Missing Steps - Cant Print SpreadCycle StealthChop tuning help

[carcamerarig]

@droftarts
The 1st bang was within 2 minutes on the 2nd layer, is it even possible to heat up that fast? I have had bangs on the travel move immediately after the purge line.

[carcamerarig]

@droftarts said in Missing Steps - Cant Print SpreadCycle StealthChop tuning help:

@carcamerarig hmm, yes, very disappointing, sorry this still isn’t resolved. As you seem to be able to reproduce the problem very reliably, can you update to the firmware from this post https://forum.duet3d.com/post/226010 and report using the commands @dc42 says? The only way we’re going to be able to fix it is to catch the fault in reporting.

Just the .uf2 file Ian?

[droftarts]

@carcamerarig yes, ignore the .map file. I also don’t think it’s to do with heat, but it came up earlier in the thread.

Ian

[Argo]

@droftarts

I'm running out of plausible explanations tbh.
With the CoreXY setup it might be an issue with the Mini 2 stepper expansion board using all channels but @carcamerarig and I almost have the same printer and you could personally check mechanical issues. I guess you checked that first before storming into a day of air-printing.

Those parts are the same for our printers:
24v PSU
1.8 LDO motors X/Y/Z
Bondtech extruder
same dimensions of the print bed
same bed heater

only difference: his frame uses other extrusions and he has 10mm rods and not 8mm rods for X/Y/Z.

I gave him my config.g which you also saw and checked when he was visiting you.
Unfortunately the MCU temperature is not readable via software but depending on the load the MCU should already reach it's working temperature after a short period of time under heavy load. But I do not know how much load a typical print generates.

Yes it's just a wild guess but what else can it be when the same board is working in a almost identical printer? Also the stepper motors worked perfectly in his previous setup with an EINSY 8 bit board.

I think he tried the last 3-4 weeks (nights) to solve the issues. To rule out any hardware issue, couldn't you from Duet send him a 100% verified working Mini5+ board and he sends in his board to verify? With a typical hardware store infrared sensor you can't really measure possible hot spots on a chip.
We have at least still two people with skipping layer problems regardless of the used mode (Stealth/Spread). The Mini5+ is still a young product and I guess the sale figures are still low because of the global situation but I've seen "many" with failed SD card slot in the forum (even the replacement board isn't sure to have no issues) so I wouldn't rule out a hardware problem. You've verified and seen the printer so why not.

He's gone so far and ordered a SKR 1.4 board because he just wants to print something. =(
Me at the other hand just ordered another Mini5+ (+ 2 stepper expansion) because I still trust in the quality Duet usually delivers in terms of hardware and software.

When the replacement board is also having issues at his place we might have to get a ghost detector to check whether or not his place is cursed for 3D printing.

[droftarts]

@argo I understand the frustration. I do feel a bit dumb for not trying a proper print when we were testing, but we were time-constrained. I would have gladly given him my board, but because we couldn’t reproduce it, I couldn’t prove my board would be any better than his.

We very much appreciate the community support trying to fix the issue. As @carcamerarig knows, I don’t have a stock of boards to send out; replacement in this instance is a decision for @dc42 or @T3P3Tony . But equally, I wouldn’t want @carcamerarig to go through the hassle of changing his board, only for the same thing to happen, because we haven’t been able reproduce the issue in testing. So there is currently no ‘known-good’ boards.

My feeling is that it’s a similar issue to the 0V issue; that there is an issue with SPI and/or DMA that the firmware can work around, once we know what that issue is. The only way to find it is to test firmware with sufficient reporting to find the issue on a machine that exhibits the fault.

Ian

[carcamerarig]

Appreciate the thoughts and assistance on this issue guys, Chris, Steve from the USA and Ray from NZ, Ben from Germany have all put in a solid 3 weeks on this with me and 2 of which have been til 4am because of the time zones, Ian has the best part of a day plus David’s late involvement. It’s a lot of effort from guys I never even met before and I’m humbled with everyone’s tenacity with it, I did order an SKR but it now feels like I’d be letting the side down if I quit and fit it. I’ll start doing some reporting on the latest fw when I get out of bed (being lazy today)
I know Chris is going to get his new mini board fired up soon so that will be another instance in the loop also, what I don’t get is why some other units aren’t showing the same issues?

[carcamerarig]

@dc42 @droftarts

What gives?

[droftarts]

@carcamerarig looks like the reporting isn’t working as @dc42 expects. He’ll need to look at this.

