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

dc42

@Exerqtor that's done. I'll now do a test print using them.

Exerqtor

@dc42
Ok, i just did the same thing, downloaded and installed the binaries you just built. I'll try one print now first with my normal IS config and see how that turns out and update the post once that's done. If it acts up i'll disable IS and run another test.

And with IS enabled it's the same behaviour as before, it stops extruding a little ways into layer 3.

While extruding:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-21 12:51:12) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 27 of 40 (40 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128608 of which 44 recycled
Never used RAM 2852, free system stack 124 words
Tasks: NETWORK(2,nWait 7,16.0%,174) HEAT(3,nWait 6,0.0%,332) Move(4,nWait 6,0.2%,241) CanReceiv(6,nWait 1,0.1%,563) CanSender(5,nWait 7,0.0%,328) CanClock(7,delaying,0.0%,340) TMC(4,delaying,0.8%,68) MAIN(1,running,81.0%,599) IDLE(0,ready,1.0%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 01:09:24 ago, cause: software
Last software reset at 2024-02-19 18:20, reason: User, Gcodes spinning, available RAM 12072, slot 1
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 4165028, completed 4165028, timed out 0, errs 0
MCU temperature: min 40.6, current 44.5, max 46.8
Supply voltage: min 23.4, current 24.0, max 24.6, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/32, heap memory allocated/used/recyclable 4096/2352/1904, gc cycles 438
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 72, reads 30477, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 72, reads 30477, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 38, reads 30487, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 37, reads 30487, writes 10, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 38, reads 30486, writes 11, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-21 17:04:57
Cache data hit count 4294967295
Slowest loop: 238.42ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 8.8ms, write time 4.8ms, max retries 0
=== Move ===
DMs created 83, segments created 39, maxWait 1529482ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 33 ticks, enabled
Moves shaped first try 78, on retry 2, too short 33, wrong shape 335, maybepossible 21
=== DDARing 0 ===
Scheduled moves 306, completed 267, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 1], 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 5, 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 20689, received 37300, lost 0, errs 13199, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 36947, free buffers 26 (min 25), ts 9124/9111/0
Tx timeouts 0,0,13,0,0,8 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 206.88ms; fastest: 0.06ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.37, flash size 2097152, free heap 41072
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.3+ (2024-02-21 15:51:16)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 3688, free system stack 91 words
Tasks: Move(3,nWait 7,0.0%,91) HEAT(2,nWait 6,0.4%,99) CanAsync(5,nWait 4,0.0%,55) CanRecv(3,nWait 1,0.0%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,delaying,3.4%,53) MAIN(1,running,91.2%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,4.9%,112), total 100.0%
Owned mutexes:
Last reset 00:04:11 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, ok, SG min 0, read errors 0, write errors 1, ifcnt 29, reads 60061, writes 13, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 45444
Moves scheduled 193, completed 191, in progress 1, hiccups 7, segs 12, step errors 0, maxLate 0 maxPrep 268, maxOverdue 38, maxInc 38, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter -1/9, peak Rx sync delay 207, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.3, current 24.1, max 24.4
MCU temperature: min 60.5C, current 65.6C, max 65.6C
Last sensors broadcast 0x00000012 found 2 168 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 5136, send timeouts 0, received 2603, 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 326, adv 35737/74646
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 4 to 1454us
Driver 0: ok

Not extruding:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-21 12:51:12) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128608 of which 44 recycled
Never used RAM 2852, free system stack 124 words
Tasks: NETWORK(1,ready,18.1%,174) HEAT(3,nWait 6,0.0%,332) Move(4,nWait 6,2.4%,241) CanReceiv(6,nWait 1,0.1%,563) CanSender(5,nWait 7,0.0%,328) CanClock(7,delaying,0.0%,340) TMC(4,nWait 6,0.9%,68) MAIN(1,running,76.4%,599) IDLE(0,ready,1.2%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 01:14:00 ago, cause: software
Last software reset at 2024-02-19 18:20, reason: User, Gcodes spinning, available RAM 12072, slot 1
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 4441220, completed 4441220, timed out 0, errs 0
MCU temperature: min 44.5, current 46.4, max 47.0
Supply voltage: min 23.7, current 24.0, max 24.4, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 4096/1956/1496, gc cycles 464
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 0, ifcnt 72, reads 14528, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 72, reads 14527, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 38, reads 14528, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 37, reads 14528, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 38, reads 14528, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-21 17:09:33
Cache data hit count 4294967295
Slowest loop: 38.31ms; fastest: 0.10ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 8.6ms, write time 4.3ms, max retries 0
=== Move ===
DMs created 83, segments created 39, maxWait 2726ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 81 ticks, enabled
Moves shaped first try 296, on retry 68, too short 130, wrong shape 2590, maybepossible 65
=== DDARing 0 ===
Scheduled moves 4080, completed 4058, hiccups 0, stepErrors 0, LaErrors 2, 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 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 doing "G4 P250" 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 6, 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 5933, received 5691, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 165, free buffers 26 (min 25), ts 1381/1381/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 19.88ms; fastest: 0.07ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 42872
WiFi IP address 192.168.10.x
Signal strength -51dBm, 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.3+ (2024-02-21 15:51:16)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 3112, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,85) HEAT(2,nWait 6,0.4%,99) CanAsync(5,nWait 4,0.0%,55) CanRecv(3,nWait 1,0.1%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,delaying,3.5%,53) MAIN(1,running,90.6%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.1%,112), total 100.0%
Owned mutexes:
Last reset 00:08:46 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 0, ifcnt 29, reads 6214, writes 0, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 340512
Moves scheduled 2820, completed 2820, in progress 0, hiccups 106, segs 36, step errors 0, maxLate 0 maxPrep 860, maxOverdue 155, maxInc 95, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter -1/11, peak Rx sync delay 257, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.9, current 24.1, max 24.4
MCU temperature: min 60.5C, current 67.4C, max 67.7C
Last sensors broadcast 0x00000012 found 2 66 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 5680, send timeouts 0, received 5905, 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 366, adv 36093/104573
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 9 to 1498us
Driver 0: ok

