Whenever homing the axes of this large custom designed printer, the axes says "Warning: Driver 72.0 warning: position tolerance exceeded". I assume this is because the motors are moving fast when they suddenly stop at a limit switch. How do I fix this warning? Is there a way to fix it without compromising the speed?

I am using a mainboard 6HC connected to M23CL motors, which then have lead screws/pulleys to actuate a gantry.

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 X1500 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 V2000 ; 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 E120   ; 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
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

homex.g

; homex.g
; called to home the X axis
;
; generated by RepRapFirmware Configuration Tool v3.5.10 on Sun Jan 19 2025 10:11:00 GMT-0800 (Pacific Standard Time)

; increase Z
G90; ABSOLUTE positioning
G1 H2 Z200 ; move z axis to 5mm from top
G90 ; absolute positioning

; home X
G91 ; relative positioning
var maxTravel = move.axes[0].max - move.axes[0].min + 5 ; calculate how far X can travel plus 5mm
G1 H1 X{-var.maxTravel} F5000 ; coarse home in the -X direction
G1 X5 F6000 ; move back 5mm
G1 H1 X{-var.maxTravel} F300 ; fine home in the -X direction
G90 ; absolute positioning

@dc42 I tried a different probe, checked the continuity connection on the ribbon cable, and tried a different ribbon cable as well, it didn't change anything. I believe this device stopped working only when I was working on trying to setup a 2D mesh scan.

I originally had the Z axis probe outputting garbage values to the mainboard 6HC but now it stopped working and it only reads 0. I have attached the config file.

My setup is: I have a Mainboard 6HC connected to a Revo Roto TDB on which is a scanning Z axis SZP probe.

; 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

; Smart 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; driver 0.0 goes forwards (X axis)
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; driver 0.0 goes forwards (X axis)
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; driver 0.0 goes forward s (X axis)
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; driver 0.0 goes forwards (X axis)
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 X1500 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 V2000 ; 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 E120   ; 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
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

; M558.1 K0 A-3.798e-4 B-2.723e-9 C3.136e-15

I narrowed it down, and this happens to this axis only whenever I write M17 after start up? (with the 8x microstepping ON)

I am trying to change one of the motors to change from 16x microstepping to 8x microstepping. It works for 16x microstepping, but when I try to change it to 8x microstepping, the motor moves once, very quickly in the opposite direction, then fails to move for any following commands due to a position tolerance issue. Once suppressing the position tolerance issue, the motor works fine, but this jerking motion occurs upon every restart of the mainboard.

I am using a Duet3D 6HC mainboard with M23CL motors.

M569 P73.0 S0 R1
M569.1 P73.0 T3 R100 I0
M569 P73.0 D4



M584 X70.0 Y71.0 Z72.0 U73.0 V74.0 E75.0
M350 X16 Y16 Z16 U16 V16 I1
M92 X640 Y640 Z1969.23077 U34.188034 V27.350427
M350 U8 I1

When I comment out the last M350 U8 I1 command, it works fine. I also tried changing the microstepping in the first M350 command as well as in M92, but that didn't work either.

This worked! It was the homing issue G92. Thank you!

@droftarts Apologies for that, I am fairly new to this. Below is an updated output from the diagnostic command, and attached is the config.g file.

M122 B71.0
Diagnostics for board 71:
Duet M23CL firmware version 3.5.2 (2024-06-10 13:23:16)
Bootloader ID: SAME5x bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 45108, free system stack 202 words
Tasks: EncCal(1,nWait 6,0.0%,469) Move(3,nWait 7,0.0%,174) CLSend(3,nWait 6,0.0%,147) HEAT(2,nWait 6,0.0%,117) CanAsync(5,nWait 4,0.0%,66) CanRecv(3,nWait 1,0.0%,79) CanClock(5,nWait 1,0.0%,64) TMC(4,nWait 6,0.0%,397) MAIN(1,running,97.5%,303) IDLE(0,ready,0.0%,29) AIN(2,nWait 2,2.5%,255), total 100.0%
Owned mutexes:
Last reset 00:05:30 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 80.0 steps/mm, not tuned/calibrated, SG min n/a, mspos 0, reads 0, writes 0 timeouts 0, steps req 0 done 0
Moves scheduled 0, completed 0, in progress 0, hiccups 0, segs 0, step errors 0, maxLate 0 maxPrep 0, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 0.00
Peak sync jitter -15/4, peak Rx sync delay 185, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 11.9, current 11.9, max 11.9
V12 voltage: min 10.4, current 10.4, max 10.5
MCU temperature: min 26.3C, current 26.5C, max 26.7C
Last sensors broadcast 0x00000000 found 0 8 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 2674, send timeouts 0, received 1670, lost 0, errs 0, boc 0, free buffers 38, min 38, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 0
Closed loop driver 0 mode: closed loop, pre-error threshold: 2.00, error threshold: 4.00, encoder type rotaryAS5047, position -5801
Encoder reverse polarity: no, full rotations -1, last angle 10583, minCorrection=0.0, maxCorrection=0.0, agc 66, mag 4695, no error
Tuning mode: 0, tuning error: 0x2, collecting data: no
Control loop runtime (us): min=5726621, max=1, frequency (Hz): min=750000, max=0

config.g

; Default config.g template for DuetPi
; Replace this with a proper configuration file (e.g from https://configtool.reprapfirmware.org)

; Display initial welcome message
; M291 P"Please go to <a href=""https://www.duet3d.com/StartHere"" target=""_blank"">this</a> page for further instructions on how to set it up." R"Welcome to your new Duet 3!" S1 T0

G4 S2 ; Wait for expansion boards to start


; Setup X axis motor
M569.1 P70.0 T3 ; Assign magnetic encoder
M569 P70.0 D4 S1 ; Assign closed loop control and forward movement
M584 X70.0 ; Set motor to X axis control
M906 X1000 ; Set current limit

; Setup Y axis motor
M569.1 P71.0 T3 ; Assign magnetic encoder
M569 P71.0 D4 S1 ; Assign closed loop control and forward movement
M584 Y71.0 ; Set motor to Y axis control
M906 Y1000 ; Set current limit

; Setup V axis motor
M569.1 P74.0 T3 ; Assign magnetic encoder
M569 P74.0 D4 S1 ; Assign closed loop control and forward movement
M584 V74.0 ; Set motor to X axis control
M906 V1000 ; Set current limit

M17 ; Allow motors to move

I just realized that the other two motors I setup were 2407B00010 but this one that is not working is 2402B00021. I can't find on Google how this makes a difference (they look identical).

I am facing an issue getting a new M23CL motor to calibrate/move. I have attached pictures with the sequential commands I ran on this motor.

Following these same commands, I successfully set up two other motors using the same cables/connectors/setup, just swapping out the motor.

I've powered things up/down a few times, I updated the firmware of the mainboard (3.5.2) and of the motor (3.5.2), and tried resetting CAN on the motor; none to any avail.