Ian

[droftarts]

@carcamerarig actually, I think it’s just a typo, and the E should be an R. See https://duet3d.dozuki.com/Wiki/Gcode#Section_M569_2_Read_or_write_stepper_driver_register
So send M569.2 P# R0

Ian

[carcamerarig]

@droftarts @dc42

2 bangs / layer shifts, new reporting below, please advise if you can see the issue within the reporting.

m122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.3beta2+2 (2021-04-15 16:55:30) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: Z9NZN-A296U-D65J0-40KM4-LY03Z-ZPQPD
Used output buffers: 3 of 40 (18 max)
=== RTOS ===
Static ram: 100104
Dynamic ram: 106340 of which 32 recycled
Never used RAM 34372, free system stack 132 words
Tasks: NETWORK(ready,233) HEAT(delaying,318) CanReceiv(notifyWait,944) CanSender(notifyWait,357) CanClock(notifyWait,334) TMC(notifyWait,105) MAIN(running,312) IDLE(ready,20) AIN(notifyWait,266)
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:01:20 ago, cause: power up
Last software reset at 2021-04-18 12:27, reason: User, GCodes spinning, available RAM 34372, 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
Aux1 errors 0,0,0
MCU revision 3, ADC conversions started 95990, completed 95989, timed out 0, errs 0
Step timer max interval 2246
Supply voltage: min 23.5, current 23.5, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/1910/1910, gc cycles 0
Driver 0: position 39400, standstill, SG min/max 0/428, read errors 0, write errors 0, ifcnt 16, reads 4210, writes 16, timeouts 0, DMA errors 0
Driver 1: position 19000, standstill, SG min/max 0/338, read errors 0, write errors 0, ifcnt 15, reads 4210, writes 15, timeouts 0, DMA errors 0
Driver 2: position 20000, standstill, SG min/max 0/274, read errors 0, write errors 0, ifcnt 13, reads 4212, writes 13, timeouts 0, DMA errors 0
Driver 3: position 0, standstill, SG min/max 0/0, read errors 0, write errors 0, ifcnt 11, reads 4214, writes 11, timeouts 0, DMA errors 0
Driver 4: position 0, standstill, SG min/max 0/276, read errors 0, write errors 0, ifcnt 14, reads 4211, writes 14, timeouts 0, DMA errors 0
Driver 5: position 0, assumed not present
Driver 6: position 0, assumed not present
Date/time: 2021-04-18 13:04:31
Cache data hit count 138727319
Slowest loop: 1000.11ms; fastest: 0.07ms
=== Storage ===
Free file entries: 8
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 1.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, maxWait 21893ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 1], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters = 0 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.0
Heater 1 is on, I-accum = 0.1
=== GCodes ===
Segments left: 0
Movement lock held by File
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "M116 P0" in state(s) 0 24, running macro
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
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty.
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 742, send timeouts 738, received 0, lost 0, longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 17 (min 16)
Last cancelled message type 4514 dest 127
=== Network ===
Slowest loop: 129.66ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8
- WiFi -
Network state is active
WiFi module is connected to access point 
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.25beta0
WiFi MAC address f4:cf:a2:6f:e9:78
WiFi Vcc 3.36, reset reason Power up
WiFi flash size 2097152, free heap 24696
WiFi IP address 192.168.1.226
WiFi signal strength -44dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

18/04/2021, 13:09:09	M569.2 P0.4 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:09:04	M569.2 P0.3 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:09:00	M569.2 P0.2 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:08:56	M569.2 P0.1 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:08:50	M569.2 P0.0 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:08:38	Resume state saved
18/04/2021, 13:05:10	M569.2 P0.4 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:05:05	M569.2 P0.3 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:05:01	M569.2 P0.2 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:04:55	M569.2 P0.1 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:04:52	M569.2 P0.0 R0
Register 0x00 value 0x000001c0

