Error: New tool too close to Z axis limit. ?

[peter247]

got a Strange error today , switched the printer on , didn't home it , heated the bed to 60c , give it a few minutes to stabilise and selected the job and noticed it started to cool with this error

M32 "0:/gcodes/BLV_Body2.gcode"
File 0:/gcodes/BLV_Body2.gcode selected for printing
Cancelled printing file 0:/gcodes/BLV_Body2.gcode, print time was 0h 0m
Error: New tool too close to Z axis limit. Aborting tool change

tried again and it is printing now !!!!

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.3 (2021-06-15 21:46:11) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: MZSV6-S096U-D65J0-40KMD-3413Z-R7859
Used output buffers: 3 of 40 (14 max)
=== RTOS ===
Static ram: 102724
Dynamic ram: 106480 of which 0 recycled
Never used RAM 31644, free system stack 130 words
Tasks: NETWORK(ready,15.1%,220) HEAT(delaying,0.0%,366) Move(notifyWait,0.2%,276) CanReceiv(notifyWait,0.0%,941) CanSender(notifyWait,0.0%,357) CanClock(delaying,0.0%,340) TMC(notifyWait,0.7%,114) MAIN(running,83.0%,426) IDLE(ready,0.1%,29) AIN(delaying,0.9%,264), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:13:39 ago, cause: power up
Last software reset at 2021-07-02 21:35, reason: User, GCodes spinning, available RAM 31468, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
MCU revision 3, ADC conversions started 819901, completed 819899, timed out 0, errs 0
Step timer max interval 1266
MCU temperature: min 34.4, current 54.1, max 54.3
Supply voltage: min 23.9, current 24.0, max 24.3, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/2, heap memory allocated/used/recyclable 2048/24/0, gc cycles 0
Driver 0: position 61789, ok, SG min/max 0/112, read errors 0, write errors 0, ifcnt 11, reads 43056, writes 11, timeouts 0, DMA errors 0
Driver 1: position 2269, ok, SG min/max 0/98, read errors 0, write errors 0, ifcnt 11, reads 43056, writes 11, timeouts 0, DMA errors 0
Driver 2: position 6880, standstill, SG min/max 0/16, read errors 0, write errors 0, ifcnt 13, reads 43054, writes 13, timeouts 0, DMA errors 0
Driver 3: position 0, standstill, SG min/max 0/6, read errors 0, write errors 0, ifcnt 13, reads 43054, writes 13, timeouts 0, DMA errors 0
Driver 4: position 0, ok, SG min/max 0/16, read errors 0, write errors 0, ifcnt 11, reads 43056, writes 11, timeouts 0, DMA errors 0
Driver 5: position 0, assumed not present
Driver 6: position 0, assumed not present
Date/time: 2021-07-09 12:28:39
Cache data hit count 1446095184
Slowest loop: 22.79ms; fastest: 0.09ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 3.5ms, write time 21.0ms, max retries 0
=== Move ===
DMs created 83, maxWait 191272ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 9425, completed moves 9385, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 2], CDDA state 3
=== 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 = 0.1
Heater 1 is on, I-accum = 0.7
=== GCodes ===
Segments left: 1
Movement lock held by null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G0 X166.003 Y164.253" 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.
=== CAN ===
Messages queued 7380, received 0, lost 0, longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 17 (min 17), ts 4099/0/0
Tx timeouts 0,3,4098,0,0,3276 last cancelled message type 4514 dest 127

=== Network ===
Slowest loop: 44.39ms; 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 1.26
WiFi MAC address f0:08:d1:02:eb:a5
WiFi Vcc 3.40, reset reason Power up
WiFi flash size 2097152, free heap 25544
WiFi IP address 192.168.0.186
WiFi signal strength -66dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

[Phaedrux]

Can you post your config.g, config-overide.g and any tool change files that may get called at startup and at print start?

[peter247]

@phaedrux

G90                                           ; send absolute coordinates.
M83                                           ; but relative extruder moves.
M550 P"BLV mgn Cube"                          ; set printer name.
M551 P"the_password"

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

; Drives
M569 P0 S1                                     ; physical drive 0 goes backwards
M569 P1 S1                                     ; physical drive 1 Direction
M569 P2 S1                                     ; physical drive 2 Direction
M569 P3 S1                                     ; physical drive 3 Direction
M569 P4 S1                                     ; physical drive 4 Direction.

