Crazy Z movement on first layer

[Work Horse XL]

Hello Guys,

I have a Duet 3 board with 3HC system running 3.3 firmware. I'm having some major issues with the Z axes running into the bed when printing. It does this running Mess bed comp and with is turned off.

The Print has been working fine until now. It will be printing the first layer just great and all the sudden on the next move it's grinding the tape up. It does it with or without Z hop enabled.
Does it with multiple files and slicing software.

Voltage looks good and stable.
No binding at all, I have taking it apart several times and checked
It has two nema motors running the Z up and down.
You can run the Z 400mm up and down and it always comes to Zero. No missed steps.
I have reset the Z probe several times and it's always the same trigger height.
It did this with 3.2 firmware also.

My config has not changed but that doesn't mean I don't have something wrong.

; Configuration file for Duet 3 (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.1.4 on Wed Nov 04 2020 17:27:13 GMT-0600 (Central Standard Time)

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

; Drives
M569 P0.0 S0 ; physical drive 0.0 goes forwards
M569 P0.2 S1 ; physical drive 0.2 goes forwards
M569 P0.3 S0 ; physical drive 0.3 goes backwards
M569 P0.5 S0 ; physical drive 0.5 goes forwards
M569 P0.4 S0 ; physical drive 0.4 goes backwards
M569 P0.1 S0 ; physical drive 0.1 goes forwards
M569 P1.0 S1 ; physical drive 1.0 goes forwards
M584 X0:1 Y2 Z3:4 E5:1.0 ; assign stepper motor channels
M350 X16 Y16 Z16 E16:16 I1 ; configure microstepping with interpolation
M92 X64.05 Y64.05 Z800.00 E430:430 ; set steps per mm
M566 X300.00 Y300.00 Z204.00 E300:300 ; set maximum instantaneous speed changes (mm/min)
M203 X18000.00 Y18000.00 Z400.00 E1200:1200 ; set maximum speeds (mm/min)
M201 X700.00 Y700.00 Z400.00 E250:250 ; set accelerations (mm/s^2)
M906 X2800 Y2800 Z2000 E1200:1200 I50 ; set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z0 S1 ; set axis minima
M208 X625 Y711 Z515 S0 ; set axis maxima

; Endstops
M574 X1 S1 P"io1.in+io2.in" ; configure active-high endstop for low end on X via pin io1.in
M574 Y1 S1 P"io3.in" ; configure active-high endstop for low end on Y via pin io2.in
M574 Z1 S1 P"io4.in+io5.in" ; configure active-high endstop for low end on Z via pin io4.in

; Z-Probe
M558 P5 C"!^io7.in" H5 F520 T7200 ; set Z probe type to switch and the dive height + speeds
G31 P1000 X-5 Y-25 Z0.579 ; set Z probe trigger value, offset and trigger height
M557 X5:580 Y25:680 S40 ; define mesh grid

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4700 ; 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
;M301 H0 S1.00 P10 I0.1 D200 T0.4 W180 B30 Use PID on bed heater
M307 H0 A252.2 C635.5 D7.0 S1.0 V0.0 B0 ; enable 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"temp1" Y"thermistor" T500000 B5300 C1.19622e-7 ; configure sensor 1 as thermistor on pin temp1
M950 H1 C"out1" T1 ; create nozzle heater output on out1 and map it to sensor 1
M307 H1 A577.4 C221.2 D5.8 S1.0 V23.9 B0 ; disable bang-bang mode for heater and set PWM limit
M143 H1 S450 ; set temperature limit for heater 1 to 450C

M308 S2 P"1.temp1" Y"thermistor" T500000 B5100 C1.19622e-7 ; configure sensor 2 as thermistor on pin 1.temp1
M950 H2 C"1.out0" T2 ; create nozzle heater output on 1.out0 and map it to sensor 2
M307 H2 A577.4 C221.2 D5.8 S1.0 V23.9 B0 ; disable bang-bang mode for heater and set PWM limit
M143 H2 S450 ; set temperature limit for heater 2 to 500C

