Posts made by charliedrums

I think I figured it out. I bought the A type cable which the ends are in line and I need the B type cable which the ends are opposite?
Is this it?

So I accidentally broke the ribbon cable on my scanning z probe. I got some replacement from amazon (uxcell Flexible Flat Cable, 4 Pins 0.5mm Pitch 76mm FPC FFC Flexible Ribbon Cable for LCD TV Car Audio DVD Player Laptop 10Pcs (A Type) ) but now my scanning z probe does not calibrate. Did I get the wrong flex cable?

I get constant

M558.2 K1 S-1
Error: M558.2: failed to calibrate sensor drive current

M558.2 K1
Sensor drive current is 31, offset is 144968

Before the cable changed drive current read 14. Everything worked fine up until the cable changed. Maybe these cables are not the ones? any help will be appreciated. Thank you.

@droftarts Thanks for the reply. I'll switch it to a 31x31 then.

So I have a scanning z probe on a duet 3 6hc on FW 3.5.3. A bed that is 24 x 24in and I was wondering what is the maximum amount of points I can configure the probe to read? I have it set to 900 points. Can I go higher than 900?

M557 X29:609 Y40:603 P30:30  

I was reading the wiki under M557 but it states "There is a firmware-dependent maximum number of probe points supported. Currently this is 441 for the Duet 2 and Duet 3 (enough for a 21x21 grid), and 121 on the Duet 06/085 (enough for a 11x11 grid)."

Hi,
For some reason I'm getting an error Error: Expansion board 120 stopped sending status once I updated to 3.5.3

120 is the z scanning probe. It happens a couple of ours into the print. It doesn't seem to affect the print what so ever but I have no Idea why I'm getting the error code all of the sudden.
I'm running in SBC mode with a raspberry pi 5
M122 B120

M122 B120
Diagnostics for board 120:
Duet SZP firmware version 3.5.3 (2024-09-17 14:34:54)
Bootloader ID: SAMC21 bootloader version 2.10 (2023-11-16)
All averaging filters OK
Never used RAM 13756, free system stack 110 words
Tasks: HEAT(2,nWait 6,0.1%,128) CanAsync(5,nWait 4,0.0%,50) CanRecv(3,nWait 1,0.0%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) MAIN(1,running,71.9%,394) IDLE(0,ready,0.0%,26) AIN(2,nWait 4,27.9%,72), total 100.0%
Owned mutexes: I2C(AIN)
Last reset 06:18:30 ago, cause: software
Last software reset at 2024-03-12 06:08, reason: StackOverflow, available RAM 14136, slot 0
Software reset code 0x0100 ICSR 0x0041a00e SP 0x20007f34 Task ACCE Freestk 5138 ok
Stack: 20002e70 20002ea4 00014913 200029a4 20002ac0 20002998 000139f1 20002ac0 fffffffd 0000002a 00000000 20007f8c 00000000 20007f8c 00014677 00000000 200010a4 20001028 00013eb7 20001028 200010a4 00000032 454c4449 00019000 00012683 200011c0 200011c0
Peak sync jitter 2/6, peak Rx sync delay 213, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 4.9, current 4.9, max 5.0
MCU temperature: min 31.0C, current 40.5C, max 43.5C
Last sensors broadcast 0x00000400 found 1 23 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 3265, send timeouts 0, received 5265, lost 0, errs 13, boc 0, free buffers 18, min 18, error reg 150000
Accelerometer: LIS2DW, status: 00
Inductive sensor: raw value 38352142, frequency 3.57MHz, current setting 14, ok
I2C bus errors 0, naks 0, contentions 0, other errors 0

M122 B121

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.3 (2024-09-17 14:35:31)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 2948, free system stack 69 words
Tasks: Move(3,nWait 7,0.3%,84) HEAT(2,nWait 6,0.3%,106) CanAsync(5,nWait 4,0.0%,54) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,delaying,3.7%,52) MAIN(1,running,90.7%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.9%,112), total 100.0%
Owned mutexes:
Last reset 06:19:45 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 2, write errors 0, ifcnt 89, reads 5398, writes 0, timeouts 3, DMA errors 0, CC errors 0, failedOp 0x6a, steps req 0 done 1093428
Moves scheduled 326562, completed 326561, in progress 1, hiccups 129, segs 34, step errors 0, maxLate 0 maxPrep 348, maxOverdue 111, maxInc 48, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 1/7, peak Rx sync delay 244, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 23.9, current 24.0, max 24.6
MCU temperature: min 41.3C, current 60.6C, max 63.5C
Last sensors broadcast 0x00000002 found 1 140 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 21797, send timeouts 0, received 29511, lost 0, errs 84, boc 0, free buffers 18, min 17, error reg 5f0000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 406, adv 36059/74667
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 1 to 105us, poll 22 to 1614us
Driver 0: ok

