Z motor stalled on "long" retracts

[Phaedrux]

Thanks for the video, it does show it a lot better. Very strange.

Can you capture and post the results of M122 and M122 B20 after you've caused the problem to happen?

Can you also try adding a G4 S4 near the start of your config.g?

Couple other things I noticed, but probably unrelated.

M201 X400.00 Y400.00 Z100.00 E10000.00 ; set accelerations (mm/s^2) The E accel of 10000 is maybe a bit extreme. Try reducing that to 3000.

@p8blr said in Z motor stalled on "long" retracts:

; Miscellaneous M575 P1 S1 B57600 ; enable support for PanelDue

If you move that to the start of config.g the paneldue will be enabled sooner in the startup process.

@p8blr said in Z motor stalled on "long" retracts:

; Mesh Leveling G29 S1 ;load mesh leveling and activate compensation

Best not to load the mesh in config.g. It's better to either put it in the slicer start gcode after the axis have been homed.

And finally, it looks like you've got simplify3d set to use absolute extrusion. I would suggest you switch to relative extrusion.

[p8blr]

@phaedrux

Thank you for the suggestions. I have made the necessary changes to Simplify3D and config.g

New config.g:

; Configuration file for Duet 3 (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.2.3 on Mon Jul 26 2021 12:02:50 GMT-0500 (Central Daylight Time)

; Miscellaneous
M575 P1 S1 B57600 ; enable support for PanelDue

G4 S4 ;dwell

; General preferences
G90 ; send absolute coordinates...
M83 ; ...but relative extruder moves
M550 P"TXT Stacker 2" ; set printer name

; Network
M552 P0.0.0.0 S1 ; enable network and acquire dynamic address via DHCP
M586 P0 S1 ; enable HTTP
M586 P1 S0 ; disable FTP
M586 P2 S0 ; disable Telnet

; Drives
M569 P0.0 S1 ; physical drive 0.0 goes forwards
M569 P0.1 S1 ; physical drive 0.1 goes forwards
M569 P0.2 S0 ; physical drive 0.2 goes backwards
M569 P20.0 S1 ; physical drive 20.0 goes forwards
M584 X0.0 Y0.1 Z0.2 E20.0 ; set drive mapping
M350 X16 Y32 Z16 E16 I1 ; configure microstepping with interpolation
M92 X72.85 Y146.59 Z1600 E400.00 ; set steps per mm
M566 X900.00 Y900.00 Z18.00 E600.00 ; set maximum instantaneous speed changes (mm/min)
M203 X12000.00 Y12000.00 Z600.00 E1200.00 ; set maximum speeds (mm/min)
M201 X400.00 Y400.00 Z100.00 E3000.00 ; set accelerations (mm/s^2) was z50
M906 X1000 Y1000 Z1000 E450 I30 ; set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

; Axis Limits
M208 X0 Y-45 Z-2 S1 ; set axis minima
M208 X490 Y330 Z645 S0 ; set axis maxima

; Endstops
M574 X1 S1 P"!io1.in" ; configure active-low endstop for low end on X via pin io0.in with pullup resistor
;M574 X2 S1 P"!io3.in" ; configure active-low endstop for low end on X via pin io0.in with pullup resistor
M574 Y1 S1 P"!io2.in" ; configure active-low endstop for low end on Y via pin io1.in with pullup resistor
;M574 Y2 S1 P"!io4.in" ; configure active-low endstop for high end on Y via pin io1.in with pullup resistor
M574 Z1 S2.2 ; configure Z-probe endstop for low end on Z

; Z-Probe
M558 P8 C"20.io0.in" H5 F600 T6000 ; set Z probe type to switch and the dive height + speeds
G31 P500 X0 Y21.2 Z.94 ; set Z probe trigger value, offset and trigger height
M557 X0:490 Y10:335 P10:7 ; define mesh grid

; 3-point Bed leveling
; Z probe has a Y offset ot 21.1mm
; back left (72,330)
; back right (400,330)
; front middle (236,75)
; thread pitch M4 X 0.7mm
M671 X72:400:236 Y330:330:75 P0.7

