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

[hamel]

@dc42 I just installed a new toolboard with updated firmware. I have the exact same symptoms, which are:

Extrudes fine with DWC
Extruder drive just jitters and does not turn when printing gcode
If I pause, I am able to extrude just fine, but again fails to extrude when resumed
I am using the same firmware, config.g, and gcode as posted before
I have put a DMM on all connections, and they pass the wiggle test
I have tried in SBC and standalone. I am back to SBC now.

Has tons of torque when commanding from DWC, but no torque when printing (I have tried a free motor with no load, and it will not even turn when printing). I do not see any gcode issue, and I think my config.g is set up correctly (could you please double check it?). My drive settings are similar to what others are using on the same extruder.

[hamel]

Any idea as to what my next step in troubleshooting this would be? I have played with config.g drive settings some more, but nothing seems to change the behavior.

[Phaedrux]

sorry about that delay.

Can you confirm that the newly received tool board has been updated with matching firmware for the main board?

[hamel]

No worries. I know it only takes a day to have tons of new posts to look through.

Yes, I can confirm that they are both running 3.3 beta2.

m115 b121
Duet TOOL1LC firmware version 3.3beta2 (2021-03-10 10:06:22)

m115
FIRMWARE_NAME: RepRapFirmware for Duet 3 MB6HC FIRMWARE_VERSION: 3.3beta2 ELECTRONICS: Duet 3 MB6HC v0.6 or 1.0 FIRMWARE_DATE: 2021-03-10 13:39:39

[Phaedrux]

Thanks. Hopefully DC42 will have some time to take a look soon.

[dc42]

Hi @hamel, I'm sorry to hear that you are still having problems.

1. Is your config.g file still the same as when you posted it in this thread on 8 March?
2. Please post your config.override.g file.
3. Please provide a sample GCode file that hows this problem. I will try running it on my bench system using your config files.

[hamel]

@dc42 Here are my files and some gcode I am running:

; Configuration file for Duet 3 (firmware version 3.3Beta2)
; 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 S2 ;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 backwards
M569 P0.4 S0 ; physical drive 0.2 goes backwards
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 E500.00 ; set maximum instantaneous speed changes (mm/min)
M203 X10000.00 Y10000.00 Z8000.00 E10000.00 ; set maximum speeds (mm/min)
M201 X3000.00 Y3000.00 Z200.00 E500.00 ; set accelerations (mm/s^2)
M906 X1100 Y1100 Z1000 E850 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" H10 F600 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 B4725 C7.06e-8 ; 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 150C
M308 S1 P"121.temp0" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin 121.temp0
M950 H1 C"nil" ; free up H1
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" ; free up F0
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

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

config-override.g
; Heater model parameters
M307 H0 R0.995 C146.5 D3.59 S1.00 V30.3
M307 H1 R7.632 C173.800:173.800 D11.40 S0.4 V28.4 B0
; Workplace coordinates
G10 L2 P1 X0.00 Y0.00 Z0.00
G10 L2 P2 X0.00 Y0.00 Z0.00
G10 L2 P3 X0.00 Y0.00 Z0.00
G10 L2 P4 X0.00 Y0.00 Z0.00
G10 L2 P5 X0.00 Y0.00 Z0.00
G10 L2 P6 X0.00 Y0.00 Z0.00
G10 L2 P7 X0.00 Y0.00 Z0.00
G10 L2 P8 X0.00 Y0.00 Z0.00
G10 L2 P9 X0.00 Y0.00 Z0.00

Gcode file:
https://drive.google.com/file/d/1arUmgvHX2YdvrwHeZu3cwaWV2b-UkRiP/view?usp=sharing

Gcode snip:

;FLAVOR:RepRap
;TIME:3785
;Filament used: 4.39049m
;Layer height: 0.2
;MINX:-19.925
;MINY:-19.926
;MINZ:0.2
;MAXX:19.925
;MAXY:19.926
;MAXZ:30.5
;Generated with Cura_SteamEngine 4.8.0
T0
M190 S80
M104 S260
M109 S260
M82 ;absolute extrusion mode
print_start
T0
G28
M83 ;relative extrusion mode
G1 F3600 E-6.5
;LAYER_COUNT:150
;LAYER:0
M107
G1 F600 Z0.7
G0 F7200 X-19.925 Y-8.452 Z0.7
;TYPE:SKIRT
G1 F600 Z0.2
G1 F1440 E6.5
G1 F1500 X-19.915 Y-9.157 E0.02638
G1 X-19.867 Y-9.789 E0.02372
G1 X-19.739 Y-10.41 E0.02372
G1 X-19.533 Y-11.009 E0.0237
G1 X-19.254 Y-11.578 E0.02371
G1 X-18.906 Y-12.108 E0.02372
G1 X-18.58 Y-12.499 E0.01905
G1 X-18.444 Y-12.646 E0.00749
G1 X-18.165 Y-12.933 E0.01498
G1 X-13.073 Y-18.025 E0.26945
G1 X-12.588 Y-18.496 E0.0253
G1 X-12.106 Y-18.908 E0.02373
G1 X-11.577 Y-19.256 E0.02369
G1 X-11.007 Y-19.535 E0.02375
G1 X-10.408 Y-19.739 E0.02368
G1 X-9.787 Y-19.867 E0.02372
G1 X-9.257 Y-19.913 E0.01991
G1 X-9 Y-19.921 E0.00962
G1 X-8.53 Y-19.926 E0.01759
G1 X8.458 Y-19.924 E0.63565
G1 X9.158 Y-19.914 E0.0262
G1 X9.79 Y-19.865 E0.02372
G1 X10.41 Y-19.737 E0.02369
G1 X11.01 Y-19.532 E0.02372
G1 X11.579 Y-19.253 E0.02371
G1 X12.108 Y-18.905 E0.02369
G1 X12.512 Y-18.566 E0.01973
G1 X12.729 Y-18.362 E0.01114
G1 X12.942 Y-18.154 E0.01114
G1 X18.027 Y-13.068 E0.26911
G1 X18.498 Y-12.582 E0.02532
G1 X18.91 Y-12.1 E0.02373
G1 X19.257 Y-11.57 E0.0237
G1 X19.535 Y-11.001 E0.0237
G1 X19.74 Y-10.401 E0.02372
G1 X19.867 Y-9.78 E0.02372
G1 X19.912 Y-9.254 E0.01975
G1 X19.92 Y-8.997 E0.00962
G1 X19.925 Y-8.588 E0.0153
G1 X19.924 Y8.455 E0.63771
G1 X19.914 Y9.157 E0.02627
G1 X19.866 Y9.788 E0.02368
G1 X19.737 Y10.409 E0.02373
G1 X19.532 Y11.009 E0.02372
G1 X19.253 Y11.578 E0.02371
G1 X18.905 Y12.107 E0.02369
G1 X18.581 Y12.495 E0.01891
G1 X18.357 Y12.734 E0.01226
G1 X18.074 Y13.022 E0.01511
G1 X13.091 Y18.007 E0.26374
G1 X12.582 Y18.5 E0.02651
G1 X12.1 Y18.912 E0.02373
G1 X11.57 Y19.259 E0.0237
G1 X11 Y19.537 E0.02373
G1 X10.4 Y19.741 E0.02371
G1 X9.779 Y19.868 E0.02372
G1 X9.273 Y19.913 E0.01901
G1 X8.978 Y19.922 E0.01104
G1 X8.544 Y19.926 E0.01624
G1 X-8.462 Y19.924 E0.63632
G1 X-9.127 Y19.914 E0.02489
G1 X-9.758 Y19.865 E0.02368
G1 X-10.379 Y19.736 E0.02373
G1 X-10.978 Y19.531 E0.02369
G1 X-11.547 Y19.251 E0.02373
G1 X-12.042 Y18.928 E0.02212
G1 X-12.231 Y18.787 E0.00882
G1 X-12.745 Y18.347 E0.02532
G1 X-12.987 Y18.11 E0.01267
G1 X-18.031 Y13.065 E0.26694
G1 X-18.502 Y12.578 E0.02535
G1 X-18.913 Y12.096 E0.0237
G1 X-19.26 Y11.566 E0.0237
G1 X-19.537 Y10.996 E0.02371
G1 X-19.741 Y10.396 E0.02371
G1 X-19.867 Y9.775 E0.02371
G1 X-19.912 Y9.255 E0.01953

[hamel]

I have just confirmed that this is not extruding, but I did have one instance of it extruding with gcode until I paused for less than 5 seconds, and then it reverted back to the same behaviour of not extruding upon resuming the print. I have tried 20 times since, and all attempts do not extrude. I can still extrude just fine with DWC at very high rates, I have tested extrusion with all wires being tugged and wiggled, and I have tried 3 different motors and motor cables, all showing no change.

[dc42]

Thanks, I'll try that file on my Tool Changer, which uses tool boards.

[hamel]

Thank you @dc42 . Just as a note, I do not have to reboot to get a good print going (when it does happen). I just cancel and restart over and over, and after a few tries it will start working correctly. When it does not extrude, I can still pause and extrude fine, but it will only extrude with gcode when I do multiple "restart print"s.