M122

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.3 (2024-09-18 11:27:36) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 12 of 40 (34 max)
=== RTOS ===
Static ram: 155352
Dynamic ram: 91836 of which 3104 recycled
Never used RAM 92124, free system stack 122 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,rWait:,1.1%,821) HEAT(3,nWait 6,0.0%,321) Move(4,nWait 6,2.2%,211) CanReceiv(6,nWait 1,0.0%,771) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,10.3%,53) MAIN(2,running,86.3%,101) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 06:20:06 ago, cause: software
Last software reset at 2024-10-15 14:32, reason: User, Gcodes spinning, available RAM 92532, slot 2
Software reset code 0x6803 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0043c000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU temperature: min 52.6, current 60.5, max 61.1
Supply voltage: min 23.7, current 23.9, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/72/72, gc cycles 0
Events: 2 queued, 2 completed
Driver 0: ok, SG min 0, mspos 843, reads 20644, writes 17 timeouts 0
Driver 1: ok, SG min 0, mspos 793, reads 20644, writes 17 timeouts 0
Driver 2: ok, SG min 0, mspos 376, reads 20644, writes 17 timeouts 0
Driver 3: ok, SG min 0, mspos 968, reads 20644, writes 17 timeouts 0
Driver 4: ok, SG min 0, mspos 824, reads 20645, writes 17 timeouts 0
Driver 5: ok, SG min 0, mspos 808, reads 20645, writes 17 timeouts 0
Date/time: 2024-10-15 20:52:58
Slowest loop: 91.49ms; fastest: 0.04ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 30, maxWait 92107ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 20 ticks, disabled
Moves shaped first try 30486, on retry 15394, too short 35040, wrong shape 199834, maybepossible 8649
=== DDARing 0 ===
Scheduled moves 365344, completed 365314, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
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 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.3
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0
Telnet is idle in state(s) 0
File* is doing "G1 X416.789001 Y435.783997 E0.016750" 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 idle in state(s) 0
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 0x80000007
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 data received
=== CAN ===
Messages queued 533765, received 650864, lost 0, errs 37341, boc 270
Longest wait 7ms for reply type 6024, peak Tx sync delay 2917, free buffers 50 (min 48), ts 114031/113904/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 58887/58887
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24d04
Buffer RX/TX: 2432/3720-0, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.3 (2024-09-21 10:23:58, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Panderos/12in/Pandero_Panal_12in_0.6n_0.3mm_PETG_EXOCUBE_19h56m.gcode is selected, processing
Failed to deserialize the following properties:
- Board -> BoardState from "timedOut"
File:
Buffered code: G1 X416.789 Y435.784 E.01675
Buffered code: G1 X423.25 Y443.993 E.72489
Buffered code: G1 X423.46 Y444.35 E.02874
Buffered code: G1 X423.463 Y444.475 E.00868
Buffered code: G1 X423.464 Y444.565 E.00625
Buffered code: G1 X423.365 Y444.852 E.02107
Buffered code: G1 X423.068 Y445.256 E.03479
Buffered code: G1 X421.701 Y446.316 E.12003
Buffered code: G1 X419.858 Y447.685 E.15931
Buffered code: G1 X419.496 Y447.9 E.02922
Buffered code: G1 X419.135 Y447.995 E.0259
Buffered code: G1 X418.751 Y447.966 E.02672
Buffered code: G1 X418.514 Y447.789 E.02053
Buffered code: G1 X412.403 Y439.273 E.72732
Buffered code: G1 X412.265 Y439.004 E.02098
Buffered code: G1 E-.6 F2400
Buffered code: G1 F28800
Buffered code: G1 X412.224 Y438.924 E-.00712
Buffered code: G1 X412.229 Y438.699 E-.01782
Buffered code: G1 X412.392 Y438.333 E-.03172
Buffered code: G1 X412.751 Y437.954 E-.04133
Buffered code: G1 X415.58 Y435.84 E-.27959
Buffered code: G1 X416.038 Y435.612 E-.0405
Buffered code: G1 X416.282 Y435.588 E-.01941
Buffered code: G1 X416.599 Y435.635 E-.02537
Buffered code: G1 X416.789 Y435.784 E-.01912
Buffered code: G1 X417.711 Y436.955 E-.11802
Buffered code: G1 Z20.6 F720
Buffered code: G1 X417.907 Y441.929 F36000
Buffered code: G1 Z20 F720
Buffered codes: 1400 bytes total
Code buffer space: 2344
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.95, max time between full transfers: 76.7ms, max pin wait times: 71.8ms/7.1ms
Codes per second: 16.97
Maximum length of RX/TX data transfers: 4524/1308

After many weeks of testing, I figured out the problem. I started re-wiring every cable to eliminate any problem with the harnesses. Once I got to the power from the Mainboard 6HC to the tool distribution board. I measured the power from this cable with a multimeter and everything was reading normal. For some reason once I rewired this harness everything seems to be working now.

I’ve done dozens of 20–50-hour prints with no problem so far. Updating this post in case someone is having the same issue. Check the power from the main board to the tool distribution board.