I'll stop that print, disable IS and run another test.

Exerqtor

And the same again, with IS disabled (M593 "none") it shits the bed right away. No extrusion what so ever.

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-21 12:51:12) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 25 of 40 (40 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128608 of which 44 recycled
Never used RAM 2852, free system stack 124 words
Tasks: NETWORK(2,nWait 7,18.1%,174) HEAT(3,nWait 6,0.0%,332) Move(4,nWait 6,1.4%,241) CanReceiv(6,nWait 1,0.1%,563) CanSender(5,nWait 7,0.0%,328) CanClock(7,delaying,0.0%,340) TMC(4,nWait 6,0.9%,68) MAIN(1,running,77.4%,595) IDLE(0,ready,1.3%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 01:23:42 ago, cause: software
Last software reset at 2024-02-19 18:20, reason: User, Gcodes spinning, available RAM 12072, slot 1
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 5023693, completed 5023692, timed out 0, errs 0
MCU temperature: min 43.4, current 46.4, max 46.7
Supply voltage: min 23.4, current 24.0, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 4096/3684/3224, gc cycles 525
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 91, reads 30609, writes 19, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 90, reads 30611, writes 18, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 45, reads 30621, writes 7, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 44, reads 30621, writes 7, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 46, reads 30620, writes 8, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-21 17:19:15
Cache data hit count 4294967295
Slowest loop: 226.04ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 9.0ms, write time 6.2ms, max retries 0
=== Move ===
DMs created 83, segments created 39, maxWait 127541ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 121 ticks, enabled
Moves shaped first try 525, on retry 158, too short 148, wrong shape 2212, maybepossible 91
=== DDARing 0 ===
Scheduled moves 1713, completed 1689, hiccups 0, stepErrors 0, LaErrors 5, Underruns [0, 0, 2], 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 doing "G4 P250" 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 3, 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 10329, received 12134, lost 0, errs 0, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 228, free buffers 26 (min 25), ts 2911/2911/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 208.54ms; fastest: 0.06ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.37, flash size 2097152, free heap 42700
WiFi IP address 192.168.10.x
Signal strength -51dBm, 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.3+ (2024-02-21 15:51:16)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 3112, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,85) HEAT(2,nWait 6,0.4%,99) CanAsync(5,nWait 4,0.0%,49) CanRecv(3,nWait 1,0.1%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,delaying,3.4%,53) MAIN(1,running,90.9%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.0%,112), total 100.0%
Owned mutexes:
Last reset 00:18:30 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 31, reads 28986, writes 2, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 106034
Moves scheduled 3054, completed 3054, in progress 0, hiccups 117, segs 36, step errors 0, maxLate 0 maxPrep 891, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter 0/11, peak Rx sync delay 215, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.4, current 24.0, max 24.5
MCU temperature: min 60.5C, current 69.1C, max 69.4C
Last sensors broadcast 0x00000012 found 2 84 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 12160, send timeouts 0, received 10346, 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 344, adv 35820/104577
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 5 to 1697us
Driver 0: ok

dc42

@Exerqtor that's weird, my print using a 6HC and 1LC worked perfectly, as usual.

Exerqtor

@dc42 Beats me, could the issue be isolated to a Mini teamed up with a 1LC?

dc42

@Exerqtor said in 1LC - extruder randomly stopping/reversing - ≤3.5.0-r1:

@dc42 Beats me, could the issue be isolated to a Mini teamed up with a 1LC?

I think that's unlikely. Do you have just the one TOOL1LC board? I'm wondering whether it could be a hardware issue that only the 3.5 firmware is affected by, as nobody else has reported this issue.

Exerqtor

@dc42 said in 1LC - extruder randomly stopping/reversing - ≤3.5.0-r1:

@Exerqtor said in 1LC - extruder randomly stopping/reversing - ≤3.5.0-r1:

@dc42 Beats me, could the issue be isolated to a Mini teamed up with a 1LC?

I think that's unlikely. Do you have just the one TOOL1LC board? I'm wondering whether it could be a hardware issue that only the 3.5 firmware is affected by, as nobody else has reported this issue.

I only have the one 1LC v1.2 avalible, so I can't rule that out without doing a warranty return on it or something like that. I bought the board from E3D march 2022 at least.

But wouldn't a fw version dependant hardware fault be a little bit unlikely too?

