@phaedrux, @williamwestonn My first reaction to seeing the example photos was that it was a mechanical problem. However, since only the electronics were replaced It seems unlikely that a new mechanical problem was accidentally introduced. So the problem must be with the current settings. Running bed auto-tune and implementing PID is easy, and I offered this as a suggestion because it was something that I would try if this was happening to me. It is a more precise way to control temperature so I still recommend it.

I have Delta that is using microstepping interpolation, and also have an Ormerod 2 cartesian that has microstepping interpolation turned OFF. Here is a thread about why this is recommended:
https://forum.duet3d.com/topic/79/microstep-interpolation/11

@williamwestonn Yes you will need to add an M307 command for the H0 after running the autotune. Instructions are here:
https://duet3d.dozuki.com/Wiki/Tuning_the_heater_temperature_control

Duet's safety temperature monitoring is explained here:
https://duet3d.dozuki.com/Wiki/Spurious_heater_faults_and_how_to_avoid_them

Did you change your M350 command to disable microstepping interpolation?

The RepRapFirmware Configuration Tool still works for the Duet 0.8.5:
https://configurator.reprapfirmware.org/

I'd first test each motor individually to make sure they are running in the right direction:
https://duet3d.dozuki.com/Wiki/ConfiguringRepRapFirmwareDeltaPrinter.

@dc42 Thanks very much for this reply. I was not aware that there was any distinction with USB cables! The several that I had tried were all charging only. I kept trying cables until the Kindle cable did the trick.

Nothing shows up

Just completed a Railcore II build yesterday that was started last year. The paneldue worked fine until I erased it to install the latest firmware. The erase button worked but the reset button had no effect. The screen went blank but the paneldue is not recognized by Device Manager (Win7). I've tried different USB cables on 2 different Win7 PCs and the paneldue is not showing up. Is there anything else I can try to recover this?

To reset a heater fault without restarting, simply enter M562. No other parameters are needed and this will clear a heater fault on all heaters

I can't explain the mystery as to why PA is causing this problem, very strange that everything works when it is turned off. PA is such a good feature, its worth trying to get it to work. I am recommending that you consider increasing your extruder motor current. 400mA seems low to me, as I am running 800mA on my Ormerod 2 and 700mA on my Delta.

Your M665 command is using a value of H1026.4, but according to your drawing is really only 111.4 (102.4+9). My guess is that your smart effector autocalibration routine that you are relying upon to set your endstops might be a little less inaccurate if you used a value that was closer to what the actual value is. I'd change it to H116.4 (based upon your drawing and photo + 5mm) and re-check. Once your calibration is set simply transfer those settings it derived (for M665 and M666) to your config.g

Pardon me while I go order another titan extruder cover.

I replaced the clickety-clackety titan on my Kossel this summer with a Bondtech BMG. (After reading @deckingman's excellent review.) Do yourself a favor, you won't regret it.

Something I think being missed is that this "pattern" is fairly consistent.

Consistency makes me think the problem is with your motion-mechanics. If the problem was with the nozzle you would not be experiencing this consistency. I think that something new has either loosed up, or is now binding. Do you see anything wiggle when you attempt to move the effector around with one finger pushing under the hotend? Is your Orion mount still ok? Pulley grubscrews and effector rod connections still tight? Motor mount screws tight? Carriages still free? Also examine the drive belts carefully for damage or stretch marks.

@dc42 This makes sense as I've recently lowered the speed setting down to 30mm/s on the Ormerod. Thanks for your help.

Good idea, I'll try it when I'm back at layer 1. Just started a 6 hour job..