Error: G1: intermediate position outside machine limits

Aurimas

this is doing my head in
was working find now suddenly it doesn't work any more

01-TCM-03-029 REVB_ABS_6h6m_nozzle_0.6.gcode

3.6.0-beta.2 and just tested its same with 3.5.4

there is nothing obvious in the gcode and it is working on the other machine
@dc42

config.g

; Configuration file for Duet 3 Mini 5+ (firmware version 3)
; executed by the firmware on start-up
G90                                                  ; send absolute coordinates...
M83                                                  ; ...but relative extruder moves
M550 P"Vega2.0"                                      ; set printer name

; Network
M552 S1                                              ; enable network
M586 P0 S1                                           ; enable HTTP
M586 P1 S0                                           ; disable FTP
M586 P2 S0                                           ; disable Telnet

; Drives
M569 P0.0 S1 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
M584 X0.0 Y0.1 Z0.4 E0.2                         ; set drive mapping
M350 X16 Y16 Z16 E16 I1                           ; configure microstepping with interpolation
M92 X100.00 Y80.00 Z1920.00 E400.00             ; set steps per mm
M566 X300.00 Y300.00 Z60.00 E120.00           ; set maximum instantaneous speed changes (mm/min)
M203 X9000.00 Y9000.00 Z180.00 E1200.00      ; set maximum speeds (mm/min)
M201 X2500.00 Y2500.00 Z20.00 E250.00           ; set accelerations (mm/s^2)
M906 X1200 Y1200 Z900 E650 I30                   ; set motor currents (mA) and motor idle factor in per cent
M84 S90                                              ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z0 S1                                     ; set axis minima
M208 X320 Y300 Z350 S0                               ; set axis maxima

; Endstops
M574 X1 S1 P"io2.in"                                ; configure active-high endstop for low end on X via pin !io2.in
M574 Y2 S1 P"!io4.in"                                ; configure active-high endstop for low end on Y via pin !io4.in
M574 Z1 S2                                           ; configure Z-probe endstop for low end on Z

; Z-Probe
;M950 S0 C"io3.out" 
M950 S0 C"121.io0.out"                                   ; create servo pin 0 for BLTouch
;M558 P9 C"^io3.in" H5 F120 T6000
M558 P9 C"121.^io0.in" H5 F3000 T8000 S0.25                      ; set Z probe type to bltouch and the dive height + speeds
G31 P500 X-30 Y10 Z4                                ; set Z probe trigger value, offset and trigger height
M557 X20:280 Y20:280 S60                             ; define mesh grid

; 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 S160                                         ; set temperature limit for heater 0 to 120C
M308 S1 P"temp1" Y"pt1000" R2200                     ; configure sensor 1 as PT1000 on pin temp1
M950 H1 C"out1" T1                                   ; create nozzle heater output on out1 and map it to sensor 1
M307 H1 B0 S1.00                                     ; disable bang-bang mode for heater  and set PWM limit
M143 H1 S350                                         ; set temperature limit for heater 1 to 350C
M308 S2 P"temp2" Y"pt1000" R2200                     ; configure sensor 2 as PT1000 on pin temp2
M950 H2 C"out2" T2                                   ; create nozzle heater output on out2 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

; Fans
M950 F0 C"out3" Q500                                 ; create fan 0 on pin out3 and set its frequency
M106 P0 S0 H-1                                       ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"out4" Q500                                 ; create fan 1 on pin out4 and set its frequency
M106 P1 S1 H-1                                       ; set fan 1 value. Thermostatic control is turned off
M950 F2 C"out5" Q500                                 ; create fan 2 on pin out5 and set its frequency
M106 P2 S1 H1 T45                                    ; set fan 2 value. Thermostatic control is turned on
M950 F3 C"out6" Q500                                 ; create fan 3 on pin out6 and set its frequency
M106 P3 S1 H2 T45                                    ; set fan 3 value. Thermostatic control is turned on

; Tools
M563 P0 S"Left Extruder" D0 H1 F0                    ; define tool 1
G10 P0 X0 Y0 Z0                                      ; set tool 1 axis offsets
G10 P0 R0 S0                                         ; set initial tool 1 active and standby temperatures to 0C
;

; Custom settings are not defined

; Miscellaneous
M575 P1 S0 B57600                                    ; enable support for PanelDue
M501                                                 ; load saved parameters from non-volatile memory
;
T0                                                   ; select first tool

droftarts

@Aurimas At what point during the job do you get the message? I assume at the start?

The job start sequence appears to be to home all, move the nozzle to Y1 Z3, wait for temperatures, then do a mesh scan of the print area. Does that all work?

