for reply type 6013, free buffers 48
    === SBC interface ===
    State: 3, failed transfers: 0
    Last transfer: 0ms ago
    RX/TX seq numbers: 5808/5808
    SPI underruns 0, overruns 0
    Number of disconnects: 0, IAP RAM available 0x2c884
    Buffer RX/TX: 0/0-0
    === Duet Control Server ===
    Duet Control Server v3.2.2
    HTTP:
    Buffered code: M25
    ==> 24 bytes
    Number of flush requests: 1
    Code buffer space: 4096
    Configured SPI speed: 8000000 Hz
    Full transfers per second: 37.07
    Maximum length of RX/TX data transfers: 3204/1512
    File /opt/dsf/sd/gcodes/VC_2020SpoolHolderRedu.gcode is selected, paused
    ok

    undefined 1 Reply Last reply 2 Mar 2021, 18:49 Reply Quote 0
    • undefined
      T3P3Tony administrators
      last edited by 1 Mar 2021, 22:32

      Your post says RRF3.3 but the M122 output is RRF 3.2.2, what are you running on the toolboard?

      When you get an issue please send M122 and M122 B121 so we can see if there are any issues reported by the toolboard.

      www.duet3d.com

      1 Reply Last reply Reply Quote 0
      • undefined
        hamel
        last edited by 1 Mar 2021, 22:36

        Sorry for that. It is 3.2 on both. Thanks for the quick reply.

        m122 B121
        Diagnostics for board 121:
        Duet TOOL1LC firmware version 3.2.2 (2021-02-12)
        Bootloader ID: not available
        Never used RAM 3984, free system stack 48 words
        HEAT 90 CanAsync 89 CanRecv 83 TMC 56 MAIN 218 AIN 64
        Last reset 00:17:46 ago, cause: software
        Last software reset data not available
        Driver 0: position -3534, 426.0 steps/mm, standstill, SG min/max 0/16, read errors 0, write errors 1, ifcnt 59, reads 9098, writes 17, timeouts 0, DMA errors 0
        Moves scheduled 1556, completed 1556, in progress 0, hiccups 0
        No step interrupt scheduled
        VIN: 30.2V
        MCU temperature: min 39.6C, current 41.1C, max 47.5C
        Ticks since heat task active 97, ADC conversions started 1062642, completed 1062641, timed out 0
        Last sensors broadcast 0x00000002 found 1 101 ticks ago, loop time 0
        CAN messages queued 12778, send timeouts 6, received 11172, lost 0, free buffers 36

        1 Reply Last reply Reply Quote 0
        • undefined
          Phaedrux Moderator
          last edited by 2 Mar 2021, 00:23

          Cura 4.5 is pretty out of date now. Try 4.8 maybe?
          Try PrusaSlicer?

          I also notice you're using SBC mode. Would you be able to setup in standalone mode to test?

          https://duet3d.dozuki.com/Wiki/Getting_Started_With_Duet_3#Section_Running_in_standalone_mode

          Z-Bot CoreXY Build | Thingiverse Profile

          undefined 1 Reply Last reply 2 Mar 2021, 04:36 Reply Quote 0
          • undefined
            hamel @Phaedrux
            last edited by 2 Mar 2021, 04:36

            @Phaedrux Thanks for the reply. I have tried 4.8, as well as KISS. They are all producing good looking gcode to me, although I am not sure if I am missing something special in start needed for RR3.2 or duet and the tool board. It is a v0.6 if that matters. I am also pretty unsure of how reasonable my config.g is, as this is my first corexy, triple z, and my first time with RR3.

            I can try SBC mode tomorrow and report back the results.

            I am really stumped by the whole extrudes are being sent in gcode, but it doesn't extrude when printing that gcode. The speeds and accels are reasonable to my knowledge, and it does do anything the firmware sends (like retracts on pause, and if I pause it in the middle of a print I can extrude with DWS). Is it correct that if this were a communication issues with CAN, I would see fault messages and more faults in the M122?