m122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.3beta2+2 (2021-04-15 16:55:30) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: Z9NZN-A296U-D65J0-40KM4-LY03Z-ZPQPD
Used output buffers: 3 of 40 (26 max)
=== RTOS ===
Static ram: 100104
Dynamic ram: 106340 of which 32 recycled
Never used RAM 34372, free system stack 132 words
Tasks: NETWORK(ready,232) HEAT(delaying,298) CanReceiv(notifyWait,944) CanSender(notifyWait,357) CanClock(delaying,334) TMC(notifyWait,105) MAIN(running,312) IDLE(ready,20) AIN(notifyWait,266)
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:06:09 ago, cause: power up
Last software reset at 2021-04-18 12:27, reason: User, GCodes spinning, available RAM 34372, 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
Aux1 errors 0,0,0
MCU revision 3, ADC conversions started 427660, completed 427659, timed out 0, errs 0
Step timer max interval 75162
Supply voltage: min 23.4, current 23.6, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/2, heap memory allocated/used/recyclable 2048/798/744, gc cycles 4
Driver 0: position 2000, standstill, SG min/max 0/470, read errors 0, write errors 0, ifcnt 20, reads 14529, writes 4, timeouts 0, DMA errors 0
Driver 1: position 0, standstill, SG min/max 2/452, read errors 0, write errors 0, ifcnt 19, reads 14529, writes 4, timeouts 0, DMA errors 0
Driver 2: position 4077, standstill, SG min/max 0/192, read errors 0, write errors 0, ifcnt 17, reads 14529, writes 4, timeouts 0, DMA errors 0
Driver 3: position 0, standstill, SG min/max 0/426, read errors 0, write errors 0, ifcnt 13, reads 14531, writes 2, timeouts 0, DMA errors 0
Driver 4: position 0, standstill, SG min/max 0/198, read errors 0, write errors 0, ifcnt 18, reads 14530, writes 4, timeouts 0, DMA errors 0
Driver 5: position 0, assumed not present
Driver 6: position 0, assumed not present
Date/time: 2021-04-18 13:09:19
Cache data hit count 525126543
Slowest loop: 100.47ms; fastest: 0.07ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 99.5ms, write time 5.0ms, max retries 0
=== Move ===
DMs created 83, maxWait 126070ms, bed compensation in use: mesh, comp offset 0.000
=== MainDDARing ===
Scheduled moves 438, completed moves 438, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 9, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters = 0 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.3
Heater 1 is on, I-accum = 0.4
=== GCodes ===
Segments left: 0
Movement lock held by null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X71.895 Y40.877 E0.88464" 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 idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty.
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 2597, send timeouts 2597, received 0, lost 0, longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 17 (min 17)
Last cancelled message type 4514 dest 127
=== Network ===
Slowest loop: 202.94ms; fastest: 0.08ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8
- WiFi -
Network state is active
WiFi module is connected to access point 
Failed messages: pending 0, notready 0, noresp 1
WiFi firmware version 1.25beta0
WiFi MAC address f4:cf:a2:6f:e9:78
WiFi Vcc 3.36, reset reason Power up
WiFi flash size 2097152, free heap 24584
WiFi IP address 192.168.1.226
WiFi signal strength -41dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

18/04/2021, 13:16:03	M569.2 P0.4 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:15:56	M569.2 P0.3 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:15:52	M569.2 P0.2 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:15:47	M569.2 P0.1 R0
Register 0x00 value 0x000001c0
18/04/2021, 13:15:39	M569.2 P0.0 R0
Register 0x00 value 0x000001c0

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.3beta2+2 (2021-04-15 16:55:30) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: Z9NZN-A296U-D65J0-40KM4-LY03Z-ZPQPD
Used output buffers: 12 of 40 (27 max)
=== RTOS ===
Static ram: 100104
Dynamic ram: 106340 of which 32 recycled
Never used RAM 34372, free system stack 132 words
Tasks: NETWORK(ready,222) HEAT(delaying,294) CanReceiv(notifyWait,944) CanSender(notifyWait,357) CanClock(delaying,334) TMC(notifyWait,105) MAIN(running,312) IDLE(ready,20) AIN(notifyWait,266)
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:13:08 ago, cause: power up
Last software reset at 2021-04-18 12:27, reason: User, GCodes spinning, available RAM 34372, 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
Aux1 errors 0,0,0
MCU revision 3, ADC conversions started 904380, completed 904379, timed out 0, errs 0
Step timer max interval 71916
Supply voltage: min 23.4, current 23.6, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/2, heap memory allocated/used/recyclable 2048/918/864, gc cycles 9
Driver 0: position 2000, standstill, SG min/max 0/508, read errors 0, write errors 0, ifcnt 20, reads 20898, writes 0, timeouts 0, DMA errors 0
Driver 1: position 0, standstill, SG min/max 0/430, read errors 0, write errors 0, ifcnt 19, reads 20899, writes 0, timeouts 0, DMA errors 0
Driver 2: position 4477, standstill, SG min/max 0/268, read errors 0, write errors 0, ifcnt 17, reads 20898, writes 0, timeouts 0, DMA errors 0
Driver 3: position 0, standstill, SG min/max 0/486, read errors 0, write errors 0, ifcnt 13, reads 20898, writes 0, timeouts 0, DMA errors 0
Driver 4: position 0, standstill, SG min/max 0/268, read errors 0, write errors 0, ifcnt 18, reads 20898, writes 0, timeouts 0, DMA errors 0
Driver 5: position 0, assumed not present
Driver 6: position 0, assumed not present
Date/time: 2021-04-18 13:16:19
Cache data hit count 1088363188
Slowest loop: 95.98ms; fastest: 0.07ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 38.3ms, write time 5.0ms, max retries 0
=== Move ===
DMs created 83, maxWait 0ms, bed compensation in use: mesh, comp offset 0.000
=== MainDDARing ===
Scheduled moves 4986, completed moves 4986, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 118, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed moves 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters = 0 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.3
Heater 1 is on, I-accum = 0.5
=== GCodes ===
Segments left: 0
Movement lock held by null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X71.333 Y69.865 E0.99279" 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 idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty.
=== Filament sensors ===
Extruder 0 sensor: ok
=== CAN ===
Messages queued 3778, send timeouts 3778, received 0, lost 0, longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 17 (min 17)
Last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 290.58ms; fastest: 0.08ms
Responder states: HTTP(0) HTTP(4) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8
- WiFi -
Network state is active
WiFi module is connected to access point 
Failed messages: pending 0, notready 0, noresp 1
WiFi firmware version 1.25beta0
WiFi MAC address f4:cf:a2:6f:e9:78
WiFi Vcc 3.36, reset reason Power up
WiFi flash size 2097152, free heap 24696
WiFi IP address 192.168.1.226
WiFi signal strength -42dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 4 2 0 0 0 0 0 0

