weird issue with fans

Aurimas

So having weird issue with fan.
It is IDEX setup as per the config file attached
when using single extruder the fans turn on on and off as supposed.
when it is using Tool 2 or tool 3 the fans do not turn on as supposed to.
Requested speed reports as supposed to, but actual sits at 0
if paused/resumed - fans come on

Firmware version is 3.5.0 RC3. I know that it is not the latest, but not keen to upgrade to latest due to all issues I have been having

; Configuration file for Duet 3 Mini 5+ (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.2.3 on Sat May 08 2021 10:30:29 GMT+1000 (Australian Eastern Standard Time)

; General preferences
G90                                                  ; send absolute coordinates...
M83                                                  ; ...but relative extruder moves
M550 P"Vega300-IDEX"                                      ; set printer name
G4 S1   ;wait for expansion boards to start
; Network
;M551 P"Vega"                                         ; set password
M552 S1                                              ; enable network
M586 P0 S1                                           ; enable HTTP
M586 P1 S0                                           ; disable FTP
M586 P2 S0                                           ; disable Telnet
M575 P1 S1 B57600
M584 X0.2 Y0.3 Z0.0:0.1 U0.4 E121.0:20.0                         ; set drive mapping
M669 K1 X1:1:0:0 Y-1:1:0:0 U0:0:0:1 Z0:0:1:0                                       ; select CoreXY mode

; Drives
M569 P0.0 S0 D3 V40                                         ; physical drive 0.0 goes forwards
M569 P0.1 S0 D3 V40                                        ; physical drive 0.1 goes forwards
M569 P0.2 S1 ;D3 V40                                      ; physical drive 0.2 goes forwards
M569 P0.3 S1 ;D3 V40                                       ; physical drive 0.3 goes forwards
M569 P0.4 S0 ;D3 V40                                       ; physical drive 0.4 goes forwards
M569 P121.0 S0 D3 V40
M569 P20.0 S0 D3 V40

M350 X16 Y16 Z16 U16 T1 E16:16 I1                           ; configure microstepping with interpolation
M671 X-125:465 Y170:170 S14
M92 X80.00 Y80.00 Z2400.00 U80.00 E400.0:400.0             ; set steps per mm
M566 X1200.00 Y1200.00 Z20.00 U1200 E3200.00:3200.00           ; set maximum instantaneous speed changes (mm/min)
M203 X15000.00 Y15000.00 Z280.00 U15000.00 E10200.00:10200.00      ; set maximum speeds (mm/min)
M201 X5000.00 Y5000.00 Z25.00 U5000.00 E1550.00:1550.00           ; set accelerations (mm/s^2)
M906 X1600 Y1600 Z850 U1200 E600:600 I30                   ; set motor currents (mA) and motor idle factor in per cent
M84 S90                                              ; Set idle timeout

; Axis Limits
M208 X-65 Y0 U0 Z-1 S1                                     ; set axis minima
M208 X325 Y340 U390 Z420 S0                               ; set axis maxima


; Endstops
M574 X1 S1 P"!io3.in"                               ; configure switch-type (e.g. microswitch) endstop for low end on X via pin
M574 Y1 S1 P"!io4.in"
M574 U2 S1 P"!io2.in"
M574 Z1 S2                                           ; configure Z-probe endstop for low end on Z

; Z-Probe
M950 S0 C"121.io0.out"                                   ; create servo pin 0 for BLTouch
M558 P9 C"121.^io0.in" H5 F2200 T3000 S0.25                     ; set Z probe type to bltouch and the dive height + speeds
G31 P300 X-30 Y5 Z2.5                               ; set Z probe trigger value, offset and trigger height Increase Z number if the nozzle is too far
M557 X50:330 Y25:280 S200

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4138         ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0                                   ; create bed heater output on out0 and map it to sensor 0
M307 H0 B1 S1.00                                     ; enable bang-bang mode for the bed heater and set PWM limit
M140 H0                                              ; map heated bed to heater 0
M143 H0 S120                                         ; set temperature limit for heater 0 to 120C