            I can reboot over and over, and eventually I will be able to print just fine with the exact same file. The jerky movement in XY is also gone when it prints correctly. If I stop the print and restart it, it goes back to jerky XY motion and failing to extrude during the print until I play the reboot lottery again.

            Are there any known bugs that would pertain to this? I looked back at the change logs a little bit, but the only thing I really noticed was the toolboard missing steps for some reason, and that it was fixed.

            1 Reply Last reply Reply Quote 0
            • undefined
              dc42 administrators
              last edited by dc42 3 Feb 2021, 19:15 2 Mar 2021, 07:43

              @hamel, please can you try try following:

              1. Try the same print in standalone mode instead of SBC mode.
              2. If you experience the same issue, install firmware 3.3beta1 on the 6HXC and the tool board, and try the print again. Just before printing, run M122 and also M122 B121, to clear any CAN error counts accumulated during the startup process. When you have printed enough to be sure that the issue is still occurring, run M122 and M122 B121 again, and post the results here. The 3.3beta1 firmware has improved diagnostics, and fixes an issue we have seen when the step rates are high.

              Duet WiFi hardware designer and firmware engineer
              Please do not ask me for Duet support via PM or email, use the forum
              http://www.escher3d.com, https://miscsolutions.wordpress.com

              1 Reply Last reply Reply Quote 0
              • undefined
                Phaedrux Moderator @hamel
                last edited by 2 Mar 2021, 18:49

                @hamel said in Intermittent extruder loss and stutters. 6HC/toolboard/RRF3.2:

                M566 X3000.00 Y3000.00 Z200.00 E200.00 ; set maximum instantaneous speed changes (mm/min)
                M203 X10000.00 Y10000.00 Z8000.00 E1000.00 ; set maximum speeds (mm/min)
                M201 X3000.00 Y3000.00 Z200.00 E200.00 ; set accelerations (mm/s^2)

                The extruder speed, jerk and acceleration are pretty low. This could lead to some speed consistency issues. Try increasing them.

                M203 E6000
                M201 E3000
                M566 E3000

                Z-Bot CoreXY Build | Thingiverse Profile

                1 Reply Last reply Reply Quote 0
                • undefined
                  hamel
                  last edited by 2 Mar 2021, 20:03

                  Thank you both for the help.

                  @Phaedrux I have changed them and tested with no difference.

                  @dc42 I have tried with 3.3.1beta on both boards, and I now have issues with the toolboard driver in all scenarios now. I cannot get it to extrude at all with firmware anymore. I do get some response from the driver, but it only vibrates, and does not move. I have connected a separate motor to it for testing, and it will not turn the motor, just jitters. To me that says that CAN is working, and there is an issue with the driver on the toolboard, or something in the config/setup that is causing it. I have tried changing the driver current up and down with no significant change to the symptoms. I am pretty sure it is wired correctly, as it was working fine two days ago. The issue presented after a few test prints that were working fine, yet had a step loss due to high XY accel settings. After adjusting the accel settings, the extruder drive started only working in DWC, and after this latest update to RRF3.3.1beta, I have lost all torque from the driver in all scenarios. At least I get some kind of response when commanded, but only jitters.

                  My M122s after clearing and having the issue present itself, as you requested:

                  m122
                  === Diagnostics ===
                  RepRapFirmware for Duet 3 MB6HC version 3.3beta1 running on Duet 3 MB6HC v0.6 or 1.0 (SBC mode)
                  Board ID: 08DJM-956L2-G43S8-6JTDL-3SD6J-1S3YF
                  Used output buffers: 1 of 40 (11 max)
                  === RTOS ===
                  Static ram: 148196
                  Dynamic ram: 61276 of which 708 recycled
                  Never used RAM 140492, free system stack 126 words
                  Tasks: Linux(ready,143) HEAT(delaying,302) CanReceiv(notifyWait,799) CanSender(notifyWait,359) CanClock(delaying,351) TMC(notifyWait,20) MAIN(running,924) IDLE(ready,20)
                  Owned mutexes: HTTP(MAIN)
                  === Platform ===
                  Last reset 00:03:40 ago, cause: power up
                  Last software reset at 2021-03-02 19:36, reason: User, GCodes spinning, available RAM 140492, slot 1
                  Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00400000 BFAR 0x00000000 SP 0x00000000 Task Linu Freestk 0 n/a
                  Error status: 0x00
                  Aux0 errors 0,0,0
                  Aux1 errors 0,0,0
                  MCU temperature: min 44.1, current 45.7, max 45.8
                  Supply voltage: min 30.0, current 30.3, max 30.6, under voltage events: 0, over voltage events: 0, power good: yes
                  12V rail voltage: min 12.1, current 12.1, max 12.1, under voltage events: 0
                  Driver 0: position 0, standstill, reads 37576, writes 4 timeouts 0, SG min/max 0/1023
                  Driver 1: position 0, standstill, reads 37576, writes 4 timeouts 0, SG min/max 0/1023
                  Driver 2: position 2620, standstill, reads 37576, writes 4 timeouts 0, SG min/max 0/771
                  Driver 3: position 0, standstill, reads 37576, writes 4 timeouts 0, SG min/max 0/908
                  Driver 4: position 0, standstill, reads 37575, writes 4 timeouts 0, SG min/max 0/799
                  Driver 5: position 0, standstill, reads 37575, writes 4 timeouts 0, SG min/max 0/809
                  Date/time: 2021-03-02 19:55:57
                  Slowest loop: 84.44ms; fastest: 0.04ms
                  === Storage ===
                  Free file entries: 10
                  SD card 0 not detected, interface speed: 37.5MBytes/sec
                  SD card longest read time 0.0ms, write time 0.0ms, max retries 0
                  === Move ===
                  DMs created 125, maxWait 38383ms, bed compensation in use: none, comp offset 0.000
                  === MainDDARing ===
                  Scheduled moves 707, completed moves 707, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
                  === AuxDDARing ===
                  Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
                  === Heat ===
                  Bed heaters = 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamberHeaters = -1 -1 -1 -1
                  Heater 0 is on, I-accum = 0.7
                  Heater 1 is on, I-accum = 0.0
                  === GCodes ===
                  Segments left: 0
                  Movement lock held by null
                  HTTP* is doing "M122" in state(s) 0
                  Telnet is idle in state(s) 0
                  File* is idle 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
                  SBC is idle in state(s) 0
                  Daemon is idle in state(s) 0
                  Aux2 is idle in state(s) 0
                  Autopause is idle in state(s) 0
                  Code queue is empty.
                  === CAN ===
                  Messages queued 1462, send timeouts 0, received 1276, lost 0, longest wait 5ms for reply type 6029, peak Tx sync delay 58715, free buffers 49 (min 48)
                  === SBC interface ===
                  State: 4, failed transfers: 0
                  Last transfer: 2ms ago
                  RX/TX seq numbers: 7118/7118
                  SPI underruns 0, overruns 0
                  Number of disconnects: 0, IAP RAM available 0x2d410
                  Buffer RX/TX: 0/0-0
                  === Duet Control Server ===
                  Duet Control Server v3.2.0
                  Code buffer space: 4096
                  Configured SPI speed: 8000000 Hz
                  Full transfers per second: 39.04
                  Maximum length of RX/TX data transfers: 2820/1592
                  File /opt/dsf/sd/gcodes/VC_test.gcode is selected, paused