T3P3Tony

@Exerqtor I think we will arrange a replacement board being sent to you to rule this out. Can you email info@duet3d.com to co-ordinate.

Exerqtor

While waiting for the replacement/test board to arrive I have to get some prints done. So I reverted back to 3.5.0-b4 on the main and tool board. Then tried the same "doomed" job as I've been testing out the different 3.5.0-rc's on and it's currently going without any issues (like i expected).

Here is a couple reports, the first one is from layer1 with the second being from layer81.

Layer 1 / Z 0.25:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-beta.4 (2023-06-08 23:40:14) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 1 of 40 (30 max)
=== RTOS ===
Static ram: 102996
Dynamic ram: 130800 of which 0 recycled
Never used RAM 4316, free system stack 138 words
Tasks: NETWORK(1,ready,19.3%,197) HEAT(3,nWait,0.0%,331) Move(4,nWait,0.1%,244) CanReceiv(6,nWait,0.1%,557) CanSender(5,nWait,0.0%,337) CanClock(7,delaying,0.0%,342) TMC(4,nWait,0.7%,74) MAIN(1,running,78.0%,578) IDLE(0,ready,1.1%,29) AIN(4,delaying,0.8%,266), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:19:17 ago, cause: software
Last software reset at 2024-02-24 13:14, reason: User, Gcodes spinning, available RAM 11080, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 1157769, completed 1157767, timed out 0, errs 0
MCU temperature: min 38.3, current 44.3, max 44.3
Supply voltage: min 3.0, current 24.1, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/516/56, gc cycles 277
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 32, reads 60866, writes 32, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 32, reads 60866, writes 32, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 60877, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 60877, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 60877, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-24 13:34:08
Cache data hit count 1894456688
Slowest loop: 226.36ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 7.9ms, write time 5.7ms, max retries 0
=== Move ===
DMs created 83, segments created 12, maxWait 1002320ms, bed compensation in use: mesh, height map offset 0.000, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 106 ticks, enabled
=== DDARing 0 ===
Scheduled moves 439, completed 400, hiccups 0, stepErrors 0, LaErrors 0, 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 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 doing "G4 P250                                                                      " 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 4, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 10819, received 23940, lost 0, boc 0
Longest wait 3ms for reply type 6053, peak Tx sync delay 4577, free buffers 18 (min 17), ts 5787/5785/0
Tx timeouts 0,0,1,0,0,0 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 207.25ms; 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, notready 0, noresp 0
Firmware version 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 43028
WiFi IP address 192.168.10.x
Signal strength -51dBm, 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-beta.4 (2023-06-08 16:22:30)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 1440, free system stack 88 words
Tasks: Move(3,nWait,0.0%,111) HEAT(2,nWait,0.5%,65) CanAsync(5,nWait,0.0%,53) CanRecv(3,nWait,0.0%,75) CanClock(5,nWait,0.0%,66) ACCEL(3,nWait,0.0%,53) TMC(2,nWait,3.0%,57) MAIN(1,running,91.5%,336) IDLE(0,ready,0.0%,27) AIN(2,delaying,4.9%,142), total 100.0%
Last reset 00:19:21 ago, cause: VDD brownout
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, ok, SG min 0, read errors 0, write errors 0, ifcnt 13, reads 56507, writes 13, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x6c, steps req 0 done 58104
Moves scheduled 311, completed 305, in progress 1, hiccups 6, step errors 0, maxPrep 528, maxOverdue 71, maxInc 71, mcErrs 0, gcmErrs 0, ebfmin 0.00, ebfmax 0.98
Peak sync jitter -2/9, peak Rx sync delay 215, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.3, current 24.3, max 24.5
MCU temperature: min 40.3C, current 58.4C, max 58.4C
Last sensors broadcast 0x00000012 found 2 78 ticks ago, 0 ordering errs, loop time 1
CAN messages queued 24058, send timeouts 0, received 10938, lost 0, free buffers 18, min 18, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 327, adv 35902/74656
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 2 to 2104us
Driver 0: ok