@deckingman
Yes, I can I don’t see why not. The only reason I have SBC is so I could get WIFI. Looking through the documentation I see that I can connect to the board directly with an ethernet cable. Next thing Ill do is that go Direct an eliminate the SBC and see. Thanks for the idea.

@deckingman @deckingman

I would have guessed the same but I have checked all 4 Z motors and their harnesses. Here is what leads me to determine it is over extrusion. First once the issue begins, I remove the print from under the extruder and let it print in air for a while and visibly one can tell the more amount of plastic is being forces through the nozzle.

Second, I am using the Orthus Filament Monitor. The orthus has a light that flashes intermittently when filament is running through it. The faster the blink of the light the faster the filament if passing through the sensor, when the problem begins the light flashes faster as in filament is passing faster trough the sensor/extruder. I can move the printer to the max height(365mm) and home without any problems.

I’m going one thing at a time right now I eliminated the z scanning probe and the filament sensor. Still happening. This time around I re did the harness that powers the tool distribution board (two cables 24v Vin ground) and am currently running the print to see if the problem continues after this, I’ll re do the RJ11 cable. Then continue from there.

Ok this time it was 1h 1m 28s when the over extrusion started. Any Ideas of what I could try next? Would making a new RJ11 cable from the tool distribution board help? Or re cabling the whole thing? At this point I’ll try anything.

Diagnostics:
MB6HC

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (29 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 89912 of which 5048 recycled
Never used RAM 92192, free system stack 136 words
Tasks: SBC(2,nWait 7,0.9%,821) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,2.5%,211) CanReceiv(6,nWait 1,0.0%,794) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,9.7%,53) MAIN(2,running,86.7%,101) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 01:00:13 ago, cause: software
Last software reset at 2024-07-01 22:29, reason: User, Gcodes spinning, available RAM 95744, slot 0
Software reset code 0x6003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0043c000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU temperature: min 41.9, current 44.6, max 44.7
Supply voltage: min 23.7, current 23.9, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/48/48, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 444, reads 10183, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 867, reads 10184, writes 0 timeouts 0
Driver 2: ok, SG min 0, mspos 508, reads 10184, writes 0 timeouts 0
Driver 3: ok, SG min 0, mspos 852, reads 10184, writes 0 timeouts 0
Driver 4: ok, SG min 0, mspos 628, reads 10184, writes 0 timeouts 0
Driver 5: ok, SG min 0, mspos 460, reads 10184, writes 0 timeouts 0
Date/time: 2024-07-01 23:29:26
Slowest loop: 31.88ms; fastest: 0.05ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 991ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 166 ticks, disabled
Moves shaped first try 2755, on retry 1709, too short 1471, wrong shape 35430, maybepossible 500
=== DDARing 0 ===
Scheduled moves 61679, completed 61619, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
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 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X337.981995 Y325.506012 E0.063910" 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 idle in state(s) 0
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 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 65895, received 49465, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 254, free buffers 50 (min 48), ts 12359/12359/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 11409/11409
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 1920/3424-0, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X337.982 Y325.506 E.06391
Buffered code: G1 X338.172 Y326.122 E.04473
Buffered code: G1 X338.373 Y326.988 E.06169
Buffered code: G1 X338.475 Y327.605 E.04339
Buffered code: G1 X338.532 Y328.208 E.04203
Buffered code: G1 X338.576 Y329.165 E.06648
Buffered code: G1 X338.54 Y329.812 E.04496
Buffered code: G1 X338.477 Y330.421 E.04248
Buffered code: G1 X338.404 Y330.875 E.03191
Buffered code: G1 X338.17 Y331.76 E.06352
Buffered code: G1 X337.971 Y332.224 E.03503
Buffered code: G1 X337.819 Y332.486 E.02102
Buffered code: G1 X337.248 Y333.118 E.0591
Buffered code: G1 X336.888 Y333.48 E.03543
Buffered code: G1 X336.109 Y334.03 E.06617
Buffered code: G1 X335.767 Y334.23 E.02749
Buffered code: G1 X335.59 Y333.679 F15000
Buffered code: G1 F1500
Buffered code: G1 X334.92 Y333.853 E.04803
Buffered code: G1 X334.282 Y333.984 E.04519
Buffered code: G1 X333.634 Y334.091 E.04557
Buffered code: G1 X332.588 Y334.206 E.07302
Buffered code: G1 X331.473 Y334.279 E.07753
Buffered code: G1 X328.705 Y334.286 E.19207
Buffered code: G1 X327.414 Y334.206 E.08975
Buffered code: G1 X326.38 Y334.093 E.07218
Buffered code: G1 X325.719 Y333.984 E.04649
Buffered code: G1 X324.531 Y333.728 E.08433
Buffered code: G1 X324.202 Y333.548 E.02602
Buffered code: G1 X323.572 Y333.103 E.05352
Buffered code: G1 X322.915 Y332.457 E.06394
Buffered codes: 1472 bytes total
Code buffer space: 1920
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.44, max time between full transfers: 54.9ms, max pin wait times: 54.5ms/4.6ms
Codes per second: 19.17
Maximum length of RX/TX data transfers: 4436/1124