                  m122 b121
                  Diagnostics for board 121:
                  Duet TOOL1LC firmware version 3.3beta1 (2021-02-14 16:34:04)
                  Bootloader ID: not available
                  Never used RAM 3976, free system stack 0 words
                  Tasks: Move(notifyWait,90) HEAT(delaying,91) CanAsync(notifyWait,63) CanRecv(notifyWait,75) CanClock(notifyWait,67) TMC(delaying,56) MAIN(running,254) AIN(delaying,63)
                  Last reset 00:03:36 ago, cause: power up
                  Last software reset data not available
                  Driver 0: position 43474, 426.0 steps/mm, standstill, SG min/max 0/48, read errors 0, write errors 0, ifcnt 12, reads 46552, writes 1, timeouts 0, DMA errors 0, steps req 56254 done 56254
                  Moves scheduled 531, completed 531, in progress 0, hiccups 0, step errors 0, maxPrep 490, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
                  Peak sync jitter 8, peak Rx sync delay 206, resyncs 0, no step interrupt scheduled
                  VIN: 30.2V
                  MCU temperature: min 26.8C, current 40.4C, max 40.5C
                  Ticks since heat task active 17, ADC conversions started 215389, completed 215388, timed out 0
                  Last sensors broadcast 0x00000002 found 1 24 ticks ago, loop time 0
                  CAN messages queued 1162, send timeouts 0, received 1388, lost 0, free buffers 36, min 36, error reg 0
                  dup 0, oos 0, bm 0, wbm 0

                  I am going to redo my SD now and test in standalone mode, although I am starting to question the toolboard's driver.

                  undefined 1 Reply Last reply 2 Mar 2021, 21:46 Reply Quote 0
                  • undefined
                    oliof @hamel
                    last edited by 2 Mar 2021, 21:46

                    @hamel said in Intermittent extruder loss and stutters. 6HC/toolboard/RRF3.2:

                    I have connected a separate motor to it for testing, and it will not turn the motor, just jitters.

                    Are you sure your separate motor has the same wiring as the one you use on the extruder? I.e., phase pairs neighboring. Different motors by different manufacturers may have a different order of wires (can be fixed by changing the order of crimps in the connector).

                    <>RatRig V-Minion Fly Super5Pro RRF<> V-Core 3.1 IDEX k*****r <> RatRig V-Minion SKR 2 Marlin<>

                    undefined 1 Reply Last reply 2 Mar 2021, 23:18 Reply Quote 0
                    • undefined
                      hamel @oliof
                      last edited by 2 Mar 2021, 23:18

                      @oliof Yes, the coil pairs are the same as the one that I tested with. Both act the same, and no wiring was changed since it was working properly.

                      1 Reply Last reply Reply Quote 0
                      • undefined
                        hamel
                        last edited by 2 Mar 2021, 23:27

                        @dc42 SD imager is giving me trouble, so I will make the SD at home tonight and test it tomorrow.

                        For a test I assigned the toolboard driver to the x axis, and I also get the same performance (lack of any torque to even move the motor alone).

                        1 Reply Last reply Reply Quote 0
                        • undefined
                          dc42 administrators
                          last edited by 2 Mar 2021, 23:30

                          Thanks @hamel, it does sound that there is a problem either with the driver or the motor connection. When you tested it with a different motor, did you use the same connector to plug into the tool board motor connector as when using the original motor, or did you use a different connector?

                          Duet WiFi hardware designer and firmware engineer
                          Please do not ask me for Duet support via PM or email, use the forum
                          http://www.escher3d.com, https://miscsolutions.wordpress.com

                          undefined 1 Reply Last reply 2 Mar 2021, 23:49 Reply Quote 0
                          • undefined
                            hamel @dc42
                            last edited by 2 Mar 2021, 23:49

                            @dc42 Same connector. I have another I can test with. I was initially leading towards not being a wiring issue, as I was able to extrude with DWS earlier in a pause when it was not extruding in the print, but now with no function at all I agree that I should swap them out. I have a few here for my toolchanger that are known good. I'll report back tomorrow with a standalone SD test and a swap of the wires.