Layer 81 / Z 16.25:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-beta.4 (2023-06-08 23:40:14) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 14 of 40 (37 max)
=== RTOS ===
Static ram: 102996
Dynamic ram: 130800 of which 0 recycled
Never used RAM 3668, free system stack 128 words
Tasks: NETWORK(2,nWait,18.2%,197) HEAT(3,nWait,0.0%,331) Move(4,nWait,2.4%,244) CanReceiv(6,nWait,0.1%,557) CanSender(5,nWait,0.1%,328) CanClock(7,delaying,0.0%,342) TMC(4,nWait,0.8%,74) MAIN(1,running,76.3%,578) IDLE(0,ready,1.2%,29) AIN(4,delaying,1.0%,266), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:50:38 ago, cause: software
Last software reset at 2024-02-24 13:14, reason: User, Gcodes spinning, available RAM 11080, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 3039527, completed 3039526, timed out 0, errs 0
MCU temperature: min 46.2, current 46.4, max 46.6
Supply voltage: min 23.8, current 23.9, max 24.3, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/708/248, gc cycles 679
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 32, reads 301, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 32, reads 301, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 302, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 302, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 301, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-24 14:05:30
Cache data hit count 4294967295
Slowest loop: 9.14ms; fastest: 0.12ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 8.3ms, write time 4.2ms, max retries 0
=== Move ===
DMs created 83, segments created 39, maxWait 350ms, bed compensation in use: mesh, height map offset 0.000, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 27 ticks, enabled
=== DDARing 0 ===
Scheduled moves 55744, completed 55731, hiccups 0, stepErrors 0, LaErrors 1, 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 X230.443 Y223.609 E.02122" 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 P250                                                                      " 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 1, axes/extruders owned 0x0000807
Queue 0 has 'M106 S204' for move 55735
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 157, received 118, lost 0, boc 0
Longest wait 4ms for reply type 6029, peak Tx sync delay 133, free buffers 18 (min 17), ts 28/28/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 19.54ms; fastest: 0.07ms
Responder states: MQTT(0) HTTP(2) 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, notready 0, noresp 0
Firmware version 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 36164
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-beta.4 (2023-06-08 16:22:30)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 888, free system stack 88 words
Tasks: Move(3,nWait,1.0%,111) HEAT(2,nWait,0.6%,57) CanAsync(5,nWait,0.0%,53) CanRecv(3,nWait,0.2%,75) CanClock(5,nWait,0.0%,66) ACCEL(3,nWait,0.0%,53) TMC(2,nWait,3.2%,57) MAIN(1,running,89.7%,336) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.2%,142), total 100.0%
Last reset 00:50:42 ago, cause: VDD brownout
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 13, reads 35259, writes 0, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 172975
Moves scheduled 48482, completed 48482, in progress 0, hiccups 154, step errors 0, maxPrep 1236, maxOverdue 713, maxInc 461, mcErrs 0, gcmErrs 0, ebfmin -0.99, ebfmax 1.00
Peak sync jitter 1/11, peak Rx sync delay 213, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.9, current 24.3, max 24.5
MCU temperature: min 40.3C, current 74.1C, max 74.1C
Last sensors broadcast 0x00000012 found 2 175 ticks ago, 0 ordering errs, loop time 2
CAN messages queued 1522, send timeouts 0, received 2712, lost 0, free buffers 18, min 17, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 416, adv 35935/74658
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 10 to 2689us
Driver 0: ok

(And again, the "VDD brownout reset cause" on the 1LC is the reboot after downgrading to 3.5.0-b4 and relays controlling the 24V rails flipping off/on).

Doubt it's any value in those reports, but it's atleast another proof that the issue manifest after 3.5.0-b4.

I'll let the print finish just for the sake of sanity and arguent and update this post.

And it finished without a hickup:
alt text

Exerqtor

@dc42 I received the replacement 1LC today, so I first updated the firmware to the binaries you posted a couple days ago on both the main & old tool board. Then ran a test
print with the same file as before to have solid point of reference before swaping boards.

The old board behaved just like suspected and stoped extruding a little bit into layer 3, here are the reports.
Extruding:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-27 13:52:47) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 21 of 40 (32 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128648 of which 0 recycled
Never used RAM 5512, free system stack 144 words
Tasks: NETWORK(2,nWait 7,15.9%,220) HEAT(3,nWait 6,0.0%,326) Move(4,nWait 6,0.1%,241) CanReceiv(6,nWait 1,0.1%,796) CanSender(5,nWait 7,0.0%,337) CanClock(7,delaying,0.0%,340) TMC(4,delaying,0.8%,68) MAIN(1,running,81.1%,610) IDLE(0,ready,1.2%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 00:11:35 ago, cause: software
Last software reset at 2024-02-24 13:14, reason: User, Gcodes spinning, available RAM 11080, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 696225, completed 696224, timed out 0, errs 0
MCU temperature: min 34.2, current 40.7, max 40.7
Supply voltage: min 2.6, current 23.9, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/1092/632, gc cycles 176
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 0, ifcnt 31, reads 36577, writes 31, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 31, reads 36577, writes 31, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 20, reads 36587, writes 20, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 20, reads 36587, writes 20, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 36587, writes 21, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-28 16:00:56
Cache data hit count 1133766067
Slowest loop: 217.97ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 7.5ms, write time 50.3ms, max retries 0
=== Move ===
DMs created 83, segments created 14, maxWait 557540ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 44 ticks, enabled
Moves shaped first try 43, on retry 0, too short 2, wrong shape 169, maybepossible 1
=== DDARing 0 ===
Scheduled moves 345, completed 315, hiccups 0, stepErrors 0, LaErrors 0, 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 = 0.5
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 doing "G4 P250" 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 4, 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 6581, received 14457, lost 0, errs 1237, boc 0
Longest wait 4ms for reply type 6029, peak Tx sync delay 46266, free buffers 26 (min 25), ts 3480/3478/0
Tx timeouts 0,0,1,0,0,0 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 27.07ms; 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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 43028
WiFi IP address 192.168.10.x
Signal strength -52dBm, 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.3+ (2024-02-26 15:24:37)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 3688, free system stack 91 words
Tasks: Move(3,nWait 7,0.0%,91) HEAT(2,nWait 6,0.4%,95) CanAsync(5,nWait 4,0.0%,51) CanRecv(3,nWait 1,0.0%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,nWait 6,3.4%,53) MAIN(1,running,91.2%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.0%,112), total 100.0%
Owned mutexes:
Last reset 00:11:38 ago, cause: power up
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, ok, SG min 0, read errors 0, write errors 0, ifcnt 13, reads 21380, writes 13, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 46371
Moves scheduled 194, completed 193, in progress 1, hiccups 7, segs 12, step errors 0, maxLate 0 maxPrep 297, maxOverdue 39, maxInc 39, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter -2/9, peak Rx sync delay 216, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.3, current 24.1, max 24.4
MCU temperature: min 39.2C, current 50.6C, max 50.6C
Last sensors broadcast 0x00000012 found 2 121 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 14535, send timeouts 0, received 6637, 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 324, adv 36007/74649
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 2 to 1512us
Driver 0: ok

