@deckingman

Possible solve...
I may be speaking too early on this but it's looking promising.

I've been super focused on what could cause the filament to start a phase transition
in the wrong location and I THINK I've got it.

The short of it is that the PTFE tube connecting the extruder to the hotend may have been a hair or two short of seating solidly against the heatbreak.

Long version...
The way this probably came about is, because the PTFE collet on the bottom of the extruder is not visible from above (I have a Railcore 300ZLT so it's pretty tall and sits on the floor), I'd gotten in the habit of leaving the collet on the extruder and removing the one on the heatsink coupler and just pulling the extruder and tube out in a single step. When reassembling the extruder after cleaning it, I probably seated the tubing as far into the extruder as I could, leaving a small gap between the heat break and PTFE tube. Clearly I must have cut the tube a bit short.

This was literally the only thing I could of, so I tried re-seating the tube all the way down inside the heatsink, reassembling everything, and I'm suddenly able to complete a test cube out of PLA.

Going to run a few more tests before I call this one resolved but this sort of fits what I've been seeing and is consistent with your advice about what could cause this.

Found good info on troubleshooting E3D v6 problems here.

@t3p3tony It's looking like the PTFE tube was in fact the issue. I've successfully printed out a few items in PLA now with zero stops. I've also dialed back the MFM parameters so it's no longer wide open and still no problems.

I have to pull the tube out and measure it to see just how short it was (build docs call for 91mm) but the only things I can attribute this to is my being a creature of habit. I've pulled that tube many times while yanking the extruder for cleaning and repeated the same error by installing it in the extruder first.

I'd say mark this one as resolved but I'm going to run some longer prints in PLA just to be 100% as there was an element of randomness to it.

Props to @deckingman for getting me focused on the right thing and thanks to everyone who responded!

@t3p3tony

MegaBot_Sitting_Body_Upper.gcode

@fcwilt Ive tried several brands of PLA, all with the same result.

@dc42 attached as requested.

config.g

@fcwilt had same issue w/ 3.3

@t3p3tony
Console output:

1635171097795-mfm-test-1:
Duet3D rotating magnet filament monitor v3 on pin e0stop, disabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 131 agc 75, measured sensitivity 25.89mm/rev, min 99% max 103% over 48.1mm

1635171097802-mfm-test-2:
Duet3D rotating magnet filament monitor v3 on pin e0stop, enabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 132 agc 77, measured sensitivity 26.00mm/rev, min 95% max 102% over 99.6mm

1635171097805-mfm-test-3:
Duet3D rotating magnet filament monitor v3 on pin e0stop, disabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 132 agc 75, measured sensitivity 25.87mm/rev, min 98% max 102% over 49.0mm

1635173702760-mfm-test-4:
Duet3D rotating magnet filament monitor v3 on pin e0stop, disabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 132 agc 75, measured sensitivity 26.09mm/rev, min 97% max 102% over 39.1mm

1635178672431-mfm-test-5
Duet3D rotating magnet filament monitor v3 on pin e0stop, disabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 131 agc 75, measured sensitivity 25.88mm/rev, min 98% max 102% over 99.3mm

1635178672433-mfm-test-6
Duet3D rotating magnet filament monitor v3 on pin e0stop, disabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 131 agc 75, measured sensitivity 25.99mm/rev, min 97% max 104% over 99.4mm

1635178672436-mfm-test-7
Duet3D rotating magnet filament monitor v3 on pin e0stop, disabled, sensitivity 26.50mm/rev, allow 1% to 200%, check every 3.0mm, version 3, mag 131 agc 75, measured sensitivity 25.79mm/rev, min 98% max 101% over 45.4mm

Weirdest thing... It's back up now.

WiFi module has been up the whole time (it was responding to pings(ICMP))
Telnet to ports 23 and 80 were getting nothing

I did not connect directly to USB with my workstation and try to print.
I did put a file in the gcode directory on the SD card by hand and was able to print.

I did set up and connect an OctoPi as a possible work around and it did seem to be communicating but I had not had a chance to print with it.

I've been beating my head against my desk for the last 8 hours trying to get this sorted
and I walk away from my desk for few minutes and its back up.

I do not like issues that seem to resolve themselves in this way for obvious reasons.

It may have something to do with burning some sage and swinging a dead chicken around but.... That's dinner so it would have happened regardless.

Just for posterity:

M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 3.4.1 (2022-06-01 21:05:28) running on Duet WiFi 1.02 or later + DueX5
Board ID: 08DJM-9178L-L2MS8-6JKDA-3S06M-K8HAP
Used output buffers: 3 of 26 (26 max)
=== RTOS ===
Static ram: 23860
Dynamic ram: 76456 of which 12 recycled
Never used RAM 8248, free system stack 96 words
Tasks: NETWORK(ready,37.5%,242) HEAT(notifyWait,0.1%,324) Move(notifyWait,2.9%,292) DUEX(notifyWait,0.0%,24) MAIN(running,59.4%,460) IDLE(ready,0.1%,30), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 01:52:37 ago, cause: power up
Last software reset at 2022-08-15 23:22, reason: User, GCodes spinning, available RAM 8608, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0041f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x0c
Aux0 errors 0,0,0
Step timer max interval 0
MCU temperature: min 15.3, current 23.6, max 28.3
Supply voltage: min 23.9, current 24.1, max 24.4, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/40/40, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: standstill, SG min 0
Driver 1: standstill, SG min 0
Driver 2: standstill, SG min n/a
Driver 3: standstill, SG min 0
Driver 4: standstill, SG min n/a
Driver 5: standstill, SG min 0
Driver 6: standstill, SG min 0
Driver 7: standstill, SG min 0
Driver 8: standstill, SG min n/a
Driver 9: standstill, SG min n/a
Driver 10:
Driver 11:
Date/time: 2022-08-29 15:49:42
Cache data hit count 4294967295
Slowest loop: 135.33ms; fastest: 0.17ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest read time 1.9ms, write time 14.1ms, max retries 0
=== Move ===
DMs created 83, segments created 27, maxWait 3482734ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 40317, completed 40317, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.0
Heater 1 is on, I-accum = 0.5
=== GCodes ===
Segments left: 0
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
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
Daemon is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty
=== Filament sensors ===
Extruder 0: pos 247.50, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0
=== DueX ===
Read count 1, 0.01 reads/min
=== Network ===
Slowest loop: 40.98ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
HTTP sessions: 1 of 8

