1LC - extruder randomly stopping/reversing - ≤3.5.0-rc1

[Exerqtor]

@gloomyandy Nope, no difference anywhere other than the different FW versions (and changes to daemon.g I've been doing on request from @dc42, which shouldn't impact much).

Haven't done any config changes in either the firmware or slicer. So what made this bug suddenly pop up is beyond me.

I litlerlaly finished one printed job, sliced a new part (with the exact same settings), uploaded, started printing and 10minutes into the print i saw it wasn't extruding. So i thought it was either a clog or had ran out of filament.

Paused the print, saw there was plenty with filament left, so i tried extruding manually through PanelDue which worked after it had finally loaded/primed the hotend again.

So i canceled the print, and restarted it. This time it started acting up on layer 7-8 or something (way earlier than it had shit the bed last time I tried). Canceled and try again, now it didn't get to layer 3 even.

[gloomyandy]

@Exerqtor So just to be clear, is this a print that you have not printed before,or have you printed it successfully in the past?

[Exerqtor]

@gloomyandy The prints I've tried now are prints that i haven't tried before.

I did first think that the issue with the file i linked here was that it has quite alot of retractions in quick sucession. So i sliced another job (same slicer settings and no fw changes), and that job did complete without issues. Then i sliced up the exact same stl that i had just sucessfully printed, only change was that i mirrored it over x-axis in the slicer since it's a right/left side model. Sliced that, uploaded and started printing it, but that failed on me.

So it's leads me to think the issue ain't the job/sliced files.

And just for referance the WiFi module has been switched off before any of these print jobs have been started due to the crash issue i've been having. So it's nothing "external" doing nothing funny 😅

[NeoDue]

@Exerqtor I don't know which slicer you use, but did you check if there might be a bug in that slicer? I just recently upgraded my Prusaslicer, hence the question. Did you confirm that the gcode files are okay in the relevant area?

[Exerqtor]

@NeoDue said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@Exerqtor I don't know which slicer you use, but did you check if there might be a bug in that slicer? I just recently upgraded my Prusaslicer, hence the question. Did you confirm that the gcode files are okay in the relevant area?

I'm using Orca Slicer 1.8.1, and i was before this problem suddenly started manifesting as well.

And since it happens on different heights (on the same job file) every time i try iy out i can't fathom how it could be a slicer generated issue.

I've read through the parts of gcode where the problem seem to have happened, and it's nothing out of the ordinary.

If you look at the file i supplied a little bit farther up, it stopped extruding somewhere between layer 1 finishing up, and layer 2 being done one of the times (I at least haven't been able to find anything that stands out as wrong within that segment of code). And the first time that print failed the print came to about 12,6mm height before it stopped ‍️

[NeoDue]

@Exerqtor that link you posted up there was too large, I could not see it

The file seems okay though.

Just to have tried it and maybe narrow down the issue - did you try to switch to absolute extrusion instead of using relative extrusion (RRF default is absolute - thus, if this works, your printer might "forget" its relative mode which you can doublecheck then)?

Apart from that, two probably unrelated issues in your code: you set global.layer_number twice for each layer, and you do a G92 E0 for each layer change - that one does not make sense if you use relative extruder coordinates. I remember commenting all these out when I switched to using relative extruder coordinates because something went strange then... but it has been a while, so I do not remember what that was.

[Exerqtor]

@NeoDue said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@Exerqtor that link you posted up there was too large, I could not see it

The file seems okay though.

Haha, hidden in plain sight 🤣

Glad i'm not the only one not able to spot any clear mistakes

Just to have tried it and maybe narrow down the issue - did you try to switch to absolute extrusion instead of using relative extrusion (RRF default is absolute - thus, if this works, your printer might "forget" its relative mode which you can doublecheck then)?

Hmm, no I haven't tried that, I'll give it a try after work!

Apart from that, two probably unrelated issues in your code: you set global.layer_number twice for each layer, and you do a G92 E0 for each layer change - that one does not make sense if you use relative extruder coordinates. I remember commenting all these out when I switched to using relative extruder coordinates because something went strange then... but it has been a while, so I do not remember what that was.

Hmm, i'll do that later too!