Not extruding:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-27 13:52:47) 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: 103264
Dynamic ram: 128648 of which 0 recycled
Never used RAM 4960, free system stack 138 words
Tasks: NETWORK(2,nWait 7,17.4%,218) HEAT(3,nWait 6,0.0%,326) Move(4,nWait 6,2.4%,241) CanReceiv(6,nWait 1,0.1%,796) CanSender(5,nWait 7,0.0%,330) CanClock(7,delaying,0.0%,340) TMC(4,nWait 6,0.9%,68) MAIN(1,running,77.0%,610) IDLE(0,ready,1.3%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:16:08 ago, cause: software
Last software reset at 2024-02-24 13:14, reason: User, Gcodes spinning, available RAM 11080, 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 968535, completed 968535, timed out 0, errs 0
MCU temperature: min 40.4, current 46.0, max 46.6
Supply voltage: min 23.7, current 24.0, max 24.4, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/772/312, gc cycles 235
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 31, reads 14324, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 31, reads 14324, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 20, reads 14324, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 20, reads 14324, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 21, reads 14324, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-28 16:05:28
Cache data hit count 1522225812
Slowest loop: 36.63ms; fastest: 0.10ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 8.4ms, write time 4.5ms, max retries 0
=== Move ===
DMs created 83, segments created 37, maxWait 2140ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 15 ticks, enabled
Moves shaped first try 290, on retry 63, too short 121, wrong shape 2546, maybepossible 57
=== DDARing 0 ===
Scheduled moves 4027, completed 3987, hiccups 0, stepErrors 0, LaErrors 2, 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 = 0.5
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 "G2 X223.055 Y232.264 I.189 J-.413 E.01443" 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 P250" 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 1, axes/extruders owned 0x0000807
Queue 0 has 'M106 S135' for move 4021
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 5799, received 5612, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 295, free buffers 26 (min 25), ts 1361/1361/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 20.10ms; fastest: 0.07ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.37, flash size 2097152, free heap 43028
WiFi IP address 192.168.10.x
Signal strength -56dBm, 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.3+ (2024-02-26 15:24:37)
Bootloader ID: SAMC21 bootloader version 2.4 (2021-12-10)
All averaging filters OK
Never used RAM 3112, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,87) HEAT(2,nWait 6,0.4%,95) CanAsync(5,nWait 4,0.0%,51) CanRecv(3,nWait 1,0.1%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,delaying,3.5%,53) MAIN(1,running,90.6%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.1%,112), total 100.0%
Owned mutexes:
Last reset 00:16:11 ago, cause: power up
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 13, reads 5275, writes 0, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 339601
Moves scheduled 2821, completed 2821, in progress 0, hiccups 111, segs 36, step errors 0, maxLate 0 maxPrep 886, maxOverdue 97, maxInc 38, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter 0/9, peak Rx sync delay 225, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.9, current 24.1, max 24.4
MCU temperature: min 39.2C, current 55.8C, max 55.9C
Last sensors broadcast 0x00000012 found 2 148 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 5639, send timeouts 0, received 5877, 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 363, adv 35929/74647
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 9 to 1728us
Driver 0: ok

Exerqtor

Had to make two posts due to character limit.