; Fans
M950 F0 C"out7" Q500 ; create fan 0 on pin out7 and set its frequency
M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off

M950 F1 C"out8" Q500 ; create fan 1 on pin out8 and set its frequency
M106 P1 S1 H1 T50 ; set fan 1 value. Thermostatic control is turned on

M950 F2 C"1.out6" Q500 ; create fan 2 on pin 1.out6 and set its frequency
M106 P2 S0 H-1 ; set fan 2 value. Thermostatic control is turned OFF

M950 F3 C"1.out7" Q500 ; create fan 3 on pin 1.out7 and set its frequency
M106 P3 S1 H1:2 T50 ; set fan 3 value. Thermostatic control is turned on

; Tools
M563 P0 S"TOOL 0 " 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

M563 P1 S"TOOL 1" D1 H2 F0 ; define tool 1
G10 P1 X0 Y25 Z0 ; set tool 1 axis offsets
G10 P1 R0 S0 ; set initial tool 1 active and standby temperatures to 0C

; Custom settings

M376 H5

; Miscellaneous
M575 P1 S1 B57600 ; enable support for PanelDue
M501 ; load saved parameters from non-volatile memory
M911 S10 R11 P"M913 X0 Y0 G91 M83 G1 Z3 E-5 F1000" ; set voltage thresholds and actions to run on power loss
M591 D0 P2 C" io6.in" S1 ; filament switch High when filament present
M591 D0
M591 D1 P2 C"1.io1.in" S1 ; filament switch High when filament present
M591 D1 ; display filament sensor parameters for extruder drive 0
T0 ; select first tool

[dc42]

@work-horse-xl there is a known issue in RRF 3.3 when the movement queue is empty, then you do a move using just a motor on a CAN-connected expansion board, followed by a move that uses motors connected to the main board. So in your case, a M400 or G4 command (or any of several other non-movement commands) followed by an extruder-only movement and then a Z motor movement could result in the Z motor movement happening at the wrong speed. The time taken by the extruder-only move would have to be within certain narrow limits for this to occur.

My investigation of this is ongoing, however it has been reported that this does not happen in firmware 3.4beta3.

See https://forum.duet3d.com/topic/24660/issues-after-prime/110, https://forum.duet3d.com/topic/24553/rrf-3-3-does-not-respect-max-accel-in-first-moves-after-tc and https://forum.duet3d.com/topic/24624/z-motor-stalled-on-long-retracts for reported instances of this issue.

[Work Horse XL]

@dc42
Thanks dc42. I will upgrade and see if it fixes it. Just so I understand this is related to the 3HC canbus board? That would explain why it's doing this. I was just running the Duet 3 board and recently added the 3HC and a second tool to the machine. Not long after that it started going down hill.

I will let you know how it works out.
Thank you

[Work Horse XL]

@dc42
When trying to upgrade to 3.4beta3 My wc keeps showing version 3.3?
Never had seen this happen. Is the files incorrect?

[Phaedrux]

Are you using an SBC as well or standalone mode?

How did you try to update to the beta?

If in standalone mode You may be missing some files needed. I suggest updating to 3.3 again first before updating to the beta.

Upload this zip file to the system tab in DWC first.

Then upload the beta firmware bin for the mainboard and expansion.
https://github.com/Duet3D/RepRapFirmware/releases/download/3.3/Duet2and3Firmware-3.3.zip

Check the versions again with M115 and M115 B# where # is the canbus address of the expansion board. Check if they are both on 3.3 and then again after the beta upload see if they have updated. If not, manually update with M997 S0 and M997 B# where # is the canbus address of the board.

[Work Horse XL]

@phaedrux
Thank you. I was able to get it updated and now I have other issues.

The Duet 3 will run in stand alone mode but will not in SBC.

I have made a fresh copy of duet pi lite and down loaded it fresh.

I keep getting DCS not started. It will run in Stand alone mode or at least it was.

