Errors during Auto Delta Calibration

JohnOCFII

OK, I did the following.

Power up the printer.
Connected from WebUI using Chrome on a Mac.
Homed printer (successfully)
Used the Web UI to manually move the effector
Re-Homed the printer
Used the Delta Auto Calibration button (successful)
Started to heat bed and hot-end
Selected file to print.
Once heater were ready, print began with it's delta auto calibration. Calibration failed by nozzle pressing into bed on 4th point.
I pressed Emergency stop button on UI.
At that point, log showed message about non-open file
Log then logged issues with movement before homing.
I homed the printer (to get nozzle off bed)
Then I ran M122.

This is with the IR sensor.

Thanks,

John

[[language]]
3:39:25 PMM122
=== Diagnostics ===
Used output buffers: 3 of 32 (8 max)
=== Platform ===
RepRapFirmware for Duet WiFi version 1.19.2 running on Duet WiFi 1.0
Board ID: 08DAM-999TL-MQ4S8-6JKDJ-3SJ6K-16BVW
Static ram used: 21176
Dynamic ram used: 96080
Recycled dynamic ram: 1528
Stack ram used: 1304 current, 4880 maximum
Never used ram: 7408
Last reset 00:01:26 ago, cause: software
Last software reset reason: User, spinning module GCodes, available RAM 3192 bytes (slot 4)
Software reset code 0x0003, HFSR 0x00000000, CFSR 0x00000000, ICSR 0x00400000, BFAR 0xe000ed38, SP 0xffffffff
Error status: 0
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms
MCU temperature: min 35.4, current 36.9, max 37.2
Supply voltage: min 12.3, current 12.3, max 12.5, under voltage events: 0, over voltage events: 0
Driver 0: stalled standstill
Driver 1: stalled standstill
Driver 2: stalled standstill
Driver 3: standstill
Driver 4: standstill
Date/time: 2017-11-05 15:39:24
Slowest main loop (seconds): 0.004133; fastest: 0.000034
=== Move ===
MaxReps: 3, StepErrors: 0, FreeDm: 240, MinFreeDm 234, MaxWait: 6667ms, Underruns: 0, 0
Scheduled moves: 8, completed moves: 8
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heater = 0, chamber heater = -1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Stack records: 1 allocated, 0 in use
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
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
Network state is running
WiFi module is connected to access point 
WiFi firmware version 1.19.2
WiFi MAC address a0:20:a6:16:eb:66
WiFi Vcc 3.10, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 38120
WiFi IP address 192.168.62.118
WiFi signal strength -54dBm
Reconnections 0
HTTP sessions: 1 of 8
Socket states: 2 0 0 0 0 0 0 0
Responder states: HTTP(1) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
3:38:45 PMAttempt to move the head of a Delta or SCARA printer before homing the towers
3:38:41 PMG28
Attempt to move the head of a Delta or SCARA printer before homing the towers
3:38:32 PMAttempt to move the head of a Delta or SCARA printer before homing the towers
3:38:28 PMM120
G91
G1 Z-10 F6000
M121
Attempt to move the head of a Delta or SCARA printer before homing the towers
3:38:08 PMConnection established!
3:37:58 PMM112
M999
Error: Attempt to seek on a non-open file.
3:35:55 PMM32 KMR3/R3-HEpcbmount_KMR3.gcode
File KMR3/R3-HEpcbmount_KMR3.gcode selected for printing
3:33:53 PMM140 S60
3:33:47 PMG10 P0 S210
3:33:32 PMG32
Calibrated 6 factors using 10 points, deviation before 0.192 after 0.025
3:31:32 PMConnection established!
3:31:32 PMPage Load complete!

JohnOCFII

More info.

I attempted again. Failed in the same way. It failed on a calibration point very near the edge of the glass between the X and Y towers. The LED light on the IR sensor never lights when it fails (where it lit properly on the previous points). I confirmed that the homing errors happen after the firmware restarts after the emergency stop. I attempt to home the printer, and due to the position of the effector, the X and Y carriage reach the endstops at almost exactly the same time, and well before the Z carriage. The system acts as if it is homed before the two carriages back off and wait for the third to home, then the error message appears, but the system does seem to home successfully after that.

I now also wonder if the "Error: Attempt to seek on a non-open file." is also a red-herring as it shows up after I press the Emergency STOP button in the UI.

It would seem the IR sensor stops sensing for some reason. Not sure what to try next.