And the new board behaves exactly the same.
Extruding:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-27 13:52:47) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 17 of 40 (32 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128512 of which 0 recycled
Never used RAM 5648, free system stack 135 words
Tasks: NETWORK(2,nWait 7,16.0%,228) HEAT(3,nWait 6,0.0%,351) Move(4,nWait 6,0.1%,241) CanReceiv(6,nWait 1,0.1%,796) CanSender(5,nWait 7,0.0%,337) CanClock(7,delaying,0.0%,340) TMC(4,nWait 6,0.8%,68) MAIN(1,running,80.8%,595) IDLE(0,ready,1.3%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:11:44 ago, cause: software
Last software reset at 2024-02-28 17:11, reason: User, Gcodes spinning, available RAM 11836, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 704369, completed 704369, timed out 0, errs 0
MCU temperature: min 34.0, current 43.4, max 43.4
Supply voltage: min 2.8, current 23.9, max 24.8, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/1924/1464, gc cycles 175
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 46, reads 36995, writes 46, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 47, reads 36994, writes 47, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 23, reads 37018, writes 23, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 24, reads 37017, writes 24, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 24, reads 37017, writes 24, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-28 17:23:20
Cache data hit count 1145422321
Slowest loop: 225.76ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 7.8ms, write time 46.0ms, max retries 0
=== Move ===
DMs created 83, segments created 14, maxWait 534741ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 65 ticks, enabled
Moves shaped first try 48, on retry 0, too short 2, wrong shape 155, maybepossible 1
=== DDARing 0 ===
Scheduled moves 307, completed 301, hiccups 0, stepErrors 0, LaErrors 0, 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 = 0.5
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 X107.735 Y134.32 E.04472" 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 P250" 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 6647, received 14643, lost 0, errs 1247, boc 0
Longest wait 2ms for reply type 6031, peak Tx sync delay 47841, free buffers 26 (min 25), ts 3521/3519/0
Tx timeouts 0,0,1,0,0,0 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 199.19ms; 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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 39764
WiFi IP address 192.168.10.x
Signal strength -51dBm, 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.3+ (2024-02-26 15:24:37)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3688, free system stack 85 words
Tasks: Move(3,nWait 7,0.0%,95) HEAT(2,nWait 6,0.4%,99) CanAsync(5,nWait 4,0.0%,49) CanRecv(3,nWait 1,0.0%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,delaying,3.4%,53) MAIN(1,running,91.2%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.0%,112), total 100.0%
Owned mutexes:
Last reset 00:11:46 ago, cause: power up
Last software reset data not available
Driver 0: pos 0, 568.8 steps/mm, ok, SG min 0, read errors 0, write errors 0, ifcnt 12, reads 25412, writes 12, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 43148
Moves scheduled 171, completed 167, in progress 1, hiccups 7, segs 12, step errors 0, maxLate 0 maxPrep 268, maxOverdue 38, maxInc 38, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 0.99
Peak sync jitter -3/9, peak Rx sync delay 216, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.7, current 24.5, max 25.3
MCU temperature: min 40.5C, current 55.5C, max 55.5C
Last sensors broadcast 0x00000012 found 2 185 ticks ago, 0 ordering errs, loop time 1
CAN messages queued 14716, send timeouts 0, received 6697, 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 322, adv 35722/74642
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 2 to 1472us
Driver 0: ok

Not extruding:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-27 13:52:47) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 22 of 40 (40 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128512 of which 0 recycled
Never used RAM 5072, free system stack 135 words
Tasks: NETWORK(2,nWait 7,17.4%,218) HEAT(3,nWait 6,0.0%,326) Move(4,nWait 6,2.4%,238) CanReceiv(6,nWait 1,0.1%,796) CanSender(5,nWait 7,0.0%,337) CanClock(7,delaying,0.0%,340) TMC(4,nWait 6,0.9%,68) MAIN(1,running,76.9%,595) IDLE(0,ready,1.4%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:17:04 ago, cause: software
Last software reset at 2024-02-28 17:11, reason: User, Gcodes spinning, available RAM 11836, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 1025081, completed 1025080, timed out 0, errs 0
MCU temperature: min 43.2, current 46.2, max 46.6
Supply voltage: min 23.5, current 24.1, max 24.3, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/580/120, gc cycles 245
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 0, ifcnt 46, reads 16870, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 47, reads 16870, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 23, reads 16870, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 24, reads 16869, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 24, reads 16870, writes 0, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-28 17:28:41
Cache data hit count 1601436176
Slowest loop: 35.52ms; fastest: 0.10ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 9.7ms, write time 10.6ms, max retries 0
=== Move ===
DMs created 83, segments created 38, maxWait 2147ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 34 ticks, enabled
Moves shaped first try 439, on retry 114, too short 173, wrong shape 3194, maybepossible 90
=== DDARing 0 ===
Scheduled moves 5246, completed 5224, hiccups 0, stepErrors 0, LaErrors 4, 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 = 0.5
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 doing "G4 P250" 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 6, 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 7296, received 6608, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 264, free buffers 26 (min 25), ts 1604/1604/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 19.51ms; fastest: 0.06ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 43020
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.3+ (2024-02-26 15:24:37)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3112, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,87) HEAT(2,nWait 6,0.4%,91) CanAsync(5,nWait 4,0.0%,49) CanRecv(3,nWait 1,0.1%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,nWait 6,3.5%,53) MAIN(1,running,90.5%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.1%,112), total 100.0%
Owned mutexes:
Last reset 00:17:06 ago, cause: power up
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 12, reads 28621, writes 0, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 359702
Moves scheduled 2891, completed 2891, in progress 0, hiccups 154, segs 36, step errors 0, maxLate 0 maxPrep 871, maxOverdue 136, maxInc 81, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter -2/10, peak Rx sync delay 214, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 24.3, current 24.4, max 25.0
MCU temperature: min 40.5C, current 60.0C, max 60.0C
Last sensors broadcast 0x00000012 found 2 104 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 6604, send timeouts 0, received 7291, 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 353, adv 35628/107888
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 9 to 1545us
Driver 0: ok

droftarts

@Exerqtor I'm going to set up a printer tomorrow with a Mini 5+ and 1LC, to see if we can replicate this issue. Can you post your current config.g and any other relevant files (I can't immediately find them in the thread, sorry if you have already posted them), and tell me a little about your printer? I think you have a Voron Trident or something similar, with a Stealthburner? It would also be good to know what extruder and hot end, nozzle size, filament type and size, etc. I'm a bit limited in hardware, but I'll try and replicate your setup at least functionally. Is the gcode file you linked in the first post of this thread still the one all the tests have been carried out on?

