Extruder motor stops during print…

ofloveandhate

1.20

ofloveandhate

what effect will changing this line have?

M111 S0                             	; Debug off

answer, kinda:

M111 S1 P15
Debugging enabled for modules:
Debugging disabled for modules: Platform(0) Network(1) Webserver(2) GCodes(3) Move(4) Heat(5) DDA(6) Roland(7) Scanner(8) PrintMonitor(9) Storage(10) PortControl(11) DuetExpansion(12) FilamentSensors(13) WiFi(14)

ofloveandhate

the Aprinter firmware claims to work on a duet. see http://reprap.org/wiki/List_of_Firmware

know anyone running it? this would be a good way for me to rule out a firmware bug.

Dougal1957

@ofloveandhate:

the Aprinter firmware claims to work on a duet. see http://reprap.org/wiki/List_of_Firmware

know anyone running it? this would be a good way for me to rule out a firmware bug.

Looking at that link and the online configurator from it it looks like only the 0.6 board is selectable so the wifi/ethernet boards are unlikely to run with it.

dc42

I really don't think it is a firmware issue. Nobody else has reported a similar problem. So I think we are looking at one of the following:

1. Trying to extrude with no tool selected, or with the heater not up to temperature. If this is the case, there will be error messages on the GCode Console page of DWC.

2. Faulty stepper motor, or (more likely) a faulty cable or crimp connection at the end of the cable.

3. Stepper driver overheating, due to a faulty stepper driver or running it at maximum current (2.4A) with inadequate cooling. If you are running firmware 1.20 or later then there would be an error message on the GCode Console page again.

4. Faulty stepper driver chip, or faulty soldering of the stepper driver chip. To rule that out, try using the E1 motor output instead of the E0 output. But I think you already tried that.

5. A good old fashioned hot end jam. Are you able to extrude immediately after cancelling the print? If you run the print with no filament in the extruder, does the motor continue turning right up to the end of the print?

6. Bad GCode causing M906 or M913 being executed to reduce the motor current. Run M906 and M913 without parameters after the fault has occurred and check the reported values.

HTH David

ofloveandhate

thanks for the list.

1. no error messages, so not this

2. replaced stepper motor already. replaced cables from bottom of whip to board once. i could replace again, including the wires in the whip. it could be this

3. no error, same behaviour with two duet boards, same problems with a heat break and active cooling on the duet. not this.

4. same behaviour with two duet boards. same problem on E1. not this

5. no, i am not able to move it – the motor does not respond to requests to move. my gut tells me there might be something to explore here. i will also try generating a fail with an unloaded extruder.

6. seem likely? will do next fault, combined with #5.

7. firmware bug seem unlikely, but we are still unable to rule it out. lack of other reports points to not this, but something with my machine... let's continue to eliminate other causes.

thanks soooo much for your ongoing advice and help. i will solve this issue!!!

dc42

After the fault has occurred, if you try to extrude (with the hot end still at operating temperature) does the motor vibrate or make any noise at all?

Are you able to turn the motor shaft or extruder gear by hand, or is it locked?

Does M563 P0 report the correct exruder drive number?

What do you have to do to get extrusion working again?

Another M122 report immediately after the fault occurred may be useful.

ofloveandhate

logging from startup gives this:

2018-02-28 21:27:52 Error: Can't open 0:/sys/oem.json to read, error code 4

```is that disconcerting?

dc42

No, that message is normal. DWC tries to open oem.json but that file is only present in a special configuration used by one of our OEMs.

ofloveandhate

another failure, most of the way through tobel60, with interpolation off.

the gcode console does not have a message about the finishing of printing.

here are the outputs of some reports:

M563 P0
Tool 0 - drives: 0; heaters (active/standby temps): 1 (0.0/0.0); xmap: X; ymap: Y; fans: 0; status: selected

M122
=== Diagnostics ===
Used output buffers: 4 of 32 (10 max)
=== Platform ===
RepRapFirmware for Duet WiFi version 1.20 running on Duet WiFi 1.0
Board ID: 08DDM-9FAM2-LW4SD-6JKD0-3SN6N-T2ZVY
Static ram used: 15448
Dynamic ram used: 99288
Recycled dynamic ram: 4048
Stack ram used: 1392 current, 8552 maximum
Never used ram: 3736
Last reset 21:25:40 ago, cause: power up
Last software reset at 2018-02-28 21:32, reason: User, spinning module GCodes, available RAM 11880 bytes (slot 2)
Software reset code 0x0003 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x0441f000, BFAR 0xe000ed38, SP 0xffffffff
Error status: 0
Free file entries: 9
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 2.8ms
MCU temperature: min 29.7, current 43.3, max 60.7
Supply voltage: min 23.8, current 24.3, max 24.9, under voltage events: 0, over voltage events: 0
Driver 0: standstill, SG min/max 0/1023
Driver 1: standstill, SG min/max 0/1023
Driver 2: standstill, SG min/max 0/1023
Driver 3: standstill, SG min/max 0/1023
Driver 4: standstill, SG min/max not available
Date/time: 2018-03-02 09:19:22
Cache data hit count 4294967295
Slowest main loop (seconds): 0.077818; fastest: 0.000044
=== Move ===
MaxReps: 1440, StepErrors: 0, FreeDm: 240, MinFreeDm 120, MaxWait: 1957299979ms, Underruns: 7045, 3
Scheduled moves: 0, completed moves: 0
Bed compensation in use: none
Bed probe heights: 0.000 0.000 0.000 0.000 0.000
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.0
Heater 1 is on, I-accum = 0.6
=== GCodes ===
Segments left: 0
Stack records: 2 allocated, 0 in use
Movement lock held by null
http is idle in state(s) 0
telnet is idle in state(s) 0
file is idle in state(s) 0
serial is idle in state(s) 0
aux is idle in state(s) 0
daemon is idle in state(s) 0
queue is idle in state(s) 0
autopause is idle in state(s) 0
Code queue is empty.
Network state is running
WiFi module is connected to access point 
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.20
WiFi MAC address 2c:3a:e8:0b:20:8d
WiFi Vcc 3.37, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 16656
WiFi IP address 10.0.1.2
WiFi signal strength -50dBm, reconnections 0, sleep mode modem
HTTP sessions: 1 of 8
Socket states: 2 0 0 0 0 0 0 0
Responder states: HTTP(1) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)

M906
Motor current (mA) - X:1000, Y:1000, Z:1000, E:400:400:400:400:400:400:400:400:400, idle factor 30%

M913
Motor current % of normal - X:100, Y:100, Z:100, E:100:100:100:100:100:100:100:100:100

M350
Microstepping - X:64, Y:64, Z:64, E:16:16(on):16:16:16:16:16:16:16

M408 S4
{"status":"I","coords":{"axesHomed":[0,0,0],"extr":[50225.4],"xyz":[0.000,0.000,430.673]},"currentTool":0,"params":{"atxPower":0,"fanPercent":[0.00,100.00,100.00,0.00,0.00,0.00,0.00,0.00,0.00],"speedFactor":100.00,"extrFactors":[100.00],"babystep":0.000},"sensors":{"probeValue":0,"fanRPM":0},"temps":{"bed":{"current":16.3,"active":0.0,"state":2,"heater":0},"current":[16.3,190.0,2000.0,2000.0,2000.0,2000.0,2000.0,2000.0],"state":[2,2,0,0,0,0,0,0],"heads":{"current":[190.0],"active":[190.0],"standby":[0.0],"state":[2]},"tools":{"active":[[190.0]],"standby":[[0.0]]},"extra":[{"name":"MCU","temp":44.0}]},"time":79008.0,"currentLayer":0,"currentLayerTime":0.0,"extrRaw":[50225.4],"fractionPrinted":0.0,"firstLayerDuration":0.0,"firstLayerHeight":0.50,"printDuration":0.0,"warmUpDuration":0.0,"timesLeft":{"file":0.0,"filament":0.0,"layer":0.0}}

i am able to turn on the heater for the extruder. attempting to extrude yields very slow moves. i can feel the motor running, but it is barely turning. i swapped motors, and it did not solve the problem. i also removed the motor from the machine, and it still is barely moving when i extrude, so it was not physical binding causing the problem.

i will leave the machine errored for a while, hoping that we can try some things together.

dc42

Thanks. Please run M92 to check that the extruder steps/mm is still correct. Also M572 to check the pressure advance setting, and M201 and M203 to check the speed and acceleration settings.

Kezat