• WiFi -
  Network state is active
  WiFi module is connected to access point
  Failed messages: pending 0, notready 0, noresp 0
  WiFi firmware version 1.26
  WiFi MAC address 84:0d:8e:ad:74:86
  WiFi Vcc 3.40, reset reason Turned on by main processor
  WiFi flash size 4194304, free heap 24680
  WiFi IP address 192.168.1.226
  WiFi signal strength -37dBm, mode 802.11n, reconnections 0, sleep mode modem
  Clock register 00002002
  Socket states: 4 0 0 0 0 0 0 0

M98 P"config.g"
HTTP is enabled on port 80
FTP is disabled
TELNET is enabled on port 23
Error: Heater 1 not switched on due to bad model

config.g

Woke up to DWC not working at all this morning.
Getting blank page. Tried obvious stuff like rebooting.

Was running 3.4b7 all the way around.

Using Duet2Wifi w/ Duex

Built new SD card w/ clean config:

DWC 3.4.1
RRF 3.4.1

Issue persists across clean config and upgrade.
telnet to port 80 produces no output from DWC.

Able to print from SD card via paneldue.

Any help troubleshooting would be greatly appreciated.

@droftarts Will give it a try! Thank you!

Does anyone have any insight as to what driver stall errors could mean? I get a fair number of driver 1 stall errors (normally a few per print job) and occasionally driver 0 stall errors.

This happens on any print job with any settings.

WiFi/Ethernet 3.4.0 (2022-03-15)
Duet WiFi Server Version: 1.26

config (1).g

Also, the "download as .csv" and "download as txt" functions on the console info do not seem to be working.

4/26/2022, 2:48:59 PM Warning: Driver 1 stalled at Z height 37.22
4/26/2022, 2:39:57 PM Warning: Driver 1 stalled at Z height 36.33
4/26/2022, 2:29:24 PM Warning: Driver 1 stalled at Z height 35.43
4/26/2022, 2:07:53 PM Warning: Driver 1 stalled at Z height 33.05
4/26/2022, 1:50:39 PM Warning: Driver 1 stalled at Z height 30.97
4/26/2022, 1:48:12 PM Warning: Driver 1 stalled at Z height 30.67
4/26/2022, 11:18:21 AM Warning: Driver 1 stalled at Z height 14.29
4/26/2022, 10:29:01 AM Warning: Driver 1 stalled at Z height 10.72

@phaedrux done. thank you!

@phaedrux
Finally got around to reprinting case. Used PLA this time instead of PETG.
It's alot cleaner on the outside but really no difference on the inside.
I ran a needle file through the feed path just to be certain there's no blobs or burrs

Initial reading (before printing first time). As you can see, AGC has gone up quite a bit.

Duet3D rotating magnet filament monitor v3 on pin e0stop, enabled, sensitivity 28.80mm/rev, allow 60% to 160%, check printing moves every 3.0mm, version 3, mag 133 agc 111, no calibration data

1st test / calibration print on 20mm calibration cube:

35% ona "too little movement error":

Duet3D rotating magnet filament monitor v3 on pin e0stop, enabled, sensitivity 28.80mm/rev, allow 60% to 160%, check printing moves every 3.0mm, version 3, mag 132 agc 109, measured sensitivity 25.84mm/rev, min 35% max 106% over 983.4mm

adjusted M591 while paused to:
M591 P3 C"e0_stop" S1 D0 L25.84 R35:130

Print completed without further error.

2nd test completed without error.

3rd test printed 2 x 20mm calibration cubes simultaneously

Stopped at 88% with the following:

M591 d0
Duet3D rotating magnet filament monitor v3 on pin e0stop, enabled, sensitivity 25.84mm/rev, allow 35% to 130%, check printing moves every 3.0mm, version 3, mag 132 agc 109, measured sensitivity 26.05mm/rev, min 0% max 109% over 2811.8mm

So... Even with the new case, it's still randomly stopping.

I'm thinking there's a problem with the MFM.

@infiniteloop No doubt! I'm still pretty new at this and I generally assume it's something I'm doing. Given what you're saying about post processing and my questionable print quality, I would not be surprised if there are tolerance issues with my casing.

@infiniteloop I have the MFM sitting directly atop the extruder and the PTFE tube comes in close to vertical so I'm not concerned about the angle of the filament path.

I am considering picking up a piece of copper tube from McMaster and replacing the bit of PTFE tubing connecting the MFM to the extruder but I really dont think that's where the problem is.

I'm inclined to print a new casing and giving that a try as I noticed that the ring on the MFM sensor from the magnet rubbing was a partial circle which would indicate to me that there's a slight tilt to the magnet.

I think an injection molded case would remove any uncertainty around it but I'm not certain that would resolve this issue.

@phaedrux I havent but I can although the casing is clean on the inside. I had some first layer issues IIRC and it still has some dry bedweld on it (got distracted and forgot to rinse).

@phaedrux

Photos as requested.
Please let me know if there's something else you'd like a pic of.