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4138 ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0 ; create bed heater output on out0 and map it to sensor 0
M307 H0 B0 R0.160 C880.7 D2.62 S1.00 V23.7 ; disable bang-bang mode for the bed heater and set PWM limit
M140 H0 ; map heated bed to heater 0
M143 H0 S120 ; set temperature limit for heater 0 to 120C
M308 S1 P"20.temp0" Y"thermistor" T100000 B4680 C6.455513e-8 ; configure sensor 1 as thermistor on pin 20.temp0
M950 H1 C"20.out0" T1 ; create nozzle heater output on 20.out0 and map it to sensor 1
M307 H1 B0 R2.925 C170.4 D6.59 S1.00 V23.5 ; disable bang-bang mode for heater and set PWM limit
M143 H1 S450 ; set temperature limit for heater 1 to 450C

; Fans
M950 F0 C"20.out1" Q500 ; create fan 0 on pin 20.out1 and set its frequency
M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"20.out2" Q500 ; create fan 1 on pin 20.out2 and set its frequency
M106 P1 S1 H1 T45 ; set fan 1 value. Thermostatic control is turned on
M950 F2 C"out7" Q500 ; create fan 2 on pin out7 and set its frequency (for LED)
M106 P2 S0 H-1 C"LED" ; set fan 2 value. Thermostatic control is turned off

; Tools
M563 P0 S"Main Tool" 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

T0 ;select tool 0

M122 after causing the error:

8/17/2021, 3:59:20 PM M122
=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.3 (2021-06-15 21:45:47) running on Duet 3 MB6HC v1.01 or later (standalone mode)
Board ID: 08DJM-9P63L-DJ3S0-7JKDJ-3SJ6T-T8M7B
Used output buffers: 3 of 40 (13 max)
=== RTOS ===
Static ram: 150904
Dynamic ram: 92144 of which 12 recycled
Never used RAM 111132, free system stack 142 words
Tasks: NETWORK(ready,28.8%,212) ETHERNET(notifyWait,0.1%,117) HEAT(delaying,0.0%,325) Move(notifyWait,0.0%,265) CanReceiv(notifyWait,0.0%,799) CanSender(notifyWait,0.0%,374) CanClock(delaying,0.0%,339) TMC(notifyWait,7.7%,93) MAIN(running,63.2%,1096) IDLE(ready,0.1%,29), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:02:41 ago, cause: software
Last software reset at 2021-08-17 15:56, reason: User, GCodes spinning, available RAM 108276, slot 1
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044a000 BFAR 0x00000000 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
Step timer max interval 168
MCU temperature: min 42.0, current 42.3, max 42.5
Supply voltage: min 23.4, current 23.5, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.2, under voltage events: 0
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Driver 0: position 17848, standstill, reads 40933, writes 17 timeouts 0, SG min/max 0/269
Driver 1: position 21080, standstill, reads 40933, writes 17 timeouts 0, SG min/max 0/363
Driver 2: position 9504, standstill, reads 40933, writes 17 timeouts 0, SG min/max 0/435
Driver 3: position 0, standstill, reads 40939, writes 11 timeouts 0, SG min/max 0/0
Driver 4: position 0, standstill, reads 40939, writes 11 timeouts 0, SG min/max 0/0
Driver 5: position 0, standstill, reads 40940, writes 11 timeouts 0, SG min/max 0/0
Date/time: 2021-08-17 15:59:19
Slowest loop: 18.14ms; fastest: 0.05ms
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 25.0MBytes/sec
SD card longest read time 2.4ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, maxWait 99041ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 16, completed moves 16, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 1], 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 = 0.2
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Movement lock held by null
HTTP is idle 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 1471, received 1921, lost 0, longest wait 2ms for reply type 6031, peak Tx sync delay 301, free buffers 49 (min 47), ts 808/807/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 18.63ms; fastest: 0.02ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions Telnet(0), 0 sessions
HTTP sessions: 1 of 8

• Ethernet -
  State: active
  Error counts: 0 0 1 0 0
  Socket states: 5 2 2 2 2 0 0 0