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 3372, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,88) HEAT(2,nWait 6,0.3%,90) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,90.7%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.9%,112), total 100.0%
Owned mutexes:
Last reset 01:00:15 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 0, write errors 2, ifcnt 168, reads 27122, writes 16826, timeouts 4, DMA errors 0, CC errors 16827, failedOp 0x71, steps req 0 done 2205650
Moves scheduled 57511, completed 57507, in progress 1, hiccups 80, segs 26, step errors 0, maxLate 0 maxPrep 354, maxOverdue 106, maxInc 52, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/6, peak Rx sync delay 252, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 11.6, current 24.2, max 24.5
MCU temperature: min 34.6C, current 45.2C, max 46.0C
Last sensors broadcast 0x00000002 found 1 143 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 49415, send timeouts 0, received 65795, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 398, adv 36262/74666
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0

Ok so I narrowed down the tool Expansion board 121 reconnected error to the harness connection between the scanning z probe and the tool board harness. I mystically did not plug it in all the way. Having plugged it in correctly I started a new test print with the new 1LC board but still I’m having the same over extrusion problem at random times. Sometimes is at the start of the print, sometimes is at layer 5, sometimes its 3+ hours into the print.

So I decided to go back to the basics I disconnected the scanning z probe and the filament sensor and updated the config.g file to comment out the scanning z probe and the filament sensor. So the only things that are plugged in to the 1LC are the extruder & cooling fan, the extruder heater, thermistor, motor, vin power and the can connection. With this configuration I started a test print to see if I keep getting the over extrusion issue. Hopefully I have a successful print on this one I really don’t want to ditch duet for Klipper and a Chinese board.

Here are my diagnostics:
MB6HC

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 11 of 40 (29 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 89888 of which 5072 recycled
Never used RAM 92192, free system stack 136 words
Tasks: SBC(2,rWait:,0.9%,821) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,1.9%,211) CanReceiv(6,nWait 1,0.0%,794) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,348) TMC(4,nWait 6,9.7%,53) MAIN(2,running,87.1%,101) IDLE(0,ready,0.3%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 00:19:02 ago, cause: software
Last software reset at 2024-07-01 22:29, reason: User, Gcodes spinning, available RAM 95744, slot 0
Software reset code 0x6003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0043c000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU temperature: min 37.2, current 42.1, max 42.2
Supply voltage: min 23.8, current 24.0, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/48/48, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 366, reads 41818, writes 17 timeouts 0
Driver 1: ok, SG min 0, mspos 1010, reads 41818, writes 17 timeouts 0
Driver 2: ok, SG min 0, mspos 277, reads 41818, writes 17 timeouts 0
Driver 3: ok, SG min 0, mspos 59, reads 41818, writes 17 timeouts 0
Driver 4: ok, SG min 0, mspos 859, reads 41818, writes 17 timeouts 0
Driver 5: ok, SG min 0, mspos 229, reads 41818, writes 17 timeouts 0
Date/time: 2024-07-01 22:48:14
Slowest loop: 1369.34ms; fastest: 0.05ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 99861ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 383 ticks, disabled
Moves shaped first try 1182, on retry 654, too short 544, wrong shape 10891, maybepossible 117
=== DDARing 0 ===
Scheduled moves 15092, completed 15032, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
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 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.2
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X329.549988 Y341.337006 E0.083270" 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 idle in state(s) 0
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 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 24111, received 22784, lost 0, errs 1, boc 0
Longest wait 2ms for reply type 6026, peak Tx sync delay 323, free buffers 50 (min 49), ts 5711/5710/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 45007/45007
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 3264/752-4080, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X329.55 Y341.337 E.08327
Buffered code: G1 X328.919 Y341.965 E.06177
Buffered code: G1 X328.509 Y342.594 E.0521
Buffered code: G1 X328.222 Y343.222 E.04791
Buffered code: G1 X328.016 Y343.85 E.04586
Buffered code: G1 X327.906 Y344.479 E.04431
Buffered code: G1 X327.95 Y344.793 E.022
Buffered code: G1 X328.205 Y345.107 E.02807
Buffered code: G1 X329.428 Y345.735 E.0954
Buffered code: G1 X330.45 Y346.364 E.08327
Buffered code: G1 X330.63 Y346.543 E.01761
Buffered code: G1 X331.455 Y346.422 E.05786
Buffered code: G1 X331.908 Y346.306 E.03245
Buffered code: G1 X332.359 Y346.157 E.03296
Buffered code: G1 X333.06 Y345.853 E.05302
Buffered code: G1 X333.762 Y345.466 E.05562
Buffered code: G1 X334.184 Y345.184 E.03522
Buffered code: G1 X334.598 Y344.867 E.03618
Buffered code: G1 X335.255 Y344.267 E.06174
Buffered code: G1 X334.577 Y343.85 E.05523
Buffered code: G1 X333.945 Y343.222 E.06182
Buffered code: G1 X333.536 Y342.594 E.052
Buffered code: G1 X333.249 Y341.965 E.04797
Buffered code: G1 X333.042 Y341.337 E.04588
Buffered code: G1 X332.933 Y340.708 E.0443
Buffered code: G1 X332.976 Y340.394 E.02199
Buffered code: G1 X333.232 Y340.08 E.02811
Buffered code: G1 X334.455 Y339.452 E.0954
Buffered code: G1 X335.476 Y338.823 E.08321
Buffered code: G1 X336.108 Y338.195 E.06182
Buffered code: G1 X336.518 Y337.567 E.05204
Buffered code: G1 X336.805 Y336.938 E.04797
Buffered codes: 1536 bytes total
Code buffer space: 2512
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.60, max time between full transfers: 50.4ms, max pin wait times: 35.8ms/5.4ms
Codes per second: 13.53
Maximum length of RX/TX data transfers: 4436/1124

