Printer acting weird for no apparent reason...
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Hi everyone,
Recently(ish), for no apparent reason, my printer seem to be hunted and act randomly... I never ever had such problem before. It started to do that last year by randomly doing random stuff here and there, but it wasn't very often and I believed it was related to some glitch introduced by the different processes, slicing, ethernet connexion packet, or anything I just don't know what could do that... A few month back, it happened 25% of the time... I tried to found the problem, without success, so I decided to put the printer aside and search a bit more before using it again. I decided to give it a try recently, because you know, having a printer sitting there doing nothing is just a nonsense to be, so yeah, I started to model and print again... But, and it get worst... For now, 50% of the time, the printer now act randomly... It throw me heating error for no reason(it just stop reading the thermistor)then start again(Yes I recalibrated the PID so many time, changed the thermistor, even the wiring)... Or, when I pause/cancel a print and try to home, one of the motor may randomly stop and since I have a quite tall delta printer, it cause the effector to move very far from the bed radius and snap the magball or hit the box wall or any unwanted s**t that could break. An other one is the random inaccuracy of the babystep. Sometime it is considered, sometime it is not, sometime the nozzle will crashed in the bed. (It didn't do that before last year, but since last year, I normally have to set -0.05 to -0.1 on baby step to have a proper bed adhesion) It's like after the auto calibration, the printer set itself short... But as I said, randomly, it use the proper height(the real one) and it caused to crash in the bed(-0.05 to -0.1mm)...
I'm using the same slicer as before, nothing had changed anywhere, same computer... But the printer just started to act weirdly. I'm seriously out of ideas... It ALL started to happen last year, about a year after I acquired all the Duet hardware I'm using and it just get worst overtime, slowly... Now I don't even dare to leave the printer for 5 minutes...
Here my info:
M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 3.3 (2021-06-15 21:44:54) running on Duet Ethernet 1.02 or later
Board ID: 0JD0M-9P6B2-NJ4S8-6J1FJ-3SJ6L-T84LK
Used output buffers: 1 of 24 (13 max)
=== RTOS ===
Static ram: 23876
Dynamic ram: 70020 of which 0 recycled
Never used RAM 20520, free system stack 116 words
Tasks: NETWORK(ready,28.7%,233) HEAT(delaying,0.0%,330) Move(notifyWait,0.1%,303) MAIN(running,70.9%,420) IDLE(ready,0.2%,29), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:07:37 ago, cause: software
Last software reset at 2022-06-13 15:52, reason: User, GCodes spinning, available RAM 20520, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0041f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
Step timer max interval 0
MCU temperature: min 34.6, current 34.7, max 35.5
Supply voltage: min 11.8, current 12.2, max 12.3, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Driver 0: position 52885, standstill, SG min/max 0/393
Driver 1: position 52885, standstill, SG min/max 0/377
Driver 2: position 52885, standstill, SG min/max 0/1023
Driver 3: position 0, standstill, SG min/max 0/621
Driver 4: position 0, standstill, SG min/max not available
Driver 5: position 0
Driver 6: position 0
Driver 7: position 0
Driver 8: position 0
Driver 9: position 0
Driver 10: position 0
Driver 11: position 0
Date/time: 2022-06-13 16:00:12
Cache data hit count 4294967295
Slowest loop: 136.17ms; fastest: 0.12ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest read time 3.9ms, write time 4.6ms, max retries 0
=== Move ===
DMs created 83, maxWait 41115ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 237, completed moves 237, 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, chamberHeaters = -1 -1 -1 -1
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.2
=== 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
Daemon is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty.
=== Network ===
Slowest loop: 140.37ms; fastest: 0.02ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8
Interface state active, link 100Mbps full duplex -
Can you share your config.g as well?
If you're coming back to a delta after a while it may be a good idea to take a look through these guides to get everything right.
https://docs.duet3d.com/en/User_manual/Machine_configuration/Configuration_linear_delta
https://docs.duet3d.com/en/User_manual/Tuning/Delta_calibration
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Also, my bowden is around 210mm long, straight... and the pressure advance need to be set way out of the parameters suggested in the instruction provided on duet3d.
The Bowden setup is made from a PTFE tube and a BMG clone, suspended by a gt2 strap. There is no bent or curvature on the PTFE...
Before it start acting crazy, I normally used (as you can see in the config file) a way lower step/mm for the extruder...
But I now have to use a way higher e-step/mm, otherwise, I'm under-extruding.
I have absolutely no clue what is suddenly happening to my printer. I worked on machine for more than 10 years of my life as an electro-technician of automated system and built myself 2 delta printer and never had this kind of randomized/weird behavior from a machine. I know it's not the case, but I felt like I was working with the machine and someone was reprogramming it every night...
I'm clueless and I ran out of expertise.
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After you go through the delta guides, can you itemize your remaining issues one at a time?
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@phaedrux Sorry for the delay...
I did all the verification/calibration except one and everything is mostly the same. The only problem remaining (I had it before) is that when I calibrate the nozzle heater as a tool, the cooling fan never turn on. The walk around I used last year was to manually start the cooling fan during the PID calibration.
Known issue with cooling fan: 60% is the real maximum speed. From standstill jump to 100%, the fan just don't kick-in... From standstill jump to 60%, the fan will kick-in... If the fan is running already, it will increase in speed until around 60%(like it should do), then the higher I go(passed the 60% limit), the slower it get... At 100%, it's like being at around 20%-25%? (hard to tell, but it's definitely slower). If I jump from anything lower than 80% to 100%, the fan will stop spinning(I didn't test higher than 85%)... The only way to reach 100%, is to slowly increase, wait a bit, and repeat... Maybe that's the reason why the fan never spin during the PID sequence ?
For info: I connected 2x 3031 5v fan in parallel.
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Sounds like the 2 fans in parallel aren't responding to the PWM signal very well. This is to be expected. You can try increasing the PWM frequency, but that may reduce the speed range as well. Worth trying though.
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I tried 800, 700, 600, they all are worst... 550 just get slightly better with a peak at 65%, but the fan stop passed 90% and the second serie I tested is at 450, 430, 480, 470 the fan try to kick-in if I jump from 0% to 100% but the fan just "wiggle" a bit and stop after 2 sec. Also, the fan power is way weaker at any level... but it will kick-in if I jump from standstill to 99%... not at 100%...
What are the frequency range I can work with without damaging the fan or the motherboard ?
-EDIT- I also tested 525 and get the highest peak at 60%, with the same symptoms... from 0 to 99%, the fan kick-in but is weak... from 0-100% it just "wiggle".
-EDIT 2- I also tested 1000 and beside having a fan blowing even harder on the whole spectrum until 60-65%, I have the same behavior overall. At 1% we clearly hear the high pitch frequency noise from the fan. The noise is lesser the closer to 60-65% I get... passed 70% we clearly hear the bearing rattling... passed 80% the performance drop significantly... at 0-100% the fan wiggle again, but wont kick-in and at 0-99% is will start but the air flow is weaker as usual...
Did the same test at 2000Hz... same result but a slightly higher flow between 0 to 60-65%, weaker flow passed 70-75%, the bearing rattle is stronger and the initial high pitch sound is slightly stronger...
I guess that if I keep raising the Hz, I'll just damage/destroy the fans...
So what is my solution?
Is there a way to set the maximum fan speed to 60% for the PID calibration?
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Do the fans have a large impact on maintaining a steady temperature? If not, you can tune as a heater rather than tool. If it does have a large impact you can try and aim the fans better and add a silicone sock to help stop the drop. Or you can just set the fan speed manually and tune as a heater and get most of the effect as tuning as a tool.