M669 K1 									   ; switch to CoreXY mode

M584 X0 Y1 Z2:3 E4                             ; set drive mapping
M350 X16 Y16 Z16 I1                            ; configure microstepping with interpolation
M350 E16 I0                                    ; configure microstepping without interpolation
M92  X200.00 Y200.00 Z1600.00 E409             ; set steps per mm  , e380 , e135 , bmg 420 cal
M566 X300.00 Y300.00 Z24.00 E300               ; set maximum instantaneous speed changes (mm/min)
M203 X18000.00 Y18000.00 Z180.00 E2700.00        ; set maximum speeds (mm/min)
M201 X3000.00 Y3000.00 Z100.00 E5000.00        ; set accelerations (mm/s^2)
M906 X1000 Y1000 Z600 E1000 I50                ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                        ; Set idle timeout

; Axis Limits
M208 X-33 Y0 Z0 S1                               ; set axis minima
M208 X300 Y320 Z300 S0   
; Endstops
M574 X1 S1 P"!io0.in"                          ; configure active-high endstop for low end on X via pin xstop
M574 Y2 S1 P"!io1.in"                          ; configure active-high endstop for low end on Y via pin ystop
;M574 Z1 S2  

; Z-Probe
M558 P9 C"io2.in" H2 F100 T8000 A5		        ; set Z probe type to bltouch and the dive height + speeds
M950 S0 C"io2.out"							    ; create servo pin 0 for BLTouch
G31 P500 X 30 Y 55 Z 1.4                        ; set Z probe trigger value, offset and trigger height
M557 X60:240 Y60:240 S30  

; External Triggers
M950 J0 C"io5.in"
M950 J1 C"io6.in"
M581 P0 T3 S1 R0 
M581 P1 T4 S1 R0 

; Heaters
;M308 S0 A"BED" P"Temp_0" Y"thermistor" T100000 B4092 ; configure sensor 0 as thermistor on pin bedtemp Ender
M308 S0 A"BED" P"Temp_0" Y"thermistor" T100000 B3950 C0; configure sensor 0 as thermistor on pin bedtemp type 3950
M950 H0 C"Out_0" Q10 T0                        ; create bed heater output on bedheat and map it to sensor 0
;M307 H0 B1 S1.00                              ; enable bang-bang mode for the bed heater and set PWM limit
M307 H0 B0 R0.734 C515.8 D11.02 S1.00		   ; tuned value 
M140 H0                                        ; map heated bed to heater 0
M143 H0 S150                                   ; set temperature limit for heater 0 to 150C
;M308 S1 A"NOZZLE" P"Temp_1" Y"thermistor" T100000 B4092  ; Ender Thermistor
M308 S1 A"NOZZLE" P"Temp_1" Y"thermistor" T100000 B4725 C7.06e-8 ; Hemera e3d Thermistor
M308 S2 A"CASE"    P"Temp_2" Y"thermistor" T100000 B4092 
M950 H1 C"Out_1" T1                           ; create nozzle heater output on e0heat and map it to sensor 1
M307 H1 B0 S1.00  

; Fans
M950 F0 C"Out_3" Q500                          ; create fan 0 on pin fan0 and set its frequency
M106 P0 S1 H1 T45                              ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"Out_4" Q500                          ; create fan 1 on pin fan1 and set its frequency
M106 P1 S0 H-1                                 ; set fan 1 value.
M950 F2 C"Out_5" Q500                          ; create fan 2 on pin fan2 and set its frequency
M106 P2 S1 H1 T45                              ; set fan 2 value.

; Tools
M563 P0 D0 H1 F1 S"hemera"                     ; define tool 0
G10 P0 X0 Y0 Z0                                ; set tool 0 axis offsets
G10 P0 R0 S0  

M572 D0 S0.025
M221 D0 S90 ; 87% extrude
;

[Phaedrux]

@peter247 said in Error: New tool too close to Z axis limit. ?:

selected the job

Since this happened after starting a print job, please post your slicer start gcode and homing files.

[peter247]

@phaedrux It is a 1 in 1000 event , so you won't find a fault in any of the homing files etc .

cura start gcode

G28 ;Home
;G29
G92 E0 ;Reset Extruder
G1 Z2.0 F3000 ;Move Z Axis up
G1 X0.1 Y30 Z0.28 F5000.0 ;Move to start position
G1 X0.1 Y290.0 Z0.28 F1500.0 E25 ;Draw the first line
G1 X0.4 Y290.0 Z0.28 F5000.0 ;Move to side a little
G1 X0.4 Y30 Z0.28 F1500.0 E30 ;Draw the second line
G92 E0 ;Reset Extruder
G1 Z2.0 F3000 ;Move Z Axis up
M300 S300 P1000

; homeall.g
; called to home all axes
;
;G28 XY
M913 X50 Y50 Z50 ; set X Y Z motors to 50% of their normal current
G91               ; relative positioning
G1 H2 Z5 F6000    ; lift Z relative to current position
G1 H1 X -330 F3000 ; move quickly to X axis endstop and stop there (first pass)
G1 H1 Y 330 F3000 ; move quickly to Y axis endstop and stop there (first pass)
;G1 H2 Z-5 F6000   ; lower Z again
G90               ; absolute positioning

G1 X125 Y103 F4000 ; Move probe to middle of bed
G30
M913 X100 Y100 Z100 ; set X Y Z motors to 50% of their normal current

[dc42]

@peter247 said in Error: New tool too close to Z axis limit. ?:

Error: New tool too close to Z axis limit. Aborting tool change

That message should only occur if you do a tool change when the Z axis is very close to maximum, and the Z offset of the new tool is higher than the Z offset of the current tool so that the printer would have to move beyond max Z to accommodate the increased Z offset. For example:

• Z max is 200
• Machine Z is 190 when tool change is commanded (user Z will differ from this by the Z offset of the old tool)
• The tfree command for the old tool or the tpre command for the new tool raises Z by 8mm; which increases machine Z to 198
• The new tool has Z offset -5mm. This means that machine Z needs to increase to 198-(-5) = 203mm, which is above the machine Z limit of 200

[peter247]

@dc42 Yes , after a little think I guessed that is what the error message meant , But I had only just switched it on and the tool was where I left it the previous day at about 25mm from the tool.