Weird of it to suddenly happen though, since i haven't done any changes in that for litlerlaly years 🤔

[gloomyandy]

@Exerqtor The Duet folks recommend the use of relative extrusion: https://docs.duet3d.com/User_manual/Reference/Slicing_recommendations#:~:text=All popular slicers support relative,you are using relative extrusion.

I suspect that is the mode that most folks are using.

It seems strange that there are no other reports of this issue from other folks. One thing that is perhaps a little unusual about your setup is that it looks like you have a filament sensor attached to the toolboard. Perhaps you could try disconnecting that (so that it no longer generates interrupts) and see if that makes any difference? Is there anything else about your toolboard setup that is unusual (so for instance do you have any neopixels running from it)? Are you using slicer or firmware retraction?

[Exerqtor]

@gloomyandy said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@Exerqtor The Duet folks recommend the use of relative extrusion: https://docs.duet3d.com/User_manual/Reference/Slicing_recommendations#:~:text=All popular slicers support relative,you are using relative extrusion.

I suspect that is the mode that most folks are using.

Yeah that's exactly why i'm using it too 🤣

It seems strange that there are no other reports of this issue from other folks. One thing that is perhaps a little unusual about your setup is that it looks like you have a filament sensor attached to the toolboard. Perhaps you could try disconnecting that (so that it no longer generates interrupts) and see if that makes any difference? Is there anything else about your toolboard setup that is unusual (so for instance do you have any neopixels running from it)? Are you using slicer or firmware retraction?

Thought most people ran at least one sensor these days lol, I can disable it in firmware and unplug it as well just to try.

The neopixels have wires ran all the way from the mainboard, since toolboard driven neopixels wasn't supported when i hooked it up 😅

I'm running firmware retraction, input shaping and pressure advance.

[dc42]

@Exerqtor please try the firmware binary at https://www.dropbox.com/scl/fo/uf8gsgetc2mfbh34hm3up/h?rlkey=bx1aavry6xplebwxhv5rx7xee&dl=0 and test it both for the WiFi resetting issue and the extruder reversal issue.

[Exerqtor]

@dc42 said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@Exerqtor please try the firmware binary at https://www.dropbox.com/scl/fo/uf8gsgetc2mfbh34hm3up/h?rlkey=bx1aavry6xplebwxhv5rx7xee&dl=0 and test it both for the WiFi resetting issue and the extruder reversal issue.

Sweet, but continue to run the "regular" 1LC 3.5.0-rc1+ firmware?

[Exerqtor]

@dc42 Ok let's see, I've installed those last binaries and the "normal" 3.5.0rc1+ release on the 1LC.

After that I tried one of the jobs that failed earlier, and it completed without reversing the extruder (or crashing).

I'll try some of the other jobs that has failed too now and see of they also complete.

Should i still leave the "stuff" we put in daemon.g be there for a while btw?

(Copying this response to the other thread too, since it's refering to the same binaries)

[Exerqtor]

@Exerqtor said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@dc42 Ok let's see, I've installed those last binaries and the "normal" 3.5.0rc1+ release on the 1LC.

After that I tried one of the jobs that failed earlier, and it completed without reversing the extruder (or crashing).

I'll try some of the other jobs that has failed too now and see of they also complete.

Should i still leave the "stuff" we put in daemon.g be there for a while btw?

(Copying this response to the other thread too, since it's refering to the same binaries)

Well that didn't last long, the next print started reversing after the second layer completed, it's still going as i type this reply.