1LC

	Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 3372, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,90) HEAT(2,nWait 6,0.3%,98) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,90.8%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.8%,112), total 100.0%
Owned mutexes:
Last reset 00:19:06 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, standstill, SG min 0, read errors 0, write errors 1, ifcnt 26, reads 48051, writes 13, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 850185
Moves scheduled 13946, completed 13943, in progress 1, hiccups 27, segs 26, step errors 0, maxLate 0 maxPrep 335, maxOverdue 102, maxInc 37, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/5, peak Rx sync delay 228, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 19.7, current 23.7, max 24.6
MCU temperature: min 34.6C, current 45.0C, max 46.0C
Last sensors broadcast 0x00000002 found 1 205 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 22882, send timeouts 0, received 24273, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 403, adv 36312/74663
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0

Ok, so the new 1LC (v1.3) board came in today. I decided to start everything with a new install on a Pi5. using
image_2024-04-19-DuetPi-arm64. Once I built the image and assembled everything I updated all the boards thought putty. Interesting that when I do a toolboard diagnostics it says that the toolboard is version 1.1 not 1.3.

Now whoever I'm having a new problem. After updating everything on FW3.5.2, I go to start the print everything looks good and is heating up as it should but once heating up finishes and it starts to move to the the homing routine a couple of things happen. *Edit Before I start any print or anything I can probe and scan the bed without any problems.

Error: Expansion board 120 reconnected
Error: Expansion board 121 reconnected

then the scanning z probe starts scanning the bed and in every pass I get this error.

Error: Board 120 does not have input handle 3040

and in DWC this is how the teperature is reported after this happens

I have no Idea whats going on now. All I did is change the 1LC board.
Here are the diagnostics. of all boards.

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 11 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91860 of which 3080 recycled
Never used RAM 92188, free system stack 136 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,rWait:,0.9%,801) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,1.8%,211) CanReceiv(6,nWait 1,0.0%,794) CanSender(5,nWait 7,0.0%,334) CanClock(7,delaying,0.0%,348) TMC(4,nWait 6,9.6%,53) MAIN(2,running,87.4%,101) IDLE(0,ready,0.2%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 00:23:03 ago, cause: power up
Last software reset at 2024-07-01 18:02, reason: MemoryProtectionFault mmarValid daccViol, Platform spinning, available RAM 92476, slot 1
Software reset code 0x4160 HFSR 0x00000000 CFSR 0x00000082 ICSR 0x0440f804 BFAR 0x00000000 SP 0x204198e8 Task IDLE Freestk 20 ok
Stack: 20419968 00000000 2041999c 20419960 a5a5a5a5 0049a485 0049a0e0 61000000 61000000 a5a5a5a5 2041999c fffc0000 20425daf 20419958 2041995c 43f8e92d 20419960 00000000 ffffffff 004999a9 43f8e92d 00000000 20419960 00000000 00000001 204199e0 4e49414d
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 33.6, current 42.0, max 42.1
Supply voltage: min 23.7, current 24.0, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/72/72, gc cycles 0
Events: 2 queued, 2 completed
Driver 0: ok, SG min 0, mspos 628, reads 55863, writes 17 timeouts 0
Driver 1: ok, SG min 0, mspos 913, reads 55863, writes 17 timeouts 0
Driver 2: standstill, SG min 0, mspos 520, reads 55863, writes 17 timeouts 0
Driver 3: standstill, SG min 0, mspos 936, reads 55863, writes 17 timeouts 0
Driver 4: standstill, SG min 0, mspos 952, reads 55863, writes 17 timeouts 0
Driver 5: standstill, SG min 0, mspos 104, reads 55864, writes 17 timeouts 0
Date/time: 2024-07-01 18:25:49
Slowest loop: 77.42ms; fastest: 0.04ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 27, maxWait 199391ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 1 ticks, disabled
Moves shaped first try 1321, on retry 722, too short 604, wrong shape 12745, maybepossible 120
=== DDARing 0 ===
Scheduled moves 17499, completed 17443, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
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 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X336.225006 Y327.441986 E0.046660" 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 idle in state(s) 0
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 0x80000007
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 data received
=== CAN ===
Messages queued 28613, received 21465, lost 0, errs 641, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 250, free buffers 50 (min 48), ts 6920/6919/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 53966/53966
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 3248/48-4096, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X336.225 Y327.442 E.04666
Buffered code: G1 X336.573 Y327.959 E.05293
Buffered code: G1 X336.881 Y328.464 E.05023
Buffered code: G1 X337.357 Y329.369 E.08267
Buffered code: G1 X337.635 Y329.988 E.05459
Buffered code: G1 X337.85 Y330.524 E.04646
Buffered code: G1 X338.183 Y331.522 E.08229
Buffered code: G1 X338.49 Y332.75 E.09722
Buffered code: G1 X338.669 Y333.816 E.08108
Buffered code: G1 X338.748 Y334.521 E.05168
Buffered code: G1 X338.797 Y335.606 E.07913
Buffered code: G1 X338.763 Y336.843 E.08942
Buffered code: G1 X338.686 Y337.585 E.05172
Buffered code: G1 X338.569 Y338.329 E.0515
Buffered code: G1 X338.414 Y339.049 E.04953
Buffered code: G1 X338.163 Y339.93 E.06047
Buffered code: G1 X337.864 Y340.77 E.05791
Buffered code: G1 X337.827 Y340.861 E.00612
Buffered codes: 864 bytes total
Code buffer space: 3200
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 38.34, max time between full transfers: 64.4ms, max pin wait times: 34.9ms/3.8ms
Codes per second: 12.04
Maximum length of RX/TX data transfers: 8176/1140

