RepRapFirmware 3.6.0-alpha.4+3 available for testing

gloomyandy

Folks if anyone has a print that generates a "Movement halted error" after a short time (so relatively early in the print) can you please post the gcode file and the config.g file for the printer. That way we can try and reproduce the issue.

@Exerqtor did your error occur on the first print after a printer restart or had you already printed a previous file? I ask because your m122 is showing a hiccup delay, but no hiccups (maybe you have run m122 more than once after the failure). If this was the second print that failed can you test to see if the same print fails as the first print after the printer is restarted?

balajiramani

@Adrian52 I haven't been able to run a successful delta calibration with the 3.6.0 firmware. This was not an issue in 3.5.2. The head crashes into the bed. The movement is not straight from one probe point to the other and it more of a 'U' shaped move. Can you post your bed.g, so that I can compare it with what I have?

Thanks,
Balaji

dc42

@balajiramani a U shaped move suggests that the auto-generated travel move is not being segmented. Please run M669 without parameters, to check that segmentation hasn't been disabled. Also please send M115 to verify that you really are running the latest alpha firmware.

balajiramani

@dc42 Here are the output of the commands:

8/31/2024, 1:20:52 PM	M115
FIRMWARE_NAME: RepRapFirmware for Duet 2 WiFi/Ethernet FIRMWARE_VERSION: 3.6.0-alpha.4+3 ELECTRONICS: Duet WiFi 1.0 or 1.01 FIRMWARE_DATE: 2024-08-28 10:03:28
8/31/2024, 1:20:40 PM	M669
Kinematics is Linear delta, 100 segments/sec, min. segment length 0.20mm

dc42

Those of you with the code 3 errors, how long was the print running? I think I've just found a bug that could cause a code 3 error if a print was running about 47 minutes after the Duet 3 was booted up (about 38 minutes for Duet 2).

dc42

@balajiramani thanks. Are you sure that the delta radius and rod length are set to approximately the correct value before calibration? I don't think anyone else has reported issues with delta calibration running recent 3.6.0 alpha versions, and calibration works perfectly on my own delta. So I am wondering whether the reason for the U-shaped moves is that either the rod length or delta radius is set incorrectly. Possibly there is an error in your M665 or M666 command and RRF 3.6 responds differently to that error. So please run M665 and M666 without parameters and check that the reported values are as expected.

tas

@dc42 Duet 2 Wifi on an Ender 5 plus stopped with the code 3 error. Your 38 minute mark sounds about right but I don't have an exact time when it stopped.

I installed 3.5.3 rc1 and ran the same gcode without issues.

Exerqtor

@gloomyandy said in RepRapFirmware 3.6.0-alpha.4+3 available for testing:

Folks if anyone has a print that generates a "Movement halted error" after a short time (so relatively early in the print) can you please post the gcode file and the config.g file for the printer. That way we can try and reproduce the issue.

For me it happened roughly 35min into the print.

@Exerqtor did your error occur on the first print after a printer restart or had you already printed a previous file? I ask because your m122 is showing a hiccup delay, but no hiccups (maybe you have run m122 more than once after the failure). If this was the second print that failed can you test to see if the same print fails as the first print after the printer is restarted?

Yeah it was the first print after the update! And you're right, it was the second M122 output. Here is the first output (including the print startinfo, error message etc:

