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    Rotating magnet filament monitor - frame errors?

    Filament Monitor
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    • themelle
      themelle last edited by themelle

      Hi there,

      I just got my rotating magnet filament monitor delivered. Installation and configuration was a no-brainer (except for the pin assignment on the sensor PCB, which I could not find anywhere - so I just made a 1:1 connection between the two molex KK connectors).

      config.h contains

      M591 D0 P3 C3 S0 R70:130 L24.8 E3.0
      

      as per documentation.

      So I fired up a test print - the infamous xyz calibration cube, at 0.3mm layers.

      First 33 layers went fine - then a DWC popup appeared.
      "Extruder 0 reports sensor not working"

      M122 says

      [...]
      Extruder 0: pos 274.22, ok, measured sens 33.79mm/rev min 22% max 136% over 54.6mm, errs: frame 49 parity 0 ovrun 0 pol 0 ovdue 0
      

      M591 D0 says

      Duet3D rotating magnet filament monitor v2 on input 3, disabled, sensitivity 24.80mm/rev, allow 70% to 130%, check every 3.0mm, current pos 107.2, measured sensitivity 35.64mm/rev, min -1% max 146% over 142.9mm
      

      So I suspect there is something wrong.

      • "errs: frame 49" is indicative of frame errors (?)
      • "min -1%" seems way off

      What to check? What to do?

      On a side note, I was able to resume the print to finish without further problems though.

      Thanks,
      Andreas

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      • themelle
        themelle last edited by

        Update: I got a shielded cable installed.

        M122 now reports only 4 from errors, but nonetheless the job stalls mid-print with "Extruder 0 reports sensor not working".

        Also, M591 D0 reports

        Duet3D rotating magnet filament monitor v2 on input 3, disabled, sensitivity 24.80mm/rev, allow 70% to 130%, check every 3.0mm, current pos 0.0, measured sensitivity 31.29mm/rev, min -2% max 129% over 1204.2mm
        

        Hmm, "min -2%" - not really better ...

        Any thoughts, @dc42 @T3P3Tony ?

        T3P3Tony 1 Reply Last reply Reply Quote 0
        • T3P3Tony
          T3P3Tony administrators @themelle last edited by

          @themelle

          It is either an issue with the PCB, the wiring noise or possibly an issue with magnet registration.
          how long is the cable between the monitor and the Duet?

          themelle 1 Reply Last reply Reply Quote 0
          • themelle
            themelle @T3P3Tony last edited by

            @t3p3tony

            The cable is about 50cm long and shielded. It contains four wires, and I used all of them by using a single wire for both GND and +3.3V, and combined two wires for SIGNAL. Could this have any negative influence leading to signal noise?

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            • dc42
              dc42 administrators last edited by dc42

              Which version Duet is it? The older ones have more filtering on the regular endstop inputs, which might be contributing to the framing errors. If so then you can connect the filament monitor to one of the endstop inputs on CONN_LCD instead.

              When you get the "sensor not working" report, is there a regular pattern of red flashes from the LED on the filament monitor?

              themelle 1 Reply Last reply Reply Quote 0
              • themelle
                themelle @dc42 last edited by

                @dc42 Thanks for joining in 🙂

                The printer is driven by a Duet Wifi 1.04 running RRF 2.04RC1.

                When the "sensor not working" popup appears, the sensor does flash green all the time at around 1Hz. No red flashes as far a I can tell you.

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                • dc42
                  dc42 administrators last edited by

                  Confirm that you are running firmware 2.03 or 2.04RC1 ?

                  themelle 2 Replies Last reply Reply Quote 0
                  • themelle
                    themelle @dc42 last edited by themelle

                    This post is deleted!
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                    • themelle
                      themelle @dc42 last edited by

                      @dc42
                      Sure, can confirm firmly 😉

                      M122
                      === Diagnostics ===
                      RepRapFirmware for Duet 2 WiFi/Ethernet version 2.04RC1 running on Duet WiFi 1.02 or later
                      [...]
                      
                      1 Reply Last reply Reply Quote 0
                      • themelle
                        themelle last edited by

                        As I need to get this issue sorted out in time I changed the sensor cable routing to be as far away from stepper wires as possible.

                        The test print stopped once with the infamous "sensor not working" message, but went otherwise fine.