Is this relate to the beta version 3.4beta?

Thank you for the help.

D

[Work Horse XL]

@phaedrux
Thank you. I was able to get it updated and now I have other issues.

The Duet 3 will run in stand alone mode but will not in SBC.

I have made a fresh copy of duet pi lite and down loaded it fresh.

I keep getting DCS not started. It will run in Stand alone mode or at least it was.

Is this relate to the beta version 3.4beta?

Thank you for the help.

D

[Phaedrux]

Ok, if you're running in SBC mode you'll need to use the unstable branch for software updates.

https://github.com/Duet3D/DuetSoftwareFramework/wiki/SBC-Setup-Guide#unstable-package-feed

[Work Horse XL]

@phaedrux
phaedrux I upgraded the firmware to 3.4 beta 3 using stand alone. So the Duet 3 and the 3HC have 3.4 beta 3 on them now.
I have done a fresh install on the sd card and updated the wpa file.
like I have always done. Now I'm not getting the DWC and just the error DCS not started. I don't know how to use the unstable branch for software updates so I have always updated the board either with usb cable or stand alone method.

Thank you

[Phaedrux]

Well to use the beta you'll need to update DCS on the Pi as well using the unstable branch as described in that link. Or just use standalone mode to test.

[Work Horse XL]

@phaedrux
Good morning phaedrux.
So I print really large files and couldn't load them on the SD card using stand alone mode. So what I did was disable all firmware related to the 3HC board. I unhooked cables and just run the single board Duet 3 using firmware 3.3 and SBC.

This thing is really crazy now. I'm running mesh bed leveling also,It does it with mesh bed level off also. This is something that has just started happening.

Now the printer worked when upgrades was made and this has just happened over the last few time of using it. It's getting worse each time I'm trying to use it. The printer runs 25 to 30 days straight most of the time.

It's so bad now when printing the purge line moving down and back it's already running into the tape on the bed. You can hear the mesh bed comp working while traveling.

Is it possible I have a bad stepper motor? Could the main driver on the Duet be bad and missing steps?

Thank you
D

[Phaedrux]

Were you able to test the 3.4 beta 3 yet?

Can you post a video of what you're describing?

[Work Horse XL]

@phaedrux

Sorry for the late reply as I have been busy and not working on the printer. I was not able to test beta version. My files are extremely larger and would not fit on the sd card in stand a lone mode. I have stripped down the machine to just one hot end trying to get it working like that with only the Main duet board with latest stable version 3.3.

I will try the next stable version when it's released. I have noticed that I am no longer having false run out of filament from my simple switch sensors now.

So I'm guessing there is also a bug in that part using can-bus boards.
I was having a lot of false triggers before. I had replaced the switches thinking they was bad when the problem is the firmware glitch it looks like.

Thank you
D

[Phaedrux]

https://duet3d.dozuki.com/Wiki/Duet_3_firmware_configuration_limitations

Check out this list of limitations for Duet 3 and canbus boards including some limits for filament sensors.

[dc42]

@work-horse-xl said in Crazy Z movement on first layer:

My files are extremely larger and would not fit on the sd card in stand a lone mode.

How large are those files?

[Work Horse XL]

@dc42 285 MB and 893 MB are the sizes.
Also the 3.3 version has a major bug in it. My printer has stopped printing twice on day 8 to 10. It's never done this with 3.2 version.

It will be printing and just go to 100% done when it was just at 70% for no reason. It's random as it doesn't stop in the same place. I'm going to load 3.2 version back on it and make sure there is nothing wrong with the file just to make sure.

D

[Work Horse XL]

@phaedrux All sensors and wiring related to the 3HC board is connected to it. The 3HC board only runs the second extruder and Hotend. I used this board because we have future plans to add more devices to the printer.

The second Hotend,Extruder,fan,temp,and second parts fan are all on the 3HC board. It is currently unplugged and just using the Duet 3 single Hotend until a fix is released to fix the crazy Z movement we are having.

Thank you for your help.
D