M122 B20

8/17/2021, 3:59:26 PM M122 B20
Diagnostics for board 20:
Duet TOOL1LC firmware version 3.3 (2021-06-15 16:12:58)
Bootloader ID: not available
Never used RAM 3604, free system stack 2745 words
Tasks: Move(notifyWait,0.0%,127) HEAT(delaying,0.2%,115) CanAsync(notifyWait,0.0%,61) CanRecv(notifyWait,0.0%,74) CanClock(notifyWait,0.0%,65) TMC(delaying,2.9%,57) MAIN(running,92.0%,342) IDLE(ready,0.0%,41) AIN(delaying,4.9%,142), total 100.0%
Last reset 00:02:48 ago, cause: software
Last software reset data not available
Driver 0: position -320, 400.0 steps/mm, standstill, SG min/max 2/4, read errors 0, write errors 1, ifcnt 32, reads 18780, writes 12, timeouts 0, DMA errors 0, steps req 320 done 320
Moves scheduled 1, completed 1, in progress 0, hiccups 0, step errors 0, maxPrep 386, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter -1/4, peak Rx sync delay 214, resyncs 0/0, no step interrupt scheduled
VIN: 23.6V
MCU temperature: min 47.6C, current 48.7C, max 49.8C
Ticks since heat task active 192, ADC conversions started 168032, completed 168031, timed out 0, errs 0
Last sensors broadcast 0x00000002 found 1 197 ticks ago, loop time 0
CAN messages queued 2018, send timeouts 0, received 1536, lost 0, free buffers 37, min 37, error reg 110000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 297, adv 37068/37068
Accelerometer detected: no
I2C bus errors 4619, naks 4619, other errors 4619

[Phaedrux]

Any change to behaviour after those changes?

[dc42]

@p8blr do you have any tool change files? If so, please post them.

[p8blr]

@phaedrux said in Z motor stalled on "long" retracts:

Any change to behaviour after those changes?

No, unfortunately not.

@dc42 said in Z motor stalled on "long" retracts:

@p8blr do you have any tool change files? If so, please post them.

I do not.

Thanks.

[dc42]

@p8blr please can you unload the filament from your hot end and try this file, which is based on yours but uses no heater:

m308 p1 ;;dc
T-1 ;;dc
G90
M82
M106 S0
;;M300 S2637 P150
;;G4 P150
;;M300 S3135 P150
;;G4 P150
;;M300 S5274 P150
;;G4 P150
;;M300 S4186 P150
;;G4 P150
;;M300 S4698 P150
;;G4 P150
;;M300 S6271 P150 ;1-UP
;;dc M104 T0 S230 ; Turn on hotend
;;dc M140 S80 ;turn on bed
M106 P2 S127 ;leds on
G28 ;home axes
G1 X0 Y-10 F5000 ;move to purge location
;;dc M109 T0 S230 ; Wait for hotend to get to temp
;;dc M190 S80 ;wait for bed to get to temp
;;M300 S440 P200 ;music
;;G4 P200
;;M300 S660 P250
;;G4 P250
;;M300 S880 P300
G4 P300
G92 E0 ;zero extruder
;dc G1 E50 F300 ;purge
G1 E5 F300 ;purge
G92 E0 ;zero extruder
;dc G4 P10000 ; wait 10s
G4 P1000
M572 D0 S0.16 ;Pressure Advance
; process Process1
; layer 1, Z = 0.200
T0
G92 E0.0000
G1 E-0.8000 F3600
; feature skirt
; tool H0.200 W0.720
G1 Z0.200 F2400
G1 X242.640 Y180.522 F9000
G1 E0.0000 F3600
G92 E0.0000
G1 X244.022 Y179.140 E0.1121 F1500
G1 X265.978 Y179.140 E1.3705
G1 X267.360 Y180.522 E1.4826
G1 X267.360 Y202.478 E2.7410
G1 X265.978 Y203.860 E2.8531
G1 X244.022 Y203.860 E4.1116
G1 X242.640 Y202.478 E4.2236
G1 X242.640 Y180.522 E5.4821
G92 E0.0000
G1 E-0.8000 F3600
; feature inner perimeter
G1 X245.360 Y181.860 F9000
G1 X245.360 Y182.339
G1 X246.800 Y183.300
G1 E0.0000 F3600
G92 E0.0000
G1 X263.200 Y183.300 E0.9400 F1238
G1 X263.200 Y199.700 E1.8801
G1 X246.800 Y199.700 E2.8201
G1 X246.800 Y183.300 E3.7602
G92 E0.0000
G1 E-0.8000 F3600
G1 X246.080 Y182.580 F9000
G1 E0.0000 F3600