30.8.2024, 20:23:36	M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.6.0-alpha.4+3 (2024-08-28 11:24:12)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 6672, free system stack 79 words
Tasks: Move(3,nWait 7,0.3%,84) TMC(2,nWait 6,3.6%,52) HEAT(2,nWait 6,0.4%,88) CanAsync(5,nWait 4,0.0%,48) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) MAIN(1,running,90.5%,318) IDLE(0,ready,0.0%,26) AIN(2,delaying,5.0%,112), total 100.0%
Owned mutexes:
Last reset 02:41:25 ago, cause: power up
Last software reset at 2024-03-12 16:55, reason: StackOverflow, available RAM 2968, slot 0
Software reset code 0x0100 ICSR 0x0042600e SP 0x20007f34 Task Move Freestk 3342 ok
Stack: 20004a80 20004ab4 0001cf33 20004c98 20004938 00000000 0001c011 20003320 fffffffd a5a5a5a5 00000000 20007f8c 00000000 20007f8c 0001cc97 00000000 200017c4 20001748 0001c4d7 20001748 200017c4 00000032 454c4449 00022700 0001ac77 200018e0 200018e0
Moves scheduled 65223, hiccups 782 (39.68/39.68ms), segs 58, step errors 2 (types 0x8), maxLate 0 maxPrep 1303, ebfmin 0.00 max 0.00
Peak sync jitter -4/10, peak Rx sync delay 255, resyncs 0/0, no timer interrupt scheduled, next step interrupt due in 3473139117 ticks, disabled
VIN voltage: min 23.7, current 24.5, max 25.0
MCU temperature: min 41.1C, current 75.4C, max 75.5C
Driver 0: pos 2824553, 568.8 steps/mm, standstill, SG min 0, read errors 1, write errors 0, ifcnt 12, reads 44905, writes 12, timeouts 3, DMA errors 0, CC errors 0, failedOp 0x6f
Last sensors broadcast 0x00000012 found 2 43 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 200813, send timeouts 0, received 154587, lost 0, ignored 0, errs 0, boc 0, free buffers 18, min 17, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 825, adv 35393/74627
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 5726621 to 0us, poll 4 to 2225us
Driver 0: ok

30.8.2024, 20:23:32	M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.6.0-alpha.4+3 (2024-08-28 10:03:49) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: XNHXF-HR6KL-K65J0-409N2-K9W1Z-RV2MZ
Used output buffers: 4 of 40 (37 max)
=== RTOS ===
Static ram: 92328
Dynamic ram: 95720 of which 0 recycled
Never used RAM 45628, free system stack 126 words
Tasks: NETWORK(1,ready,18.9%,179) HEAT(3,nWait 6,0.0%,325) Move(4,invalid,0.3%,247) TMC(4,nWait 6,0.9%,65) CanReceiv(6,nWait 1,0.1%,794) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,339) MAIN(1,running,77.7%,627) IDLE(0,ready,1.2%,29) AIN(4,delaying,0.8%,259), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 02:41:20 ago, cause: software
Last software reset at 2024-08-30 17:42, reason: User, Gcodes spinning, available RAM 52612, 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
Aux0 errors 0,1,0
MCU temperature: min 35.7, current 46.0, max 46.6
Supply voltage: min 2.7, current 23.9, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/34, heap memory allocated/used/recyclable 2048/1396/920, gc cycles 2164
Events: 0 queued, 0 completed
Date/time: 2024-08-30 20:23:27
Slowest loop: 223.44ms; fastest: 0.10ms
=== Storage ===
Free file entries: 17
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 10.2ms, write time 69.6ms, max retries 0
=== Move ===
Segments created 178, maxWait 603453ms, bed comp in use: mesh, height map offset 0.000, hiccups added 0 (0.00/39.68ms), max steps late 0, ebfmin 0.00, ebfmax 0.00
Pos req/act/dcf: -2663.00/-3086/0.45 -23548.00/-23971/0.43 33160.00/33160/-0.00
no step interrupt scheduled
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 47, reads 50443, writes 47, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 0, ifcnt 47, reads 50443, writes 47, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 0, ifcnt 22, reads 50467, writes 22, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 22, reads 50467, writes 22, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 0, ifcnt 23, reads 50467, writes 23, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
=== DDARing 0 ===
Scheduled moves 66586, completed 66560, LaErrors 217, Underruns [0, 0, 0]
=== DDARing 1 ===
Scheduled moves 0, completed 0, LaErrors 0, Underruns [0, 0, 0]
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X192.529 Y130.297 E.90485" 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 doing "G4 P250" in state(s) 0 0, running macro
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no filament
=== CAN ===
Messages queued 154539, received 200688, lost 0, ignored 0, errs 1318, boc 0
Longest wait 7ms for reply type 6029, peak Tx sync delay 10782, free buffers 26 (min 24), ts 48405/48403/0
Tx timeouts 0,0,1,0,0,0 last cancelled message type 30 dest 127
=== Network ===
Slowest loop: 210.77ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1.0
MAC address c4:5b:be:ce:91:93
Module reset reason: Power up, Vcc 3.38, flash size 2097152, free heap 43020
WiFi IP address 192.168.30.50
Signal strength -50dBm, channel 1, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 0 0 0 0 0 0 0 0

30.8.2024, 18:29:54	Error: Movement halted because a step timing error occurred (code 3). Please reset the controller.