M308 S1 P"121.temp0" Y"pt1000" R2200               ; configure sensor 1 as PT1000 on pin 121.temp0
M950 H1 C"121.out0" T1                             ; create nozzle heater output on 121.out0 and map it to sensor 1
M307 H1 B0 S1.00                                   ; disable bang-bang mode for heater  and set PWM limit
M143 H1 S350

M308 S2 P"20.temp0" Y"pt1000" R2200              ; configure sensor 2 as PT1000 on pin 121.io0.in
M950 H2 C"20.out0" T2                             ; create nozzle heater output on 122.out0 and map it to sensor 2
M307 H2 B0 S1.00                                   ; disable bang-bang mode for heater  and set PWM limit
M143 H2 S350                                       ; set temperature limit for heater 2 to 350C

M308 S4 P"temp1" Y"thermistor" T100000 B4138 ; configure sensor 2 as thermistor on pin temp2
;M950 H4 C"out5" T4                           ; create chamber heater output on out2 and map it to sensor 4
;M307 H4 B1 S1.00                             ; enable bang-bang mode for the chamber heater and set PWM limit
M141 H4                                      ; map chamber to heater 2
;M143 H4 S70                                 ; set temperature limit for heater 2 to 280C

; Fans

M950 F3 C"20.out1" Q500                           ; create fan 1 on pin 121.out2 and set its frequency
M106 P3 S0                                   ; set fan 1 value. Thermostatic control is turned on

M950 F1 C"121.out1" Q500                           ; create fan 3 on pin 122.out2 and set its frequency
M106 P1 S0                    ;                set fan 3 value. Thermostatic control is turned on

M950 F5 C"out5" Q500                         ; create fan 1 on pin out3 and set its frequency
;M106 P5 S1 H4 T55                            ; set fan 1 value. Thermostatic control is turned on

M950 F4 C"20.out2" Q500
M106 P4 T45 H2

M950 F6 C"121.out2" Q500
M106 P6 T45 H1

M950 P12 C"out1"
M42 P12 S1 ;turn the light on

M950 F10 C"out6" Q500                                 ; create fan 2 on pin out5 and set its frequency
M106 P10 S1                                    ; set fan 2 value. Thermostatic control is turned on

; Tools
M563 P0 S"Left Extruder" D0 H1 F1                   ; define tool 1
M568 P0 S0 R0 A0

M563 P1 S"Right extruder" D1 H2 X3 F3                   ; define tool 2
M568 P0 S0 R0 A0

; ''' Create a tool that prints 2 copies of the object using both carriages'''
M563 P2 S"Copy 200x340" D0:1 H1:2 X0:3 F1:3 L0; tool 2 uses both extruders, hot end heaters and fans, and maps X to both X and U
G10 P2 X30 Y0 U-165 S0 R0 ; set tool offsets and temperatures
M567 P2 E1:1 ; set mix ratio 100% on both extruders

;''' Create a tool that prints 2 copies of the object using both carriages'''
M563 P3 S"Mirror 180x340" D0:1 H1:2 X0:3 F1:3 L0; tool 2 uses both extruders, hot end heaters and fans, and maps X to both X and U
G10 P3 X50 Y0 U-370 S0 R0 ; set tool offsets and temperatures
M567 P3 E1:1 ; set mix ratio 100% on both extruders

; Custom settings are not defined
M591 D0 P3 C"121.io1.in" S1 R10:150 L24.8 E15.0 ; Duet3D rotating magnet sensor for extruder drive 0 is connected to E0 endstop input, enabled, sensitivity 24.8mm.rev, 70% to 130% tolerance, 3mm detection lengt

M591 D1 P3 C"20.io1.in" S1 R10:150 L24.8 E15.0 ; Duet3D rotating magnet sensor for extruder drive 0 is connected to E0 endstop input, enabled, sensitivity 24.8mm.rev, 70% to 130% tolerance, 3mm detection length

; Miscellaneous
M575 P1 S0 B57600                                    ; enable support for PanelDue
M501                                                 ; load saved parameters from non-volatile memory