Ian

Exerqtor

@droftarts
I'll take a complete SD-card dump and upload later today including the job file. I think I forgot to do it earlier dispite saying I was going to do so a while back🤦‍♂️

Specs:

Voron Trident
Meanwell 24v & 5v PSU (original, not clones lol)
Keenovo 230v bed heathwr, through a Omron SSR.
Stealthburner toolhead with optoTAP
Stealthburner leds connected to the mainboard (if you want / have the parts to test that)
Highflow(60w) Revo micro (with a 0.4mm HF nozzle atm)
LGX-lite and a 0.4mm highflow nozzle
Hall-element filament runout sensor
Regarding filament I've tried and comfirmed it bugging out with both 1,75MM Flashforge, Esun and Fiberlogy ABS/ABS-plus & ASA.

droftarts

@Exerqtor Okay, thanks. Your machine might be a little tricky for me to replicate with what I have on hand, as I don't have any high flow hot ends or an LGX. Was the problem noticeable when you did an air print, ie with no filament? That way I won't have to reduce speeds, which may be a factor. I do have a pancake stepper

Regarding board setup, it's just the Mini 5+ and 1LC connected? What length is the CAN bus? And you have soldered the termination jumper on the back of the 1LC?

Ian

Exerqtor

@droftarts I haven't tried an unloaded print, I can try that later today (all though i'm quite sure it will behave just the same).

Yup, just those two boards and the jumper is soldered. Regarding canbus length it's 1000-1200mm at most, done with twisted FEP wires.

Exerqtor

@droftarts
Okey, here is the SD-dump (I just took it), the only things I've left out is the "System Volume Information" folder, the debug logs and any other sliced jobs than the one I've been using for testing. And regarding IP-address and WiFi setup that's all done in runounce.g so you will have to deploy that yourself, as i suspect you're well aware of lol.

Just as a heads up regarding testing the "air print / unloaded" i'm going to alter the jobfile so the bed temp is 30C, gonna try that now and report back.

droftarts

@Exerqtor Great, thanks. This will have to wait until tomorrow now. Don't forget to enable cold extrude with M302 P1!

Ian

Exerqtor

@droftarts
Np, do it whenever you got time Yeah i skipped changing the hotend temp just incase the powerdraw to the toolboard might be a issue, ~~still haven't had time to run it yet lol.~~

Well that's for sure a definitive answer that loaded filament wasn't the issue, now it's acting up from the first layer again. Won't extrude at all during the print. However if I pause it and manuallly try to extrude through DWC or PD it extrudes without an issue.

Here is the reports from the ongoing test without any extrusion:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-27 13:52:47) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 10 of 40 (40 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128568 of which 0 recycled
Never used RAM 5016, free system stack 128 words
Tasks: NETWORK(1,ready,144.4%,182) HEAT(3,nWait 6,2.6%,326) Move(4,nWait 6,1.7%,238) CanReceiv(6,nWait 1,4.8%,773) CanSender(5,nWait 7,0.0%,336) CanClock(7,delaying,0.7%,340) TMC(4,nWait 6,72.2%,68) MAIN(1,running,290.3%,595) IDLE(0,ready,80.6%,30) AIN(4,delaying,73.6%,260), total 670.9%
Owned mutexes:
=== Platform ===
Last reset 24:25:27 ago, cause: software
Last software reset at 2024-02-28 17:11, reason: User, Gcodes spinning, available RAM 11836, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 87927453, completed 87927453, timed out 0, errs 0
MCU temperature: min 34.4, current 46.0, max 46.4
Supply voltage: min 23.4, current 24.1, max 24.7, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/1764/1304, gc cycles 18673
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 0, ifcnt 87, reads 51758, writes 41, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 88, reads 51757, writes 41, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x51
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 41, reads 51780, writes 18, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 42, reads 51780, writes 18, timeouts 1, DMA errors 0, CC errors 0, failedOp 0x01
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 42, reads 51781, writes 18, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-29 17:37:03
Cache data hit count 4294967295
Slowest loop: 229.18ms; 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 67.1ms, max retries 0
=== Move ===
DMs created 83, segments created 38, maxWait 85780177ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 13849 ticks, enabled
Moves shaped first try 1145, on retry 293, too short 345, wrong shape 6378, maybepossible 191
=== DDARing 0 ===
Scheduled moves 3966, completed 3926, hiccups 0, stepErrors 0, LaErrors 9, Underruns [0, 0, 2], 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 = 0.0
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 Z.85" 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 P250" 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 791270, received 1781906, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 276, free buffers 26 (min 25), ts 434512/434512/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 207.39ms; fastest: 0.06ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 42848
WiFi IP address 192.168.10.x
Signal strength -58dBm, 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.3+ (2024-02-26 15:24:37)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3112, free system stack 71 words
Tasks: Move(3,nWait 7,0.4%,87) HEAT(2,nWait 6,32.4%,91) CanAsync(5,nWait 4,0.0%,49) CanRecv(3,nWait 1,1.2%,71) CanClock(5,nWait 1,1.8%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,nWait 6,296.3%,53) MAIN(1,running,478.3%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,428.1%,112), total 1238.6%
Owned mutexes:
Last reset 24:25:32 ago, cause: power up
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 16, reads 921, writes 4, timeouts 6, DMA errors 0, CC errors 0, failedOp 0x6a, steps req 0 done 185963
Moves scheduled 3356, completed 3356, in progress 0, hiccups 235, segs 36, step errors 0, maxLate 0 maxPrep 894, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter -3/9, peak Rx sync delay 221, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.6, current 24.4, max 25.2
MCU temperature: min 37.8C, current 40.9C, max 63.4C
Last sensors broadcast 0x00000012 found 2 95 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 1781927, send timeouts 0, received 791335, 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 342, adv 35637/104588
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 5 to 1777us
Driver 0: ok