30.8.2024, 17:55:27	ABS filament loaded
ABS filament loaded & config applied
30.8.2024, 17:54:49	16 points probed, min error -0.030, max error 0.016, mean -0.012, deviation 0.013
Height map saved to file 0:/sys/heightmap.csv
Height map saved to file 0:/sys/adaptive_heightmap.csv
30.8.2024, 17:54:18	Default grid: X10.0:340.0, Y10.0:340.0, Number of points: X12 Y12, 144 points
Adaptive grid: X120.833:229.167, Y120.833:229.136, Number of points: X4 Y4, 16 points
30.8.2024, 17:53:57	M32 "0:/gcodes/ringing_text_test_0.2mm_ABS_0.4n_48m59s.gcode"
File 0:/gcodes/ringing_text_test_0.2mm_ABS_0.4n_48m59s.gcode selected for printing

dc42

@Exerqtor @tas thanks. I will release 3.6.-alpha.5 after doing a couple of test prints.

Exerqtor

@dc42 Awesome, i will install it and try the same testprint right away

balajiramani

@dc42 The delta calibration procedure works fine with 3.5.2. With 3.6.0-alpha*, I run into the issue. I checked the values of M665 and M666 in both 3.5.2 and 3.6.0-alpha and they are the same values.

Here is what I see with 3.5.2:

8/31/2024, 5:09:41 PM	M666
                        Endstop adjustments X-1.26 Y-1.03 Z2.30, tilt X0.00% Y0.00%
8/31/2024, 5:09:38 PM	M665
                        Diagonals 395.647:395.647:395.647, delta radius 214.803, homed height 359.884, bed radius 160.0, X -0.068°, Y -0.015°, Z 0.000°

Here is what I see with 3.6.0-alpha.4+3

8/31/2024, 5:58:57 PM	M666
                        Endstop adjustments X-1.26 Y-1.03 Z2.30, tilt X0.00% Y0.00%
8/31/2024, 5:58:56 PM	M665
                        Diagonals 395.647:395.647:395.647, delta radius 214.803, homed height 359.884, bed radius 160.0, X -0.068°, Y -0.015°, Z 0.000°

Adrian52

@balajiramani Hi - sorry for the delay
here is my bed.g. I have a 250mm dia round bed

; Auto calibration routine for large delta printer
M561                    ; clear any bed transform

; If the printer hasn't been homed, home it
;if !move.axes[0].homed || !move.axes[1].homed || !move.axes[2].homed
  G28

; Probe the bed and do auto calibration
G1 X-70 Y-60 Z10 F6000        ; go to just above the first probe point
while true
  if iterations = 5
    abort "too many auto calibration attempts"
  G30 P0 X-70 Y-60 Z-99999
  if result != 0
    continue
  G30 P1 X-85 Y0 Z-99999
  if result != 0
    continue
  G30 P2 X-50 Y75 Z-99999
  if result != 0
    continue
  G30 P3 X0 Y85 Z-99999
  if result != 0
    continue
  G30 P4 X50 Y75 Z-99999
  if result != 0
    continue
  G30 P5 X85 Y0 Z-99999
  if result != 0
    continue
  G30 P6 X75 Y-50 Z-99999
  if result != 0
    continue
  G30 P7 X0 Y-85 Z-99999
  if result != 0
    continue
  G30 P8 X-40 Y-40 Z-99999
  if result != 0
    continue
  G30 P9 X-50 Y0 Z-99999
  if result != 0
    continue
  G30 P10 X-40 Y40 Z-99999
  if result != 0
    continue
  G30 P11 X0 Y50 Z-99999
  if result != 0
    continue
  G30 P12 X40 Y40.00 Z-99999
  if result != 0
    continue
  G30 P13 X50 Y0 Z-99999
  if result != 0
    continue
  G30 P14 X40 Y-40 Z-99999
  if result != 0
    continue
  G30 P15 X-4 Y-2 Z-99999
  if result != 0
    continue
  G30 P16 X4 Y-2 Z-99999
  if result != 0
    continue
  G30 P17 X0 Y4 Z-99999 S6
  if result != 0
    continue
 