[carcamerarig]

@dc42
Any updates to the reporting please.

[droftarts]

@carcamerarig I’m testing tomorrow on my machine, parenting today. Haven’t heard back from @dc42 yet.

One suggestion: can you swap the driver the X and Y axis motors are connected to, then change M584 to reflect this change? It looked like the X axis skipping in the last pictures, so it would be good to see if doing this affects the behaviour.

Ian

[carcamerarig]

bang

[SputnikOC3d]

Patience of a saint on display here ... I think its high time to seriously consider a new board with a different driver type. Since Duet 2 would be going backwards - revision' ly ... the 6HC seems a proper choice for the customer - having dealt with So Much effort to make this work. Personally, thats where Id be at this point.

[dc42]

@carcamerarig said in Missing Steps - Cant Print SpreadCycle StealthChop tuning help:

@dc42
Any updates to the reporting please.

@carcamerarig, thanks for the reports.

1. Do the layer shifts always occur in the X direction? Can you tell whether the bangs always occur on X moves?

2. Please run M569.2 P# R6 for # = 0 to 4. Do this before you start printing, and after you have started and banging has occurred. The values I expect back are:

19/04/2021, 21:21:53 	m569.2 p4 r6
Register 0x06 value 0x21000040
19/04/2021, 21:21:48 	m569.2 p3 r6
Register 0x06 value 0x2100004c
19/04/2021, 21:21:42 	m569.2 p2 r6
Register 0x06 value 0x21000048
19/04/2021, 21:21:33 	m569.2 p1 r6
Register 0x06 value 0x21000044
19/04/2021, 21:21:27 	m569.2 p0 r6
Register 0x06 value 0x21000040

If you have the Mini2+ installed as well then P5 should return the same as P1, and P6 the same as P2. If the board is working properly then the returned values should be constant, even while the machine is printing.

EDIT: I was wrong, the values will change during printing. In particular, the P0 value may be 0x21000040 as above, or 0x21000240. Similarly for the others. You may occasionally get other values. What I am particularly interested in is whether the readings ever end in C0, C4 etc. instead of 40, 44 etc.

[carcamerarig]

@dc42 I don't have a mini2+ only mini5 in standalone at the moment. Give me an hour ill have the results posted up.

[dc42]

@carcamerarig, whatever the result of that test, I would like to try replacing your board. Expect an email from Duet3 asking for your delivery details. Is your board WiFi or Ethernet?

[carcamerarig]

@dc42
Straightaway pre print I have 4c on driver 3, normal??

Date	Event	
M569.2 P0.4 R6 Register 0x06 value 0x21000040
M569.2 P0.3 R6 Register 0x06 value 0x2100004c
M569.2 P0.2 R6 Register 0x06 value 0x21000048
M569.2 P0.1 R6 Register 0x06 value 0x21000044
M569.2 P0.0 R6 Register 0x06 value 0x21000040

[dc42]

@carcamerarig, yes those are the normal values. It's for the second-to-last digit that I am interested in values other than 4, in particular C. It may possibly change value when the chip has warmed up.

[dc42]

PS - I just spotted another register that I would like to know the value of after banging occurs, so please can you also send this command:

M569.1 P# R111

for values of # that cover at least the axis motors.