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                            • undefined
                              hamel
                              last edited by 5 Mar 2021, 13:26

                              All, I just wanted to give an update. Standalone changed nothing. New cable changed nothing. It seems that my motor was the curprit. It must have been going bad, and something about the speed of the commands sent by DWC allowed it to work a little until it finally failed. Dead coil. New one on the way. Thanks for all of the help looking into this.

                              undefined 1 Reply Last reply 5 Mar 2021, 15:58 Reply Quote 0
                              • undefined
                                dc42 administrators @hamel
                                last edited by 5 Mar 2021, 15:58

                                Thanks for the update, I'm glad you solved it.

                                It's rare for a motor coil to burn out, unless you have run it above its rated current for an extended period. My guess is that if you take the motor apart, you will find a bad connection between one of the windings and the connector if it has one, or the leads if it doesn't.

                                Duet WiFi hardware designer and firmware engineer
                                Please do not ask me for Duet support via PM or email, use the forum
                                http://www.escher3d.com, https://miscsolutions.wordpress.com

                                deckingmanundefined 1 Reply Last reply 5 Mar 2021, 16:06 Reply Quote 0
                                • deckingmanundefined
                                  deckingman @dc42
                                  last edited by 5 Mar 2021, 16:06

                                  @dc42 Probably just a coincidence, but I mentioned in another thread that I've had 3 of my 6 extruder motors connected to expansion boards fail in the last 18 months. When the last one failed, I assumed that it was a bad batch so I replaced all 6 and I haven't had a failure since. Can you think of any reason other than I'm just unlucky and/or it was probably a bad batch of motors? (Motor currents always set to 85% of quoted rated current).

                                  Ian
                                  https://somei3deas.wordpress.com/
                                  https://www.youtube.com/@deckingman

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                                  • undefined
                                    hamel
                                    last edited by hamel 3 May 2021, 16:19 5 Mar 2021, 16:19

                                    I did set to rated current during testing, but never over. I usually stick to 80% rated current, but I got desperate when troubleshooting and shot it up to 100% for a few tests. That might have done it in, as it isn't an especially nice stepper. I did tear it down, and one winding had a break about 5mm from the connection to the leads. I'll see if I can save it.

                                    I have never had a motor burn up, so I didn't really focus on that. Thank you all for the prompt help in diagnosing this rather stupid problem.

                                    undefined 1 Reply Last reply 5 Mar 2021, 16:30 Reply Quote 0
                                    • undefined
                                      dc42 administrators @hamel
                                      last edited by dc42 3 May 2021, 16:31 5 Mar 2021, 16:30

                                      @hamel said in Intermittent extruder loss and stutters. 6HC/toolboard/RRF3.2:

                                      I did set to rated current during testing, but never over. I usually stick to 80% rated current, but I got desperate when troubleshooting and shot it up to 100% for a few tests. That might have done it in, as it isn't an especially nice stepper. I did tear it down, and one winding had a break about 5mm from the connection to the leads. I'll see if I can save it.

                                      I have never had a motor burn up, so I didn't really focus on that. Thank you all for the prompt help in diagnosing this rather stupid problem.

                                      Running at rated current should not cause a problem, because the rated current is normally quoted with both phases energised, whereas microstepping drivers only energise one phase at the full peak current at a time (and currents set by M906 in RRF are peak currents).

                                      If the break was caused by excessive current, I would expect to see blackening of the wires.

                                      Duet WiFi hardware designer and firmware engineer
                                      Please do not ask me for Duet support via PM or email, use the forum
                                      http://www.escher3d.com, https://miscsolutions.wordpress.com

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                                      • undefined
                                        hamel
                                        last edited by 8 Mar 2021, 15:17

                                        Well, the issue has come back. Same symptoms. I get really bad motor movement with the gcode files while printing, but I can pause and extrude just fine with DWC. Any idea what I should be looking at next? I have swapped the motor to a much more powerful one that I just had lying around, and it can really crank out the extrudes in DWC, but when I go to print, it just stutters and skips steps. I have dropped the acceleration and jerk to 500, and I still have the issue. I do not think it is the settings, as I can extrude with those settings in DWC with no issue. When printing, I do not think the toolboard driver is giving good commands, but I have no idea why that would be.