Thanks,

John

Billhc83

I would move the probing points that seem to be causing problems to see if that rectifies the problem hth

JohnOCFII

@Billhc83:

I would move the probing points that seem to be causing problems to see if that rectifies the problem hth

The probing has failed in three difference places today. It is true that the last 3 failures were on the same point. I could certainly move the probe point, but since the error wasn't always in the same place, I'm not sure if that still will help.

Thanks,

John

Billhc83

Well if the light is not coming on consistently I would think it may be the wiring. Maybe a connection has come loose or possibly one of the IR LEDS has become bent and is not being read properly (this maybe only on the older IR boards I believe David has used different components on the newer ones - I may be mistaken) But this has happened to me with one that I have. I would think wiring though if it has happened in the same part of the bed multiple times - maybe wires are being pulled when reaching the edge of the bed?

dc42

@JohnOCFII:

More info.

I attempted again. Failed in the same way. It failed on a calibration point very near the edge of the glass between the X and Y towers. The LED light on the IR sensor never lights when it fails (where it lit properly on the previous points). I confirmed that the homing errors happen after the firmware restarts after the emergency stop. I attempt to home the printer, and due to the position of the effector, the X and Y carriage reach the endstops at almost exactly the same time, and well before the Z carriage.

If the IR sensor isn't triggering at that point near the edge of the bed, there are a few possibilities:

You are probing too close to the edge so that the sensitive area of the IR sensor is not completely over the bed
There is some difference in the surface of the bed at that point, causing the trigger height to decrease to a value below the height of the seor above the nozzle
Your effector it tilting significantly at that probe point due to geometrical errors, and that tilt is raising the IR sensor relative to the nozzle, so that it never gets close enough to the bed to trigger. Use a bulls-eye spirit level on the effector to check for tilt.

For the homing issue, see #5 at (edited) https://www.duet3d.com/wiki/Common_problems_and_their_solutions.

JohnOCFII

Thanks David. I will check those items. I'll also double check the wiring, as Billhc83 suggests.

As per usual, the main cause for my questioning is that it was working fine not three hours previous. I'm starting to wonder if something mechanical is causing a problem.

I'll have to get a bull-eye spirit level. Seems to be a useful item for a Delta. Anyone have suggestions?

Also - your link regarding the homing issue takes me to a note about someone with power issues. That doesn't seem like the correct link.

Thanks again,

dc42

Sorry, wrong link, should have been https://www.duet3d.com/wiki/Common_problems_and_their_solutions.

JohnOCFII

Thanks David.

Regarding the homing issue, I changed the following line:

[[language]]
G1 X265 Y265 Z265 F2400 S1

to

[[language]]
G1 X270 Y270 Z270 F2400 S1

With no change in behavior.

The printer is a T3P3 V3 Kossel Mini with Duet WiFi.

What I see happening is that this happens when the hot-end is near the edge of the build area centered (or nearly centered) between two towers. When I hit "home" all three carriages begin to rise. Two carriages rise up, hit the endstop, pause for a second, then re-approach the endstops before the third carriage makes it to its endstop. The printer DOES complete the homing routine, but before it does, the "Attempt to move the head of a Delta or SCARA printer before homing the towers" is logged to the console.

I've linked to a photo showing the position of the effector before hitting "Home" and a short video of the homing process.

https://i.imgur.com/9YJ2B2v.jpg

https://youtu.be/SjiHQ7l78TQ

Thanks,

John

dc42

I think 270 is still too small. Place the print head at the edge of the bed, opposite one of the towers. Then measure how far the carriage on that tower has to move up to trigger the endstop. You need to use a value greater than that measurement.

JohnOCFII

@dc42:

I think 270 is still too small. Place the print head at the edge of the bed, opposite one of the towers. Then measure how far the carriage on that tower has to move up to trigger the endstop. You need to use a value greater than that measurement.

Thanks for the detailed explanation. I measured max distance to be about 350. I modified the entries to be 370 and now it works as expected.

[[language]]
G1 X370 Y370 Z370 F2400 S1

Of course, re-reading what is in the Wiki is completely clear to me now.

Thanks - now I can back to troubleshooting the other issue.

John

JohnOCFII

This morning was the first chance I had to try this again.

I realized that I could run G32 from the DWC many times without issue. I ONLY had issues when running it as part of the pre-print calibration as part of a particular print I was trying to do. I regenerated the GCODE from S3D, and that GCODE ran fine, including the G32. I've done a couple of other small prints since then that also worked.

So - either this problem occurred with a bad GCODE file, or gremlins.

I'll consider this resolved.