So here is a few reports from when it's currently reversing:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.1++wdb (2023-12-11 09:30:48) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 12 of 40 (40 max)
=== RTOS ===
Static ram: 102844
Dynamic ram: 126732 of which 0 recycled
Never used RAM 7128, free system stack 128 words
Tasks: NETWORK(1,ready,143.3%,173) HEAT(3,nWait,0.2%,327) Move(4,nWait,6.2%,242) CanReceiv(6,nWait,0.4%,774) CanSender(5,nWait,0.2%,327) CanClock(7,delaying,0.1%,350) TMC(4,nWait,5.7%,74) MAIN(1,running,583.5%,584) IDLE(0,ready,0.9%,29) AIN(4,delaying,6.4%,264), total 746.8%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 01:50:12 ago, cause: software
Last software reset at 2023-12-11 16:03, reason: User, Gcodes spinning, available RAM 13548, slot 1
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00446000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 6612142, completed 6612142, timed out 0, errs 0
MCU temperature: min 34.7, current 46.4, max 46.8
Supply voltage: min 7.5, current 24.1, max 24.6, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/23, heap memory allocated/used/recyclable 2048/788/444, gc cycles 18
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 1, ifcnt 166, reads 20196, writes 50, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 164, reads 20196, writes 50, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 70, reads 20217, writes 28, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 72, reads 20217, writes 28, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 68, reads 20219, writes 27, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2023-12-11 17:54:00
Cache data hit count 4294967295
Slowest loop: 306.84ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 9.2ms, write time 6.2ms, max retries 0
=== Move ===
DMs created 83, segments created 44, maxWait 2843003ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 63 ticks, enabled
Moves shaped first try 2684, on retry 3142, too short 7967, wrong shape 32970, maybepossible 1754
=== DDARing 0 ===
Scheduled moves 7910, completed 7871, hiccups 0, stepErrors 0, LaErrors 31, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X170.601 Y152.656 E.00239" 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 doing "G4 S10000" in state(s) 0 0, running macro
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0, sync state 1
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
in 0 notIn 0
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 111977, received 136294, lost 0, errs 1, boc 0
Longest wait 6ms for reply type 6029, peak Tx sync delay 340, free buffers 26 (min 24), ts 33061/33060/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 210.23ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 3 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1beta4
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 42948
WiFi IP address 192.168.10.x
Signal strength -49dBm, channel 6, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.0-rc.1+ (2023-11-21 09:48:16)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 2556, free system stack 89 words
Tasks: Move(3,nWait,1.4%,71) HEAT(2,nWait,2.5%,91) CanAsync(5,nWait,0.0%,54) CanRecv(3,nWait,0.4%,77) CanClock(5,nWait,0.1%,67) ACCEL(3,nWait,0.0%,53) TMC(2,nWait,22.2%,57) MAIN(1,running,38.2%,316) IDLE(0,ready,0.0%,27) AIN(2,delaying,35.0%,114), total 100.0%
Last reset 01:50:46 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, standstill, SG min 0, read errors 0, write errors 3, ifcnt 140, reads 40832, writes 24, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 4320865
Moves scheduled 47946, completed 47946, in progress 0, hiccups 77, segs 43, step errors 0, maxPrep 887, maxOverdue 7251, maxInc 2966, mcErrs 0, gcmErrs 0, ebfmin -1.00 max inf
Peak sync jitter -2/11, peak Rx sync delay 279, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 7.7, current 24.1, max 24.5
MCU temperature: min 38.8C, current 66.5C, max 74.8C
Last sensors broadcast 0x00000012 found 2 34 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 137004, send timeouts 0, received 112920, lost 0, errs 1213, boc 0, free buffers 18, min 18, error reg 110000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 369, adv 35625/74652
Accelerometer: LIS3DH, status: 00
Inductive sensor: not found
I2C bus errors 0, naks 6, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 2 to 1966us
Driver 0: ok

[dc42]

@Exerqtor please use the 3.5.0-rc.1++ tool board/expansion board firmware from https://www.dropbox.com/scl/fo/gaxzegafmnmagaefo9mgc/h?rlkey=hk4wpttdje76oews8zkuh86q3&dl=0.

[Exerqtor]

@dc42 said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@Exerqtor please use the 3.5.0-rc.1++ tool board/expansion board firmware from https://www.dropbox.com/scl/fo/gaxzegafmnmagaefo9mgc/h?rlkey=hk4wpttdje76oews8zkuh86q3&dl=0.