If that still causes the problem on your machine, then we can try removing lines.

[p8blr]

@dc42 I tried your code and it is still stalling the Z motor.

I tried commenting things out one at a time and discovered getting rid of two of the G92s stops the Z motor from stalling.

But it's so weird because the G92s can be in there if the retraction amount is just right.
(from earlier post)
.97mm and up works
.96mm to .72mm stalls
.71mm and below works

By the way, in relative mode (M83) are G92 E0 ever necessary?

m308 p1 ;;dc
T-1 ;;dc
G90
M82
M106 S0
M106 P2 S127 ;leds on
G28 ;home axes
T0
G1 X0 Y-10 F9000 ;move to purge location
G4 P300
;G92 E0 ;zero extruder
G1 E5 F300 ;purge
;G92 E0 ;zero extruder
G4 P1000
M572 D0 S0.16 ;Pressure Advance
;G92 E0.0000
G1 E-0.8000 F3600
G1 Z0.200 F2400
G1 X242.640 Y180.522 F9000
G1 E0.0000 F3600
G92 E0.0000
G1 X244.022 Y179.140 E0.1121 F1500
G1 X265.978 Y179.140 E1.3705
G1 X267.360 Y180.522 E1.4826
G1 X267.360 Y202.478 E2.7410
G1 X265.978 Y203.860 E2.8531
G1 X244.022 Y203.860 E4.1116
G1 X242.640 Y202.478 E4.2236
G1 X242.640 Y180.522 E5.4821
G92 E0.0000
G1 E-0.8000 F3600
G1 X245.360 Y181.860 F9000
G1 X245.360 Y182.339
G1 X246.800 Y183.300
G1 E0.0000 F3600
G92 E0.0000
G1 X263.200 Y183.300 E0.9400 F1238
G1 X263.200 Y199.700 E1.8801
G1 X246.800 Y199.700 E2.8201
G1 X246.800 Y183.300 E3.7602
G92 E0.0000
G1 E-0.8000 F3600
G1 X246.080 Y182.580 F9000
G1 E0.0000 F3600

[dc42]

@p8blr please can you try the firmware build at https://www.dropbox.com/sh/cq7q3g8coymo9s3/AABtPYEzV1_unETpKEMPInSia?dl=0. Use it with caution because it has had limited testing.

[p8blr]

@dc42 "Error: M997: In-application programming binary "0:/firmware/Duet3_SDiap32_MB6HC.bin" not found" when trying to install the firmware.

[Phaedrux]

You seem to be missing some files. Please upload this zip file as is to the system tab in DWC.

https://github.com/Duet3D/RepRapFirmware/releases/download/3.3/Duet2and3Firmware-3.3.zip

That should get you everything you need to then update to the beta build.

[p8blr]

@phaedrux said in Z motor stalled on "long" retracts:

You seem to be missing some files. Please upload this zip file as is to the system tab in DWC.

https://github.com/Duet3D/RepRapFirmware/releases/download/3.3/Duet2and3Firmware-3.3.zip

That should get you everything you need to then update to the beta build.

Thank you, that got rid of the error.

@dc42 said in Z motor stalled on "long" retracts:

@p8blr please can you try the firmware build at https://www.dropbox.com/sh/cq7q3g8coymo9s3/AABtPYEzV1_unETpKEMPInSia?dl=0. Use it with caution because it has had limited testing.

This beta firmware resolved the issue! I will continue using the beta firmware, and keep my eye on the printer. Thanks!