Duet Stops mid print

BlueDust

@Phaedrux
I just re read what I wrote on my last message. I wrote it on my phone and need to stop doing that... It would appear I need English lessons from my 8 year old daughter.

Let me know if you have any other ideas or things I can look at. I tried to upload another gcode file that also had this issue but it was too big, even after trying to ZIP it.

Thanks for your help.

Phaedrux

@BlueDust said in Duet Stops mid print:

Hiccups: 1623052

I just noticed that you have an insanely high number of hiccups being reported in that last M122.

Hiccups: 14280857

Even higher before that.

Can you post your config.g again? Are you using microstepping values higher than x16?

Can you use dropbox or something to share the gcode file?

Phaedrux

Looking at your config from one of your older posts https://forum.duet3d.com/topic/12941/auto-bed-leveling-went-bad?_=1576682639924

I see that you're indeed using x256 microsteps for all axis and extruder. This will greatly limit your maximum speed before the step pulse generator is overwhelmed and hiccups occur.

For best results it's recommended to use x16 microstepping with interpolation to x256 enabled. This reduces the load on the CPU and still allows the drivers to use x256 microstepping for the motors.

BlueDust

@Phaedrux
I have had this configuration since I first setup the Duet2 last year.
M350 X256 Y256 Z256 I0 ; Configure microstepping without interpolation
M350 E16 I1 ; Configure microstepping with interpolation

Did something change in the 2.04+ ( I haven't tried older versions when testing this issue) to make this now cause an issue and the problem mentioned. Or are you saying what I have is not proper config (and causing errors... er Hiccups) and should be fixed. Possibly contributing to this problem.

As always. Thanks!

Phaedrux

@BlueDust said in Duet Stops mid print:

should be fixed. Possibly contributing to this problem.

Yes. It's not recommended to use x256 microstepping for all axis. It will likely result in high hiccup counts which may result in unexpected behaviour. I'm not sure if something changed in recent firmwares to make the lockup issue more prevalent, or if it has something to do with the Pallette 2 and the way it uses ping/pong pulses of the extruder that could be causing some issues.

Regardless, you'll likely see better behaviour by using x16 microstepping with x256 interpolation.

BlueDust

@Phaedrux

OK...
Trying to setup x16 w/Interpolation...

Should x16 with I be enabled for all axis? Are you saying that Z can be x256, but the rest should be X16 w/ i?

I just setup x16 with Interpolation for all axis and am just asking to confirm best practice on what should or shouldn't be x16i or x256.

Thanks!

droftarts

@BlueDust I’d go with all on x16i.

Ian

BlueDust

@droftarts

@Phaedrux

I am now getting a higher pitch squeal on the Z axis when moving at speed. Other axis are also slightly louder, but haven't printed anything yet... Just getting setup to do so...
Is there a way to stop this sound other than slowing it down to a crawl?

hmmm...
I don't think I enabled Silent Step or anything. Its been awhile since I setup the initial config to remember all the details... Something to look into...

Phaedrux

M350 X16 Y16 Z16 E16 I1

And adjust the M92 steps per mm accordingly.

Just as an aside to make testing alternative microstepping easier, if you set the microstepping to x16 first and then set the steps per mm accordingly for x16, you can then change the microstepping on a later line and the firmware will automatically calculate the steps per mm for you.

example:

M350 X16 Y16 Z16 E16 I1
M92 X80 Y80 Z400 E410
M350 E256

That would leave the XYZ using x16i and set the extruder as x256 and you wouldn't need to alter the M92 at all.

This should make it easier to experiment.

Phaedrux

@BlueDust said in Duet Stops mid print:

getting a higher pitch squeal on the Z axis when moving at speed

What are the commands you are using? Did you remember to recalculate your steps per mm?

BlueDust

@Phaedrux

That step trick is pretty NEAT! Good Show!

That would leave the XYZ using x16i and set the extruder as x256 and you wouldn't need to alter the M92 at all.

This should make it easier to experiment.

Old Settings
M350 X256 Y256 Z256 I0
M350 E16 I1
M92 X2560 Y2560 Z12800 E819.8589

Current Settings
M350 X16 Y16 Z16 I1
M350 E16 I1 ; I know I can turn this into one M350 line now.... just haven't yet.
M92 X160 Y160 Z800 E819.8589

Phaedrux

@BlueDust said in Duet Stops mid print:

when moving at speed

Does it seem to be moving faster than before? With such a high hiccup count it likely wasn't ever actually reaching the full requested speed. You may need to revise your speed assumptions?

Is the squeal coming from the motors?

BlueDust

@Phaedrux

Yes, it seems quicker now. Also, stall guard/sensorless homing seems to be working much better, but have only homed it 3 times so far since the changes....

I think it is is coming from the motors, but need to let the printer run a few minutes to confirm. About to start a small D&D character as a test print I have printed a few times last week (that worked each time I attempted it). Its small so the printer will not get up to any real speeds but should be an easy baseline as it was a recent print.

Thanks!

BlueDust

@Phaedrux
IMG_20191218_190842~2.jpg

Blue is from last week before x16i and Silver is after. Same code. Very close to the same time too. But as it's small, not able to get up to speed.

Just to make sure it's clear. The issue with my printer stopping was first noticed on a non Palette2 print. I tried many times only using S3d when printing on the Duet2 and having this problem. I shared the Palette2 gcode file as it occured on the same file many times/attempts.
Trying to print that same Palette2 gcode file I shared, right now and it has already gotten past the first time/layer the Duet2 would stop. If it prints another 15 layers without issue, I expect it to finish properly.
Hiccups currently say 0
Thanks!

BlueDust

@Phaedrux

Worked that time! Looks like you figured it out @Phaedrux!
Thank you! This has been driving me crazy! I don't know why this started, but now believe it is over! Hopefully I am not jumping the gun after 1 print... Lol

Marking this fixed!
Thanks again @Phaedrux!

Phaedrux

Glad it's sorted.

BlueDust

@Phaedrux

I think I met you at MRRF 2019.
If your at MRRF 2020, I would like to thank you in person. This problem really ruined a lot of prints.

Thanks again!

Phaedrux

@BlueDust said in Duet Stops mid print:

I think I met you at MRRF 2019.

Yup that was me at the Duet booth. I remember you. MRRF was a lot of fun. Would be great to go again.

BlueDust

@Phaedrux

So.. I haven't been able to actually test this properly, but it used to be if I enabled the magnetic filament sensor after a print started, it would stop the print for lack of movement.
I would have to pause the print, start the filament sensor, and resume the print. Sometimes it would still pause right before the measurements came in, but that wasn't as often.
I started an 8+ hr print with copper filament. I would hate to waste/lose this filament so enabled the Magnetic Filament monitor, but after I started the print (forgot) and it didn't stop the print. I will make sure to test this again to confirm this wasn't a one off fluke, but am now thinking that these Hiccups may have been the cause of most of the abnormal issues/behavior I have been having. Many of which I have asked for help here, on this forum.

Thanks again!

NitroFreak

I had the same issue. Even started a thread on it i think, but it never got resolved. My suspicion was s3d , after i switched to cura i never had that problem again. After i tried s3d again for a specific print and it happened again, i just wrote it off on s3d being weird.
I however had set x16 microstepping with interpolation everywhere, so i doubt it came from that.

Edit: Here is the link to my thread with the same issue;
https://forum.duet3d.com/topic/11886/duet-just-stopping-mid-print/8

I only had it with s3d and printing thin walled things, the first were lithophanes and the second were some engine covers, all about 2-3mm thick in the xy direction