                                        ; Configuration file for Duet 3 (firmware version 3)
                                        ; executed by the firmware on start-up

                                        ; General preferences
                                        G90 ; send absolute coordinates...
                                        M83 ; ...but relative extruder moves
                                        M550 P"Duet 3" ; set printer name
                                        M669 K1 ; select CoreXY mode

                                        G4 S1 ;wait for expansion boards to start

                                        ; Drives
                                        M569 P121.0 S1 ; physical drive 121.0 goes forwards
                                        M569 P0.0 S1 ; physical drive 0.0 goes forwards
                                        M569 P0.1 S1 ; physical drive 0.1 goes forwards
                                        M569 P0.2 S1 ; physical drive 0.2 goes forwards
                                        M569 P0.3 S0 ; physical drive 0.2 goes forwards
                                        M569 P0.4 S0 ; physical drive 0.2 goes forwards
                                        M569 P0.5 S1 ; physical drive 0.2 goes forwards

                                        M584 X0.1 Y0.0 Z0.2:0.3:0.5:0.4 E121.0 ; set drive mapping
                                        M350 X16 Y16 Z16 E16 I1 ; configure microstepping with interpolation
                                        M92 X98.00 Y98.00 Z400.00 E426.00 ; set steps per mm
                                        M566 X2500.00 Y2500.00 Z200.00 E200.00 ; set maximum instantaneous speed changes (mm/min)
                                        M203 X10000.00 Y10000.00 Z8000.00 E3000.00 ; set maximum speeds (mm/min)
                                        M201 X3000.00 Y3000.00 Z200.00 E200.00 ; set accelerations (mm/s^2)
                                        M906 X1100 Y1100 Z1000 E1200 I30 ; set motor currents (mA) and motor idle factor in per cent
                                        M84 S30 ; Set idle timeout

                                        ; Axis Limits
                                        M208 X-200 Y-200 Z-1 S1 ; set axis minima
                                        M208 X200 Y200 Z400 S0 ; set axis maxima

                                        ; Leadscrew Locations
                                        M671 X-322.5:-322.5:262.5:262.5 Y-250:300:300:-250 S20 F1.2 ; Z leadscrew positions

                                        ; Endstops
                                        M574 X2 S1 P"io0.in" ; X min active low endstop switch
                                        M574 Y2 S1 P"io1.in" ; Y min active low endstop switch
                                        M574 Z1 S2

                                        ; Z-Probe
                                        M558 P8 C"^!121.io0.in" H5 F300 T16000 ; set Z probe type to unfiltered switch and the dive height + speeds
                                        M558 H15 ;*** Remove this line after delta calibration has been done and new delta parameters have been saved
                                        G31 P500 X0 Y0 Z1 ; set Z probe trigger value, offset and trigger height
                                        M556 S50 X0 Y0 Z0 ; set orthogonal axis compensation parameters
                                        M557 X-200:200 Y-200:200 S100 ; define mesh grid

                                        ; Heaters
                                        M308 S0 P"temp3" Y"thermistor" T100000 B4138 ; configure sensor 0 as thermistor on pin temp3
                                        M950 H0 C"out0" T0 ; create bed heater output on out0 and map it to sensor 0
                                        M307 H0 B0 S0.50 ; disable bang-bang mode for the bed heater and set PWM limit
                                        M140 H0 ; map heated bed to heater 0
                                        M143 H0 S150 ; set temperature limit for heater 0 to 120C
                                        M308 S1 P"121.temp0" Y"thermistor" T100000 B4138 ; configure sensor 1 as thermistor on pin 121.temp0
                                        M950 H1 C"nil"
                                        M950 H1 C"121.out0" T1 ; create nozzle heater output on 121.out0 and map it to sensor 1
                                        M307 H1 B0 S0.5 ; disable bang-bang mode for heater and set PWM limit
                                        M143 H1 S350 ; set temperature limit for heater 1 to 350C