T0
                                                  ; select first tool

M307 H0 R0.21 K0.586:0.000 D3.70 E1.35 S1.00 B1

droftarts

@Aurimas said in weird issue with fans:

M563 P2 S"Copy 200x340" D0:1 H1:2 X0:3 F1:3 L0; tool 2 uses both extruders, hot end heaters and fans, and maps X to both X and U
M563 P3 S"Mirror 180x340" D0:1 H1:2 X0:3 F1:3 L0; tool 2 uses both extruders, hot end heaters and fans, and maps X to both X and U

I can see you have fans 1 and 3 defined in the tool. Can you post the response to M563 P2 (or P3) when it is selected and only one fan is working?

When exactly does this issue show? Is it when you have either T0 or T1 selected, with the fans speed already set, and change to T2 or T3, without changing the fan speed? What happens if you send an M106 command, or use the fan slider, to change fan speed? Do they both work then, or only after a pause/resume? I'm wondering if it needs an M106 command to kick both fans into life after changing tool.

The pause/resume mechanism creates the file resurrect.g on pause, and runs it when resuming. This usually has an M106 to set the fan to the speed it was running when it was paused. So I don't think pause/resume is doing anything extra than sending an M106 command. You could try adding a M106 command that sets the current fan speed again, to the tpost2.g and tpost2.g files.

Ian

Aurimas

@droftarts said in weird issue with fans:

M106 to set the fan

neither of the fans is running when P2 or P3 is selected until the pause.
see the image of the state of the fan

both fans are in the same state - requested >0 and actual is 0
IMG_5814[1].JPG

Aurimas

@dc42 @droftarts anyone?

Phaedrux

@Aurimas said in weird issue with fans:

Firmware version is 3.5.0 RC3. I know that it is not the latest, but not keen to upgrade to latest due to all issues I have been having

I understand the reluctance to upgrade but if it's already something that's been fixed or not present in a a current version. We try to ask if the problem exists in the latest release so that it can be more easily fixed in the next release.

Aurimas

@Phaedrux said in weird issue with fans:

I understand the reluctance to upgrade but if it's already something that's been fixed or not present in a a current version. We try to ask if the problem exists in the latest release so that it can be more easily fixed in the next release.

I have upgraded other machines and had nothing but problems - constant software restart.
The same on multiple machines and as far as I know no issues have been rectified.
and it is really dissapointing that topics with simple questions about configuration get lots of support, but when it comes to real firmware issues everyone just stays quiet and provides no feedback.

Doesn't really inspire to use Duet going forward. Does it?
it is not the first serious issue I am having and so far I have not received appropriate support even though I have installed multiple boards into our printers that we build.
It sounds really good when we tell customer "Please downgrade to old version of the firmware because new one has bugs and causes system issues and we get no proper support on resolving the issues"
doesn't that sound great?

My issues so far:

constant issue with magnetic rotating filament sensor - either too little movement or sensor error. IMPOSSIBLE to use
constant reboots of the boards for software reasons from RC4 - Impossible to use
no this issue with requested speed >0 and actual speed ZERO

oliof

Comparing your config to mine, I think yours should work, but I may be missing fan assignment mix ups due to the non-contiguous definitions you do.

For reference, here is the configuration of fans and tool assignments from my IDEX that didn't give me trouble so far -- with the caveat that that printer isn't on 3.5 due to time constraints. I'll give it a go tomorrow to see if the issue is repeatable.