In the error state are you able to get the extruder to move faster if you manually send a G1 commands that includes a faster speed or will it only move at one really slow speed for any move command?

ofloveandhate

still in errored state:

M92
Steps/mm: X: 800.000, Y: 800.000, Z: 800.000, E: 700.000:700.000:700.000:700.000:700.000:700.000:700.000:700.000:700.000

M572
Extruder pressure advance: 0.000, 0.000, 0.000, 0.000, 0.000, 0.000, 0.000, 0.000, 0.000

M201
Accelerations: X: 1000.0, Y: 1000.0, Z: 1000.0, E: 1000.0:1000.0:1000.0:1000.0:1000.0:1000.0:1000.0:1000.0:1000.0

M203
Maximum feedrates: X: 20000.0, Y: 20000.0, Z: 8000.0, E: 20000.0:20000.0:20000.0:20000.0:20000.0:20000.0:20000.0:20000.0:20000.0

ofloveandhate

no, putting in higher feedrates doesn't really make it move faster. this is hard to measure. putting in longer extrudes and higher feedrates doesn't seem to make a difference.

ofloveandhate

no errors in the text log, but it did log the completion of the file. thus, i cannot trust the web interface's gcode console – things show up in the text file that don't in the web interface, when i am not connected to the machine.

Kezat

@ofloveandhate:

no, putting in higher feedrates doesn't really make it move faster. this is hard to measure. putting in longer extrudes and higher feedrates doesn't seem to make a difference.

So strange, all other motors/fans/heater PIDs operate normally correct? Its only the extruder motor that stop/slows mid print yet the printer keeps on "printing" until the end of the gcode? Other then a tool change or full reset have you found any other way to clear the error state? Will another print without a reset start normally i wonder. Perhaps M92 E0 will clear it or even resending all the steps/mm, max speed, acceleration commands. (even though it tells you its correct) Also to test E movement in the error state are you heating the nozzle or enabling cold extrusion to let you test it?
Are you able to tell if the error is happening at truly the exact same spot in the gcode or just around the same layer/print time?

ofloveandhate

@Kezat – these are all good wonders. i still have the machine errored, so will try sending some gcodes to "restore" settings, see what happens.

1.

So strange, all other motors/fans/heater PIDs operate normally correct? Its only the extruder motor that stop/slows mid print yet the printer keeps on "printing" until the end of the gcode?

yep

2.

Other then a tool change or full reset have you found any other way to clear the error state? Will another print without a reset start normally i wonder

no, it's errored and nothing seems to fix it. the only way i know to get it working again is to M999 or power cycle. additional testing as you suggest it merited (re-sending machine parameters, etc). i will do that now.

3.

Also to test E movement in the error state are you heating the nozzle or enabling cold extrusion to let you test it?

A: heating it.

4.

Are you able to tell if the error is happening at truly the exact same spot in the gcode or just around the same layer/print time?

it is not the same spot every time. it varies wildly. i wish it was the same spot every time, we probably would've solved this by now, ha. repeatability / replicability is highly desirable. this is the major reason i doubt it is a firmware bug – otherwise, it would be repeatable. unless it's an intermittent problem caused by something like dynamic memory allocation, that stuff can be intermittent. so far, no-one's tried my gcode files on a duet delta machine, so i have no information on replicability.

garyd9

@ofloveandhate:

so far, no-one's tried my gcode files on a duet delta machine, so i have no information on replicability.

Not even the folks at UltiBots? That doesn't speak well for their support…

ofloveandhate

update: running

M350 X64 Y64 Z64 E16 I0

```allows me to extrude
i do not know how to return it to errored state without printing another object.

tell me, what do you think of this idea: i insert this statement into my layer change gcode, and see if i can make it through a whole file? there will be gaps where the machine went error.

ofloveandhate

@garyd9:

@ofloveandhate:

so far, no-one's tried my gcode files on a duet delta machine, so i have no information on replicability.

Not even the folks at UltiBots? That doesn't speak well for their support…

to their credit, my gcode files are long. some are 16-24 hour prints, with the error occurring anywhere in there, and not guaranteed to occur… brad has been very helpful to me so far, with a thread on the ultibots forum with > 70 posts, and several long phone calls. forum.ultibots.com/viewtopic.php?f=59&t=297

i would like someone to try my code, though… will you, dear reader? links above