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 3832, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,90) HEAT(2,nWait 6,0.1%,126) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,91.3%,412) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.5%,112), total 100.0%
Owned mutexes:
Last reset 00:18:59 ago, cause: power up
Last software reset data not available
Driver 0: pos 0, 80.0 steps/mm, ok, SG min 0, read errors 0, write errors 0, ifcnt 55, reads 21490, writes 0, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 660061
Moves scheduled 15214, completed 15210, in progress 1, hiccups 0, segs 26, step errors 0, maxLate 0 maxPrep 210, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 1/6, peak Rx sync delay 245, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 11.9, current 24.6, max 24.6
MCU temperature: min 36.0C, current 38.5C, max 38.8C
Last sensors broadcast 0x00000000 found 0 137 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 6671, send timeouts 0, received 20102, lost 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 369, adv 36213/74673
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0

Zprobe

M122 B120
Diagnostics for board 120:
Duet SZP firmware version 3.5.2 (2024-06-10 13:23:26)
Bootloader ID: SAMC21 bootloader version 2.10 (2023-11-16)
All averaging filters OK
Never used RAM 14188, free system stack 110 words
Tasks: HEAT(2,nWait 6,0.1%,132) CanAsync(5,nWait 4,0.0%,54) CanRecv(3,nWait 1,0.0%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) MAIN(1,running,64.7%,430) IDLE(0,ready,0.0%,26) AIN(2,nWait 4,35.1%,72), total 100.0%
Owned mutexes: I2C(AIN)
Last reset 00:19:13 ago, cause: power up
Last software reset at 2024-03-12 06:08, reason: StackOverflow, available RAM 14136, slot 0
Software reset code 0x0100 ICSR 0x0041a00e SP 0x20007f34 Task ACCE Freestk 5138 ok
Stack: 20002e70 20002ea4 00014913 200029a4 20002ac0 20002998 000139f1 20002ac0 fffffffd 0000002a 00000000 20007f8c 00000000 20007f8c 00014677 00000000 200010a4 20001028 00013eb7 20001028 200010a4 00000032 454c4449 00019000 00012683 200011c0 200011c0
Peak sync jitter 1/6, peak Rx sync delay 216, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 4.4, current 5.0, max 5.0
MCU temperature: min 27.5C, current 30.1C, max 30.2C
Last sensors broadcast 0x00000000 found 0 165 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 5518, send timeouts 0, received 11275, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
Accelerometer: LIS2DW, status: 00
Inductive sensor: raw value 39288477, frequency 3.66MHz, current setting 13, ok
I2C bus errors 0, naks 3, contentions 0, other errors 0

any help would be greatly appreciated.

@OwenD I have printed the gcode before. Probably like 30 t50 times and it has always worked. Still gave it a look but found nothing out of the ordinary.

Small update. While waiting for the new 1LCv1.3 to get here I decided to remake all the cable harnesses that connect to the 1LC board I got the correct crimper and crimped everything correctly with new JST-PH connectors (trying to get these perfect is not that easy). After this I tried again but same thing After a couple of hours the extruder randomly starts over extruding. So this eliminates any bad crimps or harness connections.

I also took the board off the extruder and inspected everything to see if there was any visible damage. But there was nothing that I could see. Is there any test to see if the board is busted in any way?