The only extrusion it did by itself is the load sequence right before doing the purge lines, not even the purge lines themself yielded any movement.

dc42

@Exerqtor I see that there are some hiccups on the tool board. Does it make any difference if you use M220 S50 just before starting the print, to run it at half speed?

Exerqtor

@dc42
I can add it to the job code manually and run another test, give me a couple minutes and I'll report back.

Nah, same exact thing only does the nozzle loading sequence then nothing:

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.3+ (2024-02-27 13:52:47) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 25 of 40 (40 max)
=== RTOS ===
Static ram: 103264
Dynamic ram: 128568 of which 0 recycled
Never used RAM 4992, free system stack 106 words
Tasks: NETWORK(2,nWait 7,16.2%,182) HEAT(3,nWait 6,0.0%,326) Move(4,nWait 6,0.3%,238) CanReceiv(6,nWait 1,0.1%,773) CanSender(5,nWait 7,0.0%,328) CanClock(7,delaying,0.0%,340) TMC(4,delaying,0.8%,68) MAIN(1,running,80.5%,595) IDLE(0,ready,1.1%,30) AIN(4,delaying,0.9%,260), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 24:48:18 ago, cause: software
Last software reset at 2024-02-28 17:11, reason: User, Gcodes spinning, available RAM 11836, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 89299231, completed 89299231, timed out 0, errs 0
MCU temperature: min 36.2, current 40.0, max 46.2
Supply voltage: min 23.5, current 23.7, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 198/33, heap memory allocated/used/recyclable 2048/1572/1112, gc cycles 18995
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, read errors 0, write errors 0, ifcnt 106, reads 6635, writes 19, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 0, ifcnt 107, reads 6635, writes 19, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 0, ifcnt 48, reads 6647, writes 7, timeouts 0, DMA errors 0, CC errors 0
Driver 3: ok, SG min 0, read errors 0, write errors 0, ifcnt 49, reads 6647, writes 7, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 50, reads 6646, writes 8, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-02-29 17:59:55
Cache data hit count 4294967295
Slowest loop: 229.98ms; fastest: 0.09ms
=== Storage ===
Free file entries: 16
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 9.0ms, write time 46.1ms, max retries 0
=== Move ===
DMs created 83, segments created 39, maxWait 1072427ms, bed compensation in use: mesh, height map offset 0.000, max steps late 1, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 18 ticks, enabled
Moves shaped first try 538, on retry 151, too short 149, wrong shape 2343, maybepossible 92
=== DDARing 0 ===
Scheduled moves 348, completed 319, hiccups 0, stepErrors 0, LaErrors 5, Underruns [0, 0, 3], 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 = 0.3
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 doing "G4 P250" 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 3, 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 15975, received 28320, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 156, free buffers 26 (min 25), ts 6858/6858/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 206.78ms; fastest: 0.06ms
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 2.1beta7
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 42676
WiFi IP address 192.168.10.x
Signal strength -52dBm, 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.3+ (2024-02-26 15:24:37)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3112, free system stack 71 words
Tasks: Move(3,nWait 7,0.1%,87) HEAT(2,nWait 6,0.4%,91) CanAsync(5,nWait 4,0.0%,49) CanRecv(3,nWait 1,0.0%,71) CanClock(5,nWait 1,0.0%,59) ACCEL(3,nWait 6,0.0%,53) TMC(2,delaying,3.4%,53) MAIN(1,running,91.1%,315) IDLE(0,ready,0.0%,27) AIN(2,delaying,5.0%,112), total 100.0%
Owned mutexes:
Last reset 24:48:22 ago, cause: power up
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 18, reads 29151, writes 2, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 113840
Moves scheduled 3577, completed 3577, in progress 0, hiccups 110, segs 36, step errors 0, maxLate 0 maxPrep 883, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max inf
Peak sync jitter -2/9, peak Rx sync delay 217, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.7, current 24.5, max 24.9
MCU temperature: min 37.8C, current 42.5C, max 63.4C
Last sensors broadcast 0x00000012 found 2 8 ticks ago, 0 ordering errs, loop time 1
CAN messages queued 28289, send timeouts 0, received 15909, 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 339, adv 35936/74646
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 5 to 2528us
Driver 0: ok

Those reports are taken during the first couple loops of the first layer btw.