                                        ; Fans
                                        M950 F0 C"nil"
                                        M950 F0 C"121.out2" Q500 ; create fan 0 on pin 121.out1 and set its frequency
                                        M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off
                                        M950 F1 C"121.out1" Q500 ; create fan 1 on pin 121.out2 and set its frequency
                                        M106 P1 S1 H1 T45 ; set fan 1 value. Thermostatic control is turned on

                                        ; Tools
                                        M563 P0 D0 H1 F0 ; define tool 0
                                        G10 P0 X0 Y0 Z0 ; set tool 0 axis offsets
                                        G10 P0 R0 S0 ; set initial tool 0 active and standby temperatures to 0C

                                        ; Custom settings are not defined

                                        ; Miscellaneous
                                        M501 ; load saved parameters from non-volatile memory
                                        T0 ; select first tool

                                        m122
                                        === Diagnostics ===
                                        RepRapFirmware for Duet 3 MB6HC version 3.3beta1 running on Duet 3 MB6HC v0.6 or 1.0 (SBC mode)
                                        Board ID: 08DJM-956L2-G43S8-6JTDL-3SD6J-1S3YF
                                        Used output buffers: 1 of 40 (10 max)
                                        === RTOS ===
                                        Static ram: 148196
                                        Dynamic ram: 61484 of which 500 recycled
                                        Never used RAM 140492, free system stack 121 words
                                        Tasks: Linux(ready,143) HEAT(delaying,302) CanReceiv(notifyWait,799) CanSender(notifyWait,359) CanClock(delaying,349) TMC(notifyWait,18) MAIN(running,616) IDLE(ready,20)
                                        Owned mutexes: HTTP(MAIN)
                                        === Platform ===
                                        Last reset 00:13:58 ago, cause: power up
                                        Last software reset at 2021-03-05 23:49, reason: User, none spinning, available RAM 140492, slot 0
                                        Software reset code 0x0012 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0440f000 BFAR 0x00000000 SP 0x00000000 Task Linu Freestk 0 n/a
                                        Error status: 0x00
                                        Aux0 errors 0,0,0
                                        Aux1 errors 0,0,0
                                        MCU temperature: min 28.9, current 51.2, max 51.3
                                        Supply voltage: min 27.9, current 30.0, max 30.2, under voltage events: 0, over voltage events: 0, power good: yes
                                        12V rail voltage: min 12.1, current 12.1, max 12.1, under voltage events: 0
                                        Driver 0: position 0, standstill, reads 48788, writes 31 timeouts 0, SG min/max 0/271
                                        Driver 1: position 0, standstill, reads 48788, writes 31 timeouts 0, SG min/max 0/505
                                        Driver 2: position 22080, standstill, reads 48784, writes 35 timeouts 0, SG min/max 0/263
                                        Driver 3: position 0, standstill, reads 48784, writes 35 timeouts 0, SG min/max 0/277
                                        Driver 4: position 0, standstill, reads 48785, writes 35 timeouts 0, SG min/max 0/259
                                        Driver 5: position 0, standstill, reads 48785, writes 35 timeouts 0, SG min/max 0/201
                                        Date/time: 2021-03-08 15:16:32
                                        Slowest loop: 171.53ms; fastest: 0.03ms
                                        === Storage ===
                                        Free file entries: 10
                                        SD card 0 not detected, interface speed: 37.5MBytes/sec
                                        SD card longest read time 0.0ms, write time 0.0ms, max retries 0
                                        === Move ===
                                        DMs created 125, maxWait 180288ms, bed compensation in use: none, comp offset 0.000
                                        === MainDDARing ===
                                        Scheduled moves 448, completed moves 448, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 15], CDDA state -1
                                        === AuxDDARing ===
                                        Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
                                        === Heat ===
                                        Bed heaters = 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamberHeaters = -1 -1 -1 -1
                                        === GCodes ===
                                        Segments left: 0
                                        Movement lock held by null
                                        HTTP* is doing "M122" in state(s) 0
                                        Telnet is idle in state(s) 0
                                        File* is idle 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
                                        SBC is idle in state(s) 0
                                        Daemon is idle in state(s) 0 0, running macro
                                        Aux2 is idle in state(s) 0
                                        Autopause is idle in state(s) 0
                                        Code queue is empty.
                                        === CAN ===
                                        Messages queued 8761, send timeouts 26, received 9733, lost 0, longest wait 2ms for reply type 6049, peak Tx sync delay 57602, free buffers 49 (min 47)
                                        === SBC interface ===
                                        State: 4, failed transfers: 0
                                        Last transfer: 1ms ago
                                        RX/TX seq numbers: 29686/29686
                                        SPI underruns 0, overruns 0
                                        Number of disconnects: 0, IAP RAM available 0x2d410
                                        Buffer RX/TX: 0/0-0
                                        === Duet Control Server ===
                                        Duet Control Server v3.2.0
                                        Code buffer space: 4096
                                        Configured SPI speed: 8000000 Hz
                                        Full transfers per second: 8.35
                                        Maximum length of RX/TX data transfers: 2588/1520