@gloomyandy
I don't think it is heat related. I do a lot of hueforge, so the way I have the pause script is to turn off the extruder and park the extruder. So at least twice of the tests have been, set the print and go to bed, when I wake up it has been paused for a couple of hours letting the extruder cool down. I proceed to bring it up to temperature remove filament, trim it, and finally purge filament before resuming the print. After this the problem persists. But I'll give ot a try.

I bought a new 1lcv1.3 from filastruder so I have a couple of days before it gets here where I can keep investigating to see if I can pinpoint the problem.

@droftarts
It was not grounded but it is now. Since it takes a couple of days to get here I went and ordered a 1LC v1.3 board to see if that changes anything.

I updated the bootloader on the 1LC and I have grounded the bracket and now the screws and the hemera are grounded. This time I started a print and it started over extruding right from the start. Maybe now with the updated bootloader and grounded everything, updaye everything to 3.5.2 and see what happens? I'll keep trying stuff until the new 1LC gets here. I'll keep the thread updated to my findings.

@gloomyandy
Yes, so far I’ve tried 3.4.6, 3.5.0RC4,3.5.1 and 3.5.2 and the same thing keeps happening. I'm leaning towards a faulty 1LC unless there is something that I'm missing .

@droftarts said in Random overextrusion after 3+hours of printing FW 3.5.2:

ut without running a test print on a previous RRF version that was working for you, it's hard to say why this would happen at the same time as updating to RRF 3.5.2. If it happens again, can you send M350 and check the microstepping in use is still x16, as per your

Ok, so I went back to 3.4.6 and ran the file again and the same thing happened at around 2-3 hours in, so that takes out the possibility of being software related. I think?
Here is the diagnostics:

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.4.6 (2023-07-21 14:11:38) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 153252
Dynamic ram: 67620 of which 0 recycled
Never used RAM 126272, free system stack 128 words
Tasks: SBC(resourceWait:,0.8%,446) HEAT(notifyWait,0.0%,321) Move(notifyWait,2.5%,214) CanReceiv(notifyWait,0.0%,773) CanSender(notifyWait,0.0%,327) CanClock(delaying,0.0%,347) TMC(notifyWait,8.1%,56) MAIN(running,88.5%,923) IDLE(ready,0.0%,30), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 04:20:10 ago, cause: power up
Last software reset details not available
Error status: 0x04
Aux0 errors 0,0,0
Step timer max interval 131
MCU temperature: min 41.5, current 42.5, max 42.5
Supply voltage: min 23.8, current 24.0, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/64/64, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 917, reads 44703, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 860, reads 44703, writes 0 timeouts 0
Driver 2: standstill, SG min 0, mspos 792, reads 44703, writes 0 timeouts 0
Driver 3: standstill, SG min 0, mspos 168, reads 44703, writes 0 timeouts 0
Driver 4: standstill, SG min 0, mspos 488, reads 44703, writes 0 timeouts 0
Driver 5: standstill, SG min 0, mspos 408, reads 44703, writes 0 timeouts 0
Date/time: 2024-06-27 16:15:47
Slowest loop: 29.62ms; fastest: 0.04ms
=== Storage ===
Free file entries: 10
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 28, maxWait 204ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 224744, completed 224704, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== 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 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 1
Movement lock held by null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X340.993011 Y297.888000 E0.105450" 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 idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause* is idle in state(s) 0
Code queue is empty
=== Filament sensors ===
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 10186, received 8489, lost 0, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 372, free buffers 50 (min 49), ts 1726/1726/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 19094/19094
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x2ab5c
Buffer RX/TX: 1392/2864-0, open files: 0
=== Duet Control Server ===
Duet Control Server v3.4.6
File /opt/dsf/sd/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
Executing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
> Next stack level
File:
Buffered code: G1 X340.993 Y297.888 E.10545
Buffered code: G1 X342.308 Y298.665 E.10599
Buffered code: G1 X343.57 Y299.538 E.10648
Buffered code: G1 X344.154 Y300.008 E.05202
Buffered code: G1 X344.773 Y300.507 E.05517
Buffered code: G1 X345.912 Y301.567 E.10797
Buffered code: G1 X346.982 Y302.707 E.10849
Buffered code: G1 X347.988 Y303.921 E.1094
Buffered code: G1 X348.928 Y305.199 E.11008
Buffered code: G1 X349.801 Y306.533 E.11063
Buffered code: G1 X350.614 Y307.927 E.11198
Buffered code: G1 X351.353 Y309.347 E.11108
Buffered code: G1 X352.021 Y310.789 E.11027
Buffered code: G1 X352.628 Y312.265 E.11074
Buffered code: G1 X353.165 Y313.751 E.10964
Buffered code: G1 X353.636 Y315.246 E.10876
Buffered code: G1 X354.039 Y316.739 E.10731
Buffered code: G1 X354.375 Y318.223 E.10558
Buffered code: G1 X354.641 Y319.687 E.10325
Buffered code: G1 X354.846 Y321.122 E.10058
Buffered code: G1 X354.995 Y322.53 E.09825
Buffered code: G1 X355.09 Y323.879 E.09384
Buffered code: G1 X355.137 Y325.313 E.09956
Buffered code: G1 X355.137 Y326.466 E.08001
Buffered code: G1 X355.088 Y327.775 E.09089
Buffered code: G1 X355.005 Y328.922 E.0798
Buffered code: G1 X354.754 Y330.938 E.14097
Buffered code: G1 X354.577 Y331.92 E.06924
Buffered code: G1 X354.355 Y332.922 E.07121
Buffered code: G1 X354.128 Y333.784 E.06185
Buffered code: G1 X353.652 Y335.265 E.10794
Buffered code: G1 X353.182 Y336.446 E.0882
==> 1536 bytes
Code buffer space: 1272
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 38.87, max time between full transfers: 43.7ms, max pin wait times: 56.7ms/1.0ms
Codes per second: 21.21
Maximum length of RX/TX data transfers: 3672/1664