Ian

Aurimas

@droftarts said in Error: G1: intermediate position outside machine limits:

The job start sequence appears to be to home all, move the nozzle to Y1 Z3, wait for temperatures, then do a mesh scan of the print area. Does that all work?

yes - it freaks out in the middle of the bed for some of the sections and then continues like nothing happenned and freaks out again later.
as you can imagine there are puddles of plastic where it is freaking out

droftarts

@Aurimas That sounds more like the gcode file is corrupted, or there's an SD card reading issue. Can you send M122 after one of these events? Was the gcode file you posted copied from the SD card, or from the slicer? Maybe take the file from the SD card and post that.

I think test the SD card, and replace it if there's any issues. See https://docs.duet3d.com/en/User_manual/RepRapFirmware/SD_card#troubleshooting-sd-card-issues

Ian

Aurimas

@droftarts I think you missed the part where it says: "same file works on the other machine"
tried with multiple files - direct upload, upload from slicer, different STL files - same result

droftarts

@Aurimas Okay, but something is different about this machine. Are you saying the same SD card works in the other machine?

Otherwise, something is generating interference that is somehow either sending gcode, or corrupting the Gcode being sent from the SD card. Do you have a PanelDue connected, some other display, or anything else connected to serial or spi? Perhaps try disconnecting that.

Ian

T3P3Tony

@Aurimas what is different between the two machines? Is the firmware on both the toolboard and the Mainboard in sync when you try 3.5.3 and 3.6b2?

Also as @droftarts mentioned have you tried a different SD card?

Aurimas

@droftarts not sure why are you talking about the SD card - you cannot swap them out since it runs firmware of it - it is Mini5+ board.
since then I have recreated new config file and same gcode files work just fine.
So the issue is internal related to the firmware and not the SD card and/or gcode file.
I have supplied gcode file so that you guys can have a look that there is nothing causing issue in there. I have been logging those issues and there is a warning for every single move

2024-12-18 15:02:37 [warn] 6 points probed, min error -0.165, max error 0.655, mean 0.232, deviation 0.261
Height map saved to file 0:/sys/heightmap.csv
2024-12-18 15:02:49 [warn] HTTP client 192.168.1.141 login succeeded (session key 3163552733)
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:56 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits
2024-12-18 15:02:57 [warn] Error: G1: intermediate position outside machine limits

Aurimas

@T3P3Tony there is no difference - same setup, same hardware. this machine has been running non stop for few years now and suddenly getting these errors without making any changes

T3P3Tony

@Aurimas thanks for the update.

If the same machine hardware configuration with the same firmware is running the same gcode file fine. then it's most likely corruption or interference. The other machine you are testing on that has the same hardware, are you are using 3.5.4 or 3.6b2 on that as well? If it's not then change the firmware to 3.5.4 and check the same gcode still has no errors, that will rule out a firmware issue.

It's possible, that the SD card is partly corrupted (they tend to die outright though). If this was the case then swapping the SD card would rule that out.

Trying without the panel due connected would rule out that source of possible interference (however once again, if it's every more then also unlikely but worth trying.

If neither of those work then try swapping the mini5+ out and see if that resolves the issue.

droftarts

@Aurimas Do you have a daemon.g file in /sys?
I think the logging (M111) should show the Gcode sent if you turn it on, which might give a clue where it's coming from. Send M111 P3 S1 and connect a serial monitor (eg YAT) via USB.

Ian

Aurimas

@droftarts @T3P3Tony @dc42 is it possible that bed mesh compensation might be creating this issue in the latest firmware versions?
For instance if Z axis min is set to 0 and the bed mesh has to go to -0.2mm or similar - would that throw an error?

droftarts

@Aurimas I don't think you get an error if the mesh can't reach position, it just doesn't get there, though this may have changed in recent firmware. It's easy to test; disable mesh levelling. Did you try the thinks @T3P3Tony suggested?

Ian

Aurimas

@droftarts All of the suggested kindergarten stuff has been done before asking for expert help in the forum

dc42

@Aurimas what is in config-override.g?

Do you still get the error messages if you comment out the G29 line in the job file?

Aurimas

@dc42 just yesterday I had that issue, changed the Z minimum to allow negative value and it was printing since.
although it would be difficult to test your suggestion since the error didn't happen 100% of the time or in the same spot.
so my theory would be that if there is some inconsistency in the measurements at different spots of the bed it wants to compensate below minim and that is when it has fits.
It is always in the random spots on the bed (mostly well within limits) and not always - only sometimes.