[dc42]

@hamel, thanks. The firmware I will be using for this test is at https://www.dropbox.com/sh/6203euyyobllic5/AABTHIbn7F_maK9p-oy7vq3Ea?dl=0. It's later than 3.3beta2 but I am not aware of any changes that are likely to affect this behaviour.

I note that your M122 B121 reports say that the VIN voltage to the tool board is about 30V. Is that correct?

[dc42]

I am running your print for the first time, and it is printing OK. However, I am running in standalone mode because the machine doesn't have an attached SBC.

It occurred to me that one possible explanation is that fort reasons unknown, the GCode input channel for the print form file has somehow switched to absolute extrusion. This would account for why you are still able to extrude form DWC, and also for why restarting the print sometimes clears the problem (because your GCode file includes the M83 command).

Therefore, please can you provoke the problem, then pause the print, then use the Object Model explorer plugin in DWC to examine the 'inputs' key. Element number 2 in this list should look something like this:


[Sorry, upload failed, I need to switch browser - I will post the image shortly.]

[Sorry again, I can't login at all from FireFox at present.]

What I expect is that inputs[2] shows name="File" and drivesRelative="true".

[hamel]

@dc42 Thank you. I think you might be on to something.

When it is extruding fine, and when it is not extruding, the input2 name is file, but the drivesRelative is always false (when extruding correctly or when not extruding). Sending m83 or m82 does not change the print or the issue. If I send a m82, I should see that object model change to a drivesRelative=true, and with an m83 I should see it change to a drivesRelative=false. Is that correct? That is not the behaviour I am seeing. I see no change in the object model values.

[dc42]

The drivesRelative value is maintained separately for each input channel. So sending M83 from the DWC console channel won't affect the File channel.

[dc42]

The print I did completed perfectly; but I am running in standalone mode. So my suspicion is that in SBC mode, the M83 command at line 22 of your GCode file is not being executed. My suggestions are:

1. Line 19 of the GCode file reads:

print_start

That is not a valid command. Perhaps it is confusing DSF? Please remove it, or add a leading semicolon to turn it into a comment.

2. Try running the Duet in standalone mode, to see if the problem ever occurs when not using SBC.

[hamel]

@dc42 Will do. It is a pretty long task to switch to standalone, so I will try to get that done next week. I have to get our IT department to set up the network (huge pain...I have to do it for anything connected, and I am not running a panel). I'll give standalone a shot next week and report back.

As far as the gcode goes, that was what Cura output, and it seems that it does that for all of my slices (for any printer). I commented it out and ran a test, and there was no change (extruder did not turn when printing).

Are there any tricks that will let me keep it in SBC mode and test? If so, I can try to run the tests over the weekend.

[dc42]

If connecting the Duet directly to the network is problematic, can you copy the print file to the SD card before you insert it into the Duet, and then start the print from a laptop connected to the Duet either via USB or directly using an Ethernet cable?

[hamel]

Brilliant. I will do that tomorrow. Thank you.

[hamel]

@dc42

Just wanted to let you know that in standalone mode I have a print running just fine. So it does seem to be an issue with SBC mode. Thoughts?

[T3P3Tony]

@hamel thanks for the report. I have run your print on a SBC connected Duet3 mainboard with a toolboard and it is also running fine. In this case I am using the following firmware versions:
Mainboard
FIRMWARE_NAME: RepRapFirmware for Duet 3 MB6HC FIRMWARE_VERSION: 3.3beta2+1 ELECTRONICS: Duet 3 MB6HC v0.6 or 1.0 FIRMWARE_DATE: 2021-03-22 13:48:32
Toolboard
Duet TOOL1LC firmware version 3.3beta2+1 (2021-03-20 14:03:00)
DSF
DSF Version: 3.3-b2

@dc42 will need to confirm if its worth you upgrading to those unofficial firmware versions to test., I am using them to test something unrelated to your issue.

Btw in order to make your print run on my machine I had to make the following changes to the start gcode in your print file:

T2
;M190 S80
;M104 S260
;M109 S260
M82 ;absolute extrusion mode
;print_start
T2
;G28
M83 ;relative extrusion mode
G1 F3600 E-2
;LAYER_COUNT:150
;LAYER:0
M107
G1 F600 Z0.7
G0 F7200 X-19.925 Y-8.452 Z0.7
;TYPE:SKIRT
G1 F600 Z0.2
G1 F1440 E2
G1 F1500 X-19.915 Y-9.157 E0.02638
G1 X-19.867 Y-9.789 E0.02372

I can't see how commenting out the temperature settings and homing should have anything todo with your issue though.

Also due to different extruders I changed the retract/unretract distance from 6.5mm to 2mm but once again that should not be related to this issue.