; Fans
M950 F0 C"124.out2"                                  ; x part cooling fan
M950 F1 C"124.out3"                                  ; x heatsink fan
M950 F2 C"125.out2"                                  ; u part cooling fan
M950 F3 C"125.out3"                                  ; u heatsink fan
  
M106 P0 C"left part fan" H-1 S0                      ; part cooling fan is not thermostatically controlled
M106 P1 C"left head fan" H1 T45                      ; print head fan is thermostatically controlled
M106 P2 C"right part fan" H-1 S0                     ; part cooling fan is not thermostatically controlled
M106 P3 C"right head fan" H2 T45                     ; print head fan is thermostatically controlled


; Bed and tools
M140 H0
; bed heater
; first toolhead (left)
M563 P0 S"left"  D0 H1 X0 F0                         ; first tool, X head
G10 P0 X0 Y0 Z0 S0 R0                                ; set tool 0 offsets and temperatures

; second toolhead (right)
M563 P1 S"right"  D1 H2 X3 F2                        ; second tool, U head
G10 P1 X0 Y0 Z0 S0 R0                                ; tool offsets

; -- copy mode
M563 P2 S"copy mode"  D0:1 H1:2 X0:3 F0:2            ; tool for copy mode
G10 P2 X110 Y0 U0 S0 R0                              ; tool offsets for copy mode
M567 P2 E1:1                                         ; set mix ratio 100% on both extruders for copy mode
; -- mirror mode 
M563 P3 S"mirror mode" D0:1 H1:2 X0:3 F0:2           ; tool for mirror mode
G10 P3 X110 Y0 U0 S0 R0                            ; tool offset for mirror mode (flipped X offset)
M567 P3 E1:1

oliof

@Aurimas looking at your config again, there seem to be some inconsistencies between your configs and the comments, notably the CAN address assignments (and you seem to have swapped F3 and F1 in some instance in the comments).

Can you confirm you use CAN addresses 20 and 121 for your expansion boards as configured, and not 121 and 122 as in the comments?

(also, unrelated: you can remove M574 Z1 S2 since you use a Z probe for Z homing, the S2 is only required for axes other than Z using the probe for homing as was done on the venerable Ormerod).

Aurimas

@oliof the fans work on individual extruders - no problem at all, ie when T0 and T1 is used.
it is an issue when T2 and T3 is used.
it can be seen that it is an issue when you look at the requested and actual speeds - they do not match.

oliof

@Aurimas I understood that, just trying to sort out what the differences are between your and my idex setup in this regard.

I'll try to find time to flash 3.5 rc3 and the newer releases on the idex today to see if I have the same issue. If yes, then it's likely firmware. If no, we need to look further.

Can you provide your tool change macros for completeness sake?

oliof

@Aurimas dusted off my IDEX and tested with 3.5.0-rc2 (that was the previous install), 3.5.0-rc3, and 3.5.2

With all three releases and my config, fan control works in all four modes (left/right/copy/mirror tool) and by specifying the fan directly. With M106 R2 in the tposX.g, fan control is handed over to the next tool. Interestingly enough, my printer did not turn off the second fan when switching from mirror/copy to one of the single head tools -- I added a bit of magic for that into tfree2.g and tfree3.g.

My toolchanger macros need some tough love, but for reference my full config is available at https://github.com/oliof/printerconfigs/tree/main/cr-cast

PS: Please dont be mistaken, toolchanging and IDEX can be intricate, and I debugged an intractable issue this morning where the U axis unhomed when switching out of tfree2 ... it happened during homing calls, but not for X. So I changed to manually defining the parking position.

Aurimas

@oliof said in weird issue with fans:

PS: Please dont be mistaken, toolchanging and IDEX can be intricate, and I debugged an intractable issue this morning where the U axis unhomed when switching out of tfree2 ... it happened during homing calls, but not for X. So I changed to manually defining the parking position.

the isssue is that the actual speed is not the same as the actual speed - this is reported by firmware itself. have a look once again in the image I provided

oliof

@Aurimas I've seen your issue and understand what it is; I am just telling you that I cannot recreate it on my IDEX machine and provided my configuration so you can check for any relevant differences.

Main difference between your IDEX and mine is that you have a chamber fan and an electronics fan(? seems to be disabled in the config); so it's not a perfect match but the best I can do.

Aurimas

@oliof said in weird issue with fans:

Main difference between your IDEX and mine is that you have a chamber fan and an electronics fan(? seems to be disabled in the config); so it's not a perfect match but the best I can do.

thank you for trying