Aha, ok just moved over to it. I'll try the same job file again before hitting the bunk and report back✌️

---

Just tried the same print with 3.5.0-c.1++ on the 1LC and it's the exact same behaviour:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.1++wdb (2023-12-11 09:30:48) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 4 of 40 (40 max)
=== RTOS ===
Static ram: 102844
Dynamic ram: 125540 of which 0 recycled
Never used RAM 9168, free system stack 138 words
Tasks: NETWORK(1,ready,16.8%,179) HEAT(3,nWait,0.0%,352) Move(4,nWait,0.5%,244) CanReceiv(6,nWait,0.1%,774) CanSender(5,nWait,0.0%,327) CanClock(7,delaying,0.0%,350) TMC(4,delaying,0.7%,74) MAIN(1,running,80.9%,584) IDLE(0,ready,0.2%,29) AIN(4,delaying,0.8%,264), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:25:33 ago, cause: software
Last software reset at 2023-12-11 19:17, reason: User, Gcodes spinning, available RAM 7056, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00446000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 1533781, completed 1533780, timed out 0, errs 0
MCU temperature: min 37.0, current 46.4, max 46.6
Supply voltage: min 7.8, current 24.0, max 24.7, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/23, heap memory allocated/used/recyclable 2048/1912/1572, gc cycles 7
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 1, ifcnt 201, reads 15125, writes 32, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 199, reads 15124, writes 32, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 93, reads 15136, writes 20, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 1, ifcnt 96, reads 15135, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 91, reads 15137, writes 20, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2023-12-11 19:43:28
Cache data hit count 2492399296
Slowest loop: 226.89ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 5.4ms, write time 5.1ms, max retries 0
=== Move ===
DMs created 83, segments created 42, maxWait 1083591ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 30 ticks, enabled
Moves shaped first try 265, on retry 158, too short 102, wrong shape 2987, maybepossible 63
=== DDARing 0 ===
Scheduled moves 4562, completed 4522, hiccups 0, stepErrors 0, LaErrors 5, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X187.692 Y162.442 Z1.35" 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 doing "G4 S10000" in state(s) 0 0, running macro
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0, sync state 1
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
in 0 notIn 0
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 17932, received 31633, lost 0, errs 0, boc 0
Longest wait 3ms for reply type 6013, peak Tx sync delay 327, free buffers 26 (min 25), ts 7669/7668/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 208.78ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 2 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1beta4
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 43112
WiFi IP address 192.168.10.x
Signal strength -48dBm, channel 6, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.0-rc.1++ (2023-12-07 12:52:31)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 2628, free system stack 89 words
Tasks: Move(3,nWait,0.1%,71) HEAT(2,nWait,0.3%,91) CanAsync(5,nWait,0.0%,55) CanRecv(3,nWait,0.0%,77) CanClock(5,nWait,0.0%,67) ACCEL(3,nWait,0.0%,53) TMC(2,nWait,3.0%,57) MAIN(1,running,91.7%,316) IDLE(0,ready,0.0%,27) AIN(2,delaying,4.8%,114), total 100.0%
Last reset 00:26:29 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, standstill, SG min 0, read errors 0, write errors 1, ifcnt 174, reads 7708, writes 22, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x6c, steps req 0 done 401933
Moves scheduled 2847, completed 2847, in progress 0, hiccups 1, segs 40, step errors 0, maxLate 1 maxPrep 900, maxOverdue 40, maxInc 40, mcErrs 0, gcmErrs 0, ebfmin -1.00 max inf
Peak sync jitter -2/9, peak Rx sync delay 219, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 8.1, current 24.1, max 24.7
MCU temperature: min 45.6C, current 61.2C, max 61.2C
Last sensors broadcast 0x00000012 found 2 228 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 32789, send timeouts 0, received 19593, lost 0, errs 1210, boc 0, free buffers 18, min 18, error reg 100000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 354, adv 35712/74647
Accelerometer: LIS3DH, status: 00
Inductive sensor: not found
I2C bus errors 0, naks 6, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 2 to 1314us
Driver 0: ok

[dc42]

@Exerqtor is the reversal random, or at the same point each time in a given print?

[Exerqtor]

@dc42 Seemingly random, definetly not on the same point/layer each time.

The first time it happened (where i thought it was a clog or something) it happened between layer 59-61 (based on messsuring the height of the failed print), so after making sure there was no clog etc. and restarting the print it began reversing at layer 4-5. And on the third try it started reversing on layer 2.

[Exerqtor]

@dc42 said in 1LC stepper intermittently running backwards - 3.5.0-r1+:

@Exerqtor is the reversal random, or at the same point each time in a given print?

I just saw this thread and your reply to it. And it got me to remember that i did some IS tuning and changes between it working and these issues came back. May these be connected to each other?