[dc42]

@peter247 did you home Z before attempting the tool change?

[peter247]

@dc42 No homing at all , just switch on the printer and started heating the bed to 60c,
Told it to print and got the error , But told it to print the second time I didn't get a error .
I think the firmware / mpu was have a bad day !!!

[dc42]

@peter247 maybe the print file commands a tool change before Z has been homed?

[Phaedrux]

@dc42 said in Error: New tool too close to Z axis limit. ?:

@peter247 maybe the print file commands a tool change before Z has been homed?

The slicer must be selecting a tool because there is no T0 in config.g or his slicer start gcode.

@peter247 can you share the first 50 lines or so of your gcode file?

[peter247]

@phaedrux

This isn't the gcode which errored , but haven't changed anything in my start code .

;FLAVOR:RepRap
;TIME:11613
;Filament used: 8.26945m
;Layer height: 0.2
;MINX:127.228
;MINY:135.862
;MINZ:0.2
;MAXX:168.88
;MAXY:170.83
;MAXZ:80
;Generated with Cura_SteamEngine 4.10.0
T0
M190 S60
M104 S200
M109 S200
M82 ;absolute extrusion mode
G28 ;Home
;G29
G92 E0 ;Reset Extruder
G1 Z2.0 F3000 ;Move Z Axis up
G1 X0.1 Y30 Z0.28 F5000.0 ;Move to start position
G1 X0.1 Y290.0 Z0.28 F1500.0 E25 ;Draw the first line
G1 X0.4 Y290.0 Z0.28 F5000.0 ;Move to side a little
G1 X0.4 Y30 Z0.28 F1500.0 E30 ;Draw the second line
G92 E0 ;Reset Extruder
G1 Z2.0 F3000 ;Move Z Axis up
M300 S300 P1000
G92 E0
G92 E0
G1 F5100 E-0.3
;LAYER_COUNT:400
;LAYER:0
M107
G0 F2880 X128.628 Y136.722 Z0.2
;TYPE:SKIRT
G1 F2040 E0
G1 F1200 X129.078 Y136.406 E0.02378
G1 X129.569 Y136.159 E0.04754
G1 X130.09 Y135.986 E0.07128
G1 X130.632 Y135.891 E0.09507
G1 X130.911 Y135.872 E0.10716
G1 X131.232 Y135.863 E0.12105
G1 X134.859 Y135.862 E0.27787
G1 X135.557 Y135.872 E0.30805
G1 X135.867 Y135.89 E0.32148
G1 X136.607 Y135.962 E0.35363
G1 X139.326 Y136.192 E0.47161
G1 X142.04 Y136.345 E0.58915
G1 X144.795 Y136.422 E0.70831
G1 X147.516 Y136.42 E0.82597

I only have one tool ( 0 ) and didn't I select it by making the heater active ?

[Phaedrux]

@peter247 said in Error: New tool too close to Z axis limit. ?:

I only have one tool ( 0 ) and didn't I select it by making the heater active ?

Which heater did you make active? You mention setting the bed heater to 60.

[peter247]

@phaedrux The bed heater .

I can now reproduce the error now I know what it is !!!!

( 1 ) switch it on , don't home . ( Tool position X Y Z all zero )
( 2 ) Baby step with a minus offset value.
( 3 ) Print !!!! and you get the error .
( 4 ) Print again and it prints .

[Phaedrux]

@peter247 said in Error: New tool too close to Z axis limit. ?:

( Tool position X Y Z all zero )

What do you mean by this? Are you manually setting the positions? If you haven't homed yet how do you know what the tool position is?

Are you baby stepping before anything has been homed or a tool has been selected?

When you start the print, the first command it does is select T0. then sets some temps, and then homes.

Since you only have a single tool, you should add T0 to the end of your config.g so that it is selected at startup.

Then only baby step after you've homed.

[peter247]

@phaedrux said in Error: New tool too close to Z axis limit. ?:

@peter247 said in Error: New tool too close to Z axis limit. ?:

( Tool position X Y Z all zero )

What do you mean by this? Are you manually setting the positions? If you haven't homed yet how do you know what the tool position is?

Are you baby stepping before anything has been homed or a tool has been selected?

When you start the print, the first command it does is select T0. then sets some temps, and then homes.

Since you only have a single tool, you should add T0 to the end of your config.g so that it is selected at startup.

Then only baby step after you've homed.

I just mean that the web interface says Tool position all zero , not that the tool head is at a known position.

Yes I set a baby step before I homed it

o.k I'll add T0 to the end of my config.g

I think that is a solved now .