  if move.calibration.final.deviation <= 0.03
    break
  echo "Repeating calibration because deviation is too high (" ^ move.calibration.final.deviation ^ "mm)"
; end loop
echo "Auto calibration successful, deviation", move.calibration.final.deviation ^ "mm"
G1 X0 Y0 Z150 F5000                ; get the head out of the way
M500
G28

dc42

I've put the 3.6.0-alpha.5 binaries at https://www.dropbox.com/scl/fo/u79134f365jdacqsm0km3/AKMSKB_Fz63WH4hqLkIphuQ?rlkey=bpa9lja4jylkpu9syjfp31rho&dl=0 and the release notes at https://github.com/Duet3D/RepRapFirmware/wiki/Changelog-RRF-3.x-Beta#reprapfirmware-360-alpha5.

Adrian52

@dc42 I didnt check the exact time , but just under 40 min would be about right for me too.

curieos

@dc42 Mine was actually around the 3.5-4 hour mark for the print. The print I was doing was around 3.75 hours, and it paused with around 15 minutes left. There may have been a delay in the print start too, my machine is a flying gantry so I need to rerun G32 every time the motors shut off, and I may have waited a bit of time for heat soaking since I was printing ASA, so it could've been 4-4.5 hours after the restart.

Exerqtor

@dc42 said in RepRapFirmware 3.6.0-alpha.4+3 available for testing:

I've put the 3.6.0-alpha.5 binaries at https://www.dropbox.com/scl/fo/u79134f365jdacqsm0km3/AKMSKB_Fz63WH4hqLkIphuQ?rlkey=bpa9lja4jylkpu9syjfp31rho&dl=0 and the release notes at https://github.com/Duet3D/RepRapFirmware/wiki/Changelog-RRF-3.x-Beta#reprapfirmware-360-alpha5.

Just ran the initial function test with alpha.5, and the "pause" after each probe move that I mentioned back in July is gone now. Which sure is nice

I've noticed that a bug from earlier (don't remember when) seem to have been reintroduced though, when i push the "bed leveling" button on PD i't don't display any of the messages nested in bed.g on the PD, only in DWC.

Running the same test print as earlier on alpha.5 now to see if finish without any step timing errors.

And I can also comfirm that it finished the same test print without any issues!

The PA changes is quite segnificant compared to alpha.2 as well. As can be seen in the test prints:
alt text

Pressure advance changing every 10mm in these increments:

0-10mm = PA: 0.045s.
10-20mm = PA: 0.025s.
20-30mm = PA. 0.01s.
30-40mm = PA: 0.0075s.
40-50mm = PA: 0.005s.
50-60mm = PA: 0s / off.

tas

@dc42 Testing 3.6.0-alpha.5 on my Duet2Wifi Ender 5 Plus using the same gcode that failed before. Also using DWC 3.6.0-alpha.2+1.

Just passed 40 minutes with no issues.

dc42

@curieos said in RepRapFirmware 3.6.0-alpha.4+3 available for testing:

@dc42 Mine was actually around the 3.5-4 hour mark for the print. The print I was doing was around 3.75 hours, and it paused with around 15 minutes left. There may have been a delay in the print start too, my machine is a flying gantry so I need to rerun G32 every time the motors shut off, and I may have waited a bit of time for heat soaking since I was printing ASA, so it could've been 4-4.5 hours after the restart.

Thanks. The bug could also occur at multiples of 47 (38 on Duet 2) minutes after the machine has been powered up or reset.

balajiramani

@Adrian52 Thank you for your copy of bed.g. The one big difference that I saws that the initial move in your file, after homing, is to move the head just above the probe point, where as in the version that I had, I was moving to X0 Y0. When I changed it to go just above the first point, so that the head is vertically above the first probe point, the bed calibration routine worked fine.

So, it looks like there seems to be a difference in the behavior depending on where the head is, relative to the first probe point and it is quite repetable for me. This seems to be a regression as compared to 3.5.2. At this point, I am glad that I found a way to get bed calibration working again on 3.6.0.

@dc42 can you check the behaviour on your end to see if you are able to reproduce this issue on the delta that you have?

Thanks,
Balaji

tas

@dc42
Duet2Wifi print completed after 1 hour 46 minutes without issues.
Thanks for the fix.