The only changes i did was to alter the frequency and try a couple different shapers to see what changes it did to the readings.

[Exerqtor]

@dc42 So I just grabbed the 3.5.0rc2 binaries and tried them on the machine, and it's still reversing the the print.

This time I kept a finger on the filament where it enters the reversed bowden while looking at the Z-height and it stopped extruding somewhere along Z 0.65.

Here is a couple fresh reports grabbed while it's acting up during a print:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.2 (2023-12-15 13:33:26) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 3 of 40 (40 max)
=== RTOS ===
Static ram: 102812
Dynamic ram: 128208 of which 0 recycled
Never used RAM 5756, free system stack 120 words
Tasks: NETWORK(2,nWait,21.9%,181) HEAT(3,nWait,0.0%,328) Move(4,nWait,0.5%,243) CanReceiv(6,nWait,0.1%,776) CanSender(5,nWait,0.0%,329) CanClock(7,delaying,0.0%,350) TMC(4,nWait,0.7%,80) MAIN(1,running,71.5%,603) IDLE(0,ready,4.5%,29) AIN(4,delaying,0.8%,264), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:36:34 ago, cause: software
Last software reset at 2023-12-15 17:21, reason: User, Gcodes spinning, available RAM 12348, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 2195019, completed 2195017, timed out 0, errs 0
MCU temperature: min 35.9, current 46.2, max 46.7
Supply voltage: min 7.5, current 24.2, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/28, heap memory allocated/used/recyclable 2048/1524/1120, gc cycles 4001
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 1, ifcnt 149, reads 49926, writes 32, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 1, ifcnt 149, reads 49926, writes 32, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 1, ifcnt 115, reads 49937, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 1, ifcnt 116, reads 49936, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 1, ifcnt 115, reads 49937, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2023-12-15 17:57:46
Cache data hit count 3773989065
Slowest loop: 224.53ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 11.1ms, write time 4.5ms, max retries 0
=== Move ===
DMs created 83, segments created 41, maxWait 1602827ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 795 ticks, enabled
Moves shaped first try 499, on retry 404, too short 194, wrong shape 4852, maybepossible 141
=== DDARing 0 ===
Scheduled moves 8101, completed 8061, hiccups 0, stepErrors 0, LaErrors 10, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X170.827 Y153.319 E.00731" 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 0, running macro
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0, sync state 1
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 26867, received 45197, lost 0, errs 1, boc 0
Longest wait 2ms for reply type 6031, peak Tx sync delay 403, free buffers 26 (min 25), ts 10975/10974/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 89.37ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 3 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1beta6
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 41512
WiFi IP address 192.168.10.x
Signal strength -50dBm, channel 6, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.0-rc.2 (2023-12-15 13:41:02)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 2708, free system stack 91 words
Tasks: Move(3,nWait,0.1%,73) HEAT(2,nWait,0.4%,97) CanAsync(5,nWait,0.0%,55) CanRecv(3,nWait,0.0%,77) CanClock(5,nWait,0.0%,69) ACCEL(3,nWait,0.0%,53) TMC(2,delaying,3.0%,57) MAIN(1,running,91.8%,318) IDLE(0,ready,0.0%,27) AIN(2,delaying,4.7%,114), total 100.0%
Last reset 00:36:54 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, standstill, SG min 0, read errors 0, write errors 1, ifcnt 97, reads 57835, writes 22, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 440142
Moves scheduled 3003, completed 3003, in progress 0, hiccups 4, segs 40, step errors 0, maxLate 1 maxPrep 887, maxOverdue 322, maxInc 322, mcErrs 0, gcmErrs 0, ebfmin -1.00 max inf
Peak sync jitter -2/10, peak Rx sync delay 217, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 7.7, current 24.1, max 24.5
MCU temperature: min 39.1C, current 68.7C, max 68.7C
Last sensors broadcast 0x00000012 found 2 11 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 45614, send timeouts 0, received 27424, lost 0, errs 1173, boc 0, free buffers 18, min 18, error reg 110000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 346, adv 35766/74655
Accelerometer: LIS3DH, status: 00
Inductive sensor: not found
I2C bus errors 0, naks 6, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 4 to 1409us

And the sliced file for good measure.