                        Mid-print pause

                        M122
                        Extruder 0: pos 0.00, ok, measured sens 25.32mm/rev min 13% max 111% over 6476.1mm, errs: frame 10 parity 0 ovrun 0 pol 2 ovdue 0
                        
                        M591 D0
                        Duet3D rotating magnet filament monitor v2 on input 3, disabled, sensitivity 24.80mm/rev, allow 70% to 130%, check every 3.0mm, current pos 0.0, measured sensitivity 25.32mm/rev, min 13% max 111% over 6476.1mm
                        

                        After the print

                        M122
                        Extruder 0: pos 211.29, ok, measured sens 25.34mm/rev min 93% max 105% over 175.3mm, errs: frame 11 parity 0 ovrun 0 pol 2 ovdue 0
                        
                        M591 D0
                        Duet3D rotating magnet filament monitor v2 on input 3, disabled, sensitivity 24.80mm/rev, allow 70% to 130%, check every 3.0mm, current pos 211.3, measured sensitivity 25.34mm/rev, min 93% max 105% over 175.3mm
                        

                        Measured sensitivity seems pretty consistent throughout both runs runs, and the second run even seems to have produced what I would call "real" min/max extrusion percentages.

                        But the framing errors did not go away, and "pol" errors (What are those?) did show up.
                        So I assume it is basically not an issue with cross talk between sensor and stepper cables.

                        @dc42 @T3P3Tony
                        How can we further progress on this topic?

                        Thanks in advance!

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                        • dc42
                          dc42 administrators last edited by

                          When it reports "sensor not working", what pattern of flashes do you see on the sensor LED?

                          themelle 1 Reply Last reply Reply Quote 0
                          • themelle
                            themelle @dc42 last edited by

                            @dc42 The LED flashes green at around 1Hz.

                            1 Reply Last reply Reply Quote 0
                            • themelle
                              themelle last edited by

                              @dc42 Any clues yet? Anything that I can try, measure, test?

                              1 Reply Last reply Reply Quote 0
                              • dc42
                                dc42 administrators last edited by

                                Green flashes at 1Hz are normal when there is no filament motion AFAIR.

                                In case it's a wiring issue, can you see the red endstop LED on the Duet flashing in time with the green LED on the filament monitor?

                                themelle 2 Replies Last reply Reply Quote 0
                                • themelle
                                  themelle last edited by

                                  @dc42 Thanks for your input.
                                  I'll try to verify this, probably on friday. Will come back to you with results 😉

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                                  • themelle
                                    themelle @dc42 last edited by

                                    @dc42 Got around to give it another try. When the sensor flashes, the end stop LED does not light up at all.

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                                    • themelle
                                      themelle @dc42 last edited by

                                      @dc42 Did another test - strange thing is the LED now flashes red at around 1Hz when the "sensor not working" popup appears.
                                      Also, the popup appeared tithes time for the first time immediately after starting the print from DWC, but way before any moves of the print head or extruder, as heating up had barely begun.

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                                      • dc42
                                        dc42 administrators last edited by

                                        @themelle, if the sensor LED flashes only red then it is reporting an error condition back to the Duet.

                                        If it gives several red flashes, pauses, then repeats, it is flashing an error code (count the number of flashes). When it does this, the Duet will record framing errors.

                                        themelle 1 Reply Last reply Reply Quote 0
                                        • themelle
                                          themelle @dc42 last edited by

                                          This post is deleted!
                                          themelle 1 Reply Last reply Reply Quote 0
                                          • themelle
                                            themelle @themelle last edited by

                                            @dc42, I know, there are some error codes listed over there (https://duet3d.dozuki.com/Wiki/Duet3dFilamentMonitor_RotatingMagnetVersion).
                                            But the red flashing is not paused in between - it is flashing at around 1Hz continuously ...

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                                            • themelle
                                              themelle last edited by

                                              @dc42, is there anything else I can do for now or should I contact Filastruder to issue a warranty return?

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                                              • themelle
                                                themelle last edited by

                                                @dc42 @T3P3Tony
                                                The replacement filament monitor arrived today - thanks for the really fast and painless swap!

                                                Just installed, gave it a quick go ...

                                                • no more "Sensor not working" messages
                                                • M591 D0 reports quite usable data
                                                  • Duet3D rotating magnet filament monitor v2 on input 3, disabled, sensitivity 25.33mm/rev, allow 85% to 115%, check every 3.0mm, current pos 14.8, measured sensitivity 25.21mm/rev, min 90% max 110% over 1252.5mm
                                                • M122reports no frame errors anymore
                                                  • Extruder 0: pos 14.77, ok, measured sens 25.21mm/rev min 90% max 110% over 1252.5mm, errs: frame 0 parity 0 ovrun 0 pol 1 ovdue 0

                                                Will do some more tests in the coming days, but those are by far the best results I was ever able to get!

                                                Thanks to both the teams of Filastruder and Duet3D for your great support!
                                                Much appreciated!

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