                                        m122 b121
                                        Diagnostics for board 121:
                                        Duet TOOL1LC firmware version 3.3beta1 (2021-02-14 16:34:04)
                                        Bootloader ID: not available
                                        Never used RAM 3976, free system stack 0 words
                                        Tasks: Move(notifyWait,90) HEAT(delaying,91) CanAsync(notifyWait,67) CanRecv(notifyWait,75) CanClock(notifyWait,67) TMC(delaying,56) MAIN(running,252) AIN(delaying,63)
                                        Last reset 00:14:41 ago, cause: power up
                                        Last software reset data not available
                                        Driver 0: position 34448, 426.0 steps/mm, standstill, SG min/max 0/282, read errors 0, write errors 0, ifcnt 20, reads 47135, writes 20, timeouts 0, DMA errors 0, steps req 81994 done 81994
                                        Moves scheduled 1234, completed 1234, in progress 0, hiccups 0, step errors 0, maxPrep 532, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
                                        Peak sync jitter 9, peak Rx sync delay 610, resyncs 1, no step interrupt scheduled
                                        VIN: 29.9V
                                        MCU temperature: min 25.8C, current 37.0C, max 42.1C
                                        Ticks since heat task active 249, ADC conversions started 878201, completed 878201, timed out 0
                                        Last sensors broadcast 0x00000002 found 1 5 ticks ago, loop time 0
                                        CAN messages queued 10272, send timeouts 0, received 9157, lost 0, free buffers 36, min 35, error reg 0
                                        dup 0, oos 0, bm 0, wbm 0

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                                        • undefined
                                          dc42 administrators
                                          last edited by dc42 3 Aug 2021, 16:13 8 Mar 2021, 16:13

                                          If it's an intermittent issue, then the most likely causes are:

                                          • Bad crimp connection in the motor cable. Are you using the same cable as before?
                                          • Bad solder joint between the driver chip and the PCB. Axz the pads of the driver under underneath the chip, it's impossible to tell whether the soldering is good on all pads other than by X-ray; although if you can look at the edges of the chip using microscope, you might get a clue.
                                          • Bad solder joint between the motor connector and the PCB. Unlikely, but not impossible.

                                          Duet WiFi hardware designer and firmware engineer
                                          Please do not ask me for Duet support via PM or email, use the forum
                                          http://www.escher3d.com, https://miscsolutions.wordpress.com

                                          undefined 1 Reply Last reply 8 Mar 2021, 17:57 Reply Quote 0
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