[Exerqtor]

I just adjusted my belt tention and retuned input shaping after moving to 3.5.0-rc2, to see if applying new shaper settings would remedy anything.

Started a print, and now it stops extruding earlier than ever, now it only does a tiny bit of my purge line before it stops.

So i thought fuck it and removed the extrusion reset commands from my layer change g-code, sliced the model again and did another try. The exact same behaviour.

Here is another set of M122 reports from while the problem is happening:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.2 (2023-12-15 13:33:26) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 13 of 40 (40 max)
=== RTOS ===
Static ram: 102812
Dynamic ram: 128544 of which 0 recycled
Never used RAM 5420, free system stack 120 words
Tasks: NETWORK(1,ready,83.7%,181) HEAT(3,nWait,1.0%,328) Move(4,nWait,0.3%,243) CanReceiv(6,nWait,1.7%,776) CanSender(5,nWait,0.0%,328) CanClock(7,delaying,0.3%,350) TMC(4,delaying,24.0%,74) MAIN(1,running,106.6%,584) IDLE(0,ready,179.1%,29) AIN(4,delaying,27.9%,264), total 424.7%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 17:00:25 ago, cause: software
Last software reset at 2023-12-15 17:21, reason: User, Gcodes spinning, available RAM 12348, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 61224767, completed 61224767, timed out 0, errs 0
MCU temperature: min 34.8, current 46.4, max 46.4
Supply voltage: min 23.4, current 23.9, max 24.6, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/28, heap memory allocated/used/recyclable 2048/612/192, gc cycles 119204
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 0, ifcnt 247, reads 26512, writes 98, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x71
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 247, reads 26513, writes 98, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 152, reads 26571, writes 37, timeouts 2, DMA errors 0, CC errors 0, failedOp 0x41
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 154, reads 26572, writes 38, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x6c
Driver 4: standstill, SG min 0, read errors 0, write errors 0, ifcnt 152, reads 26572, writes 37, timeouts 2, DMA errors 0, CC errors 0, failedOp 0x6f
Driver 5: not present
Driver 6: not present
Date/time: 2023-12-16 10:21:36
Cache data hit count 4294967295
Slowest loop: 408.12ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 8.7ms, write time 8.1ms, max retries 0
=== Move ===
DMs created 83, segments created 41, maxWait 53449812ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 55 ticks, enabled
Moves shaped first try 196, on retry 110, too short 86, wrong shape 1517, maybepossible 32
=== DDARing 0 ===
Scheduled moves 432, completed 422, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 49], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is idle in state(s) 3
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 0, running macro
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 533567, received 1211128, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 277, free buffers 26 (min 24), ts 295151/295151/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 211.17ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1beta6
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.37, flash size 2097152, free heap 41168
WiFi IP address 192.168.10.x
Signal strength -49dBm, channel 6, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.0-rc.2 (2023-12-15 13:41:02)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 2708, free system stack 91 words
Tasks: Move(3,nWait,0.1%,73) HEAT(2,nWait,11.4%,97) CanAsync(5,nWait,0.0%,54) CanRecv(3,nWait,0.4%,77) CanClock(5,nWait,0.6%,69) ACCEL(3,nWait,0.0%,17) TMC(2,delaying,101.1%,57) MAIN(1,running,154.7%,318) IDLE(0,ready,0.0%,27) AIN(2,delaying,159.0%,114), total 427.3%
Last reset 17:00:30 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, standstill, SG min 0, read errors 0, write errors 0, ifcnt 101, reads 16617, writes 4, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x71, steps req 0 done 91906
Moves scheduled 3087, completed 3087, in progress 0, hiccups 3, segs 40, step errors 0, maxLate 0 maxPrep 853, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter -3/10, peak Rx sync delay 219, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.3, current 24.1, max 24.6
MCU temperature: min 38.6C, current 63.8C, max 69.2C
Last sensors broadcast 0x00000012 found 2 24 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 1210805, send timeouts 0, received 533070, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 334, adv 35725/74654
Accelerometer: LIS3DH, status: 00
Inductive sensor: not found
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 5 to 1436us
Driver 0: ok

And here is the relevant config files & sliced job.
(All these files are grabbed from the printer, so it's 100% the config I'm currently running)