Exceeded Position Tolerance

ash100

I am running a large and heavy custom 3d printer, and I'm trying to increase the speed of the X and Y motors. When increasing the values in M203, this increases the speed but it throws this error:

Warning: Driver 72.0 warning: position tolerance exceeded

My running theory is that the initial acceleration/deceleration of the motors is too fast for the given inertia, but I do not know how to fix this.

Currrently, I am just doing P control PID, should I try to add the D term? Or should I adjust the M201 term? Or...?

Thank you for your help!

For my setup, I have a Mainboard 6HC connected to 2 TDB boards, which then connect to 5 M23CL motors.

config.g

; Configuration file for RepRapFirmware on Duet 3 Main Board 6HC
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.5.10 on Sun Jan 19 2025 10:10:54 GMT-0800 (Pacific Standard Time)

; General
G90 ; absolute coordinates
M83 ; relative extruder moves
M550 P"5axis" ; set hostname
G4 S2

;Drivers
M569 P70.0 S0 R1; driver 0.0 goes forwards (X axis)
M569.1 P70.0 T3 R100 I0
M569 P70.0 D4

;M569 P71.0 S1 D2 ; driver 0.1 goes forwards (Y axis)
M569 P71.0 S0 R1
M569.1 P71.0 T3 R100 I0
M569 P71.0 D4

;M569 P72.0 S1 D2 ; driver 0.2 goes forwards (Z axis)
M569 P72.0 S0 R1
M569.1 P72.0 T3 R100 I0
M569 P72.0 D4

;M569 P73.0 S1 D2 ; driver 0.4 goes forwards (U axis)
M569 P73.0 S0 R1
M569.1 P73.0 T3 R100 I0
M569 P73.0 D4

;M569 P74.0 S1 D2 ; driver 0.5 goes forwards (V axis)
M569 P74.0 S0 R1
M569.1 P74.0 T3 R100 I0
M569 P74.0 D4


; Axes
M584 X70.0 Y71.0 Z72.0 U73.0 V74.0 E75.0 ; set axis mapping
M350 X16 Y16 Z16 U16 V16 I1 ; configure microstepping with interpolation
M92 X640 Y640 Z1969.230 U800 V27.350 ; configure steps per mm
M906 X2000 Y1500 Z1500 U1500 V1500 ; set axis driver currents
M208 X0:1000 Y0:820 Z0:210 U-20:100 V-999:999 ; set minimum and maximum axis limits
M566 X500 Y500 Z500 U500 V1000 ; set maximum instantaneous speed changes (mm/min)
M203 X1500 Y1500 Z500 U500 V4000 ; set maximum speeds (mm/min)
M201 X500 Y500 Z500 U500 V1000 ; set accelerations (mm/s^2)

; Kinematics
;M669 K8 ; configure CoreXYUV kinematics

; Endstops
M574 X1 P"!io3.in" S1 ; configure X axis endstop
M574 Y1 P"!io0.in" S1 ; configure Y axis endstop
M574 Z2 P"!io7.in" S1 ; configure Z axis endstop
M574 U0 ; configure U axis endstop
M574 V0 ; configure V axis endstop

G92 V0 ; set V axis to zero upon startup
G92 U0 ; set V axis to zero upon startup

; Extruder
M350 E16 I1 ; configure microstepping with interpolation
M906 E900  ; set extruder driver currents
M92 E2682   ; configure steps per mm
M566 E300   ; set maximum instantaneous speed changes (mm/min)
M203 E3600  ; set maximum speeds (mm/min)  
M201 E250   ; set accelerations (mm/s^2)

;Nozzle Temperature
M308 S1 P"75.temp1" Y"thermistor" A"Nozzle" T100000 B4267 C7.06e-8 ; configure sensor #1
M950 H1 C"75.out0" T1 ; create heater #1 hotend heater
M143 H1 P0 S275 A0
M143 H1 P1 S285 A2
M307 H1 R4.663 K0.549:0.000 D1.95 E1.35 S1.00 B0


; Scanning Z Probe
M558 P11 C"75.i2c.ldc1612" F36000 T36000
M558.2 K0 S15 R142937
M308 A"SZP coil" S10 Y"thermistor" P"75.temp2" ; thermistor on coil
G31 Z2 X302 Y245
; M558.2 K0 S13 R142607
M557 X292:312 Y235:255 P10

; BL Touch Sensor
M950 S2 C"75.io0.out"
M558 P9 C"75.io0.in" H5 F120 T6000
G31 X0 Y0 Z3.739 P25

fcwilt

@ash100

You may have to install larger or more powerful steppers.

Frederick

dc42

@ash100 you don't appear to be using the A and V parameters in your M569.1 commands. Which firmware version are you using?

ash100

@dc42 I am using 3.5.3

M115
FIRMWARE_NAME: RepRapFirmware for Duet 3 MB6HC FIRMWARE_VERSION: 3.5.3 ELECTRONICS: Duet 3 MB6HC v1.02 or 1.02a FIRMWARE_DATE: 2024-09-18 11:27:36

dc42

@ash100 I guess you haven't run PID tuning since you were running firmware 3.4.x. I suggest you upgrade to either 3.5.4 or 3.6.0-rc.3 and then run PID tuning again. It has changed a lot since 3.4.x so read https://docs.duet3d.com/en/User_manual/Tuning/Duet_3_1HCL_tuning#manual-tuning for instructions.