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.4.6 (2023-07-21 14:17:33)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 2484, free system stack 25 words
Tasks: Move(notifyWait,0.6%,99) HEAT(notifyWait,0.5%,75) CanAsync(notifyWait,0.0%,65) CanRecv(notifyWait,0.1%,74) CanClock(notifyWait,0.0%,65) ACCEL(notifyWait,0.0%,61) TMC(delaying,2.9%,57) MAIN(running,90.9%,351) IDLE(ready,0.0%,26) AIN(delaying,5.0%,142), total 100.0%
Last reset 04:20:12 ago, cause: power up
Last software reset data not available
Driver 0: pos 7425929, 405.0 steps/mm,ok, SG min 0, read errors 0, write errors 1, ifcnt 238, reads 13513, writes 18073, timeouts 1, DMA errors 0, CC errors 18073, failedOp 0xec, steps req 281499 done 281503
Moves scheduled 215982, completed 215979, in progress 1, hiccups 0, step errors 0, maxPrep 584, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter 1/5, peak Rx sync delay 210, resyncs 0/0, next step interrupt due in 134 ticks, enabled
VIN voltage: min 20.9, current 23.7, max 24.3
MCU temperature: min 44.2C, current 53.7C, max 57.6C
Last sensors broadcast 0x00000002 found 1 152 ticks ago, 0 ordering errs, loop time 1
CAN messages queued 7108, send timeouts 0, received 10187, lost 0, free buffers 37, min 36, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 424, adv 36414/74668
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, other errors 0
=== Filament sensors ===
Interrupt 5 to 24us, poll 24 to 1733us
Driver 0: ok

I also ran M350 while printing with the over extrusion and it still says everything is a x16.

	M350
Microstepping - X:16(on), Y:16(on), Z:16(on), E:16(on)

As for the wire I tested all connections with multimeter and there doesn’t seem to be any shorts I could find. I however did not ground the hot end metal work, never did since I put it together around 2022 and it is mounted directly on the Hermes/Hemera which is mounted on a 0.25in SS bracket. While in the over extrusion face of the print I touched everything in the 1LC and nothing feels hot to the touch.

Completely missed that in the documentation. I’ve tried 3.4.6, 3.5.0RC4,3.5.1 and 3.5.2 and the same thing keeps happening. And up to this point everything was working fine even when jumping to unstable releases. I'm leaning towards a faulty 1LC unless there is something that I'm missing.

Here are the pictures requested:

*Edit:
Also, I live in Tampa Florida and these past couple of weeks we’ve seen some thunder storms for about two weeks straight. Don’t know if it is relevant but might as well mention it. I do not have the printer on an UPS.

@gloomyandy
I was using 3.5.0 and I ran 8 to 20 hour prints without any problem. The print I was running just had the same issue at the 2 hour 40 mark it started over extruding. It has been printing fine for a about two months. Could it be a busted 1LC board. My 1LC is the 1.2 not the 1.2a. I can get the 1.3 from fillastruder and try it out to see.

@gloomyandy
Right now, I went back to DuetPi 2023-09-06 (buster) on a pi 4, from there I updated to RepRapFirmware 3.5.0 RC4. I would stay in 3.4.6 but I have the Zscaning probe and If I recall correctly that one is not usable in 3.4.6.

For some reason Duet web control doesn’t update to 3.5.0RC4 and stays on 3.4.6 or I might be updating it wrong. Either way I’m on another test print 2h 13m 51s in so far.

Well, it happened again at around 3 hour and 12 minutes in it started over extruding again. This time I have not stopped the print. I just disabled the filament sensor and am going to let it print a couple of hours to have a visual on where exactly it goes wrong.

Here are the diagnostics of as of now, after it started over extruding.

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91852 of which 3088 recycled
Never used RAM 92212, free system stack 134 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,nWait 7,1.0%,819) HEAT(3,nWait 6,0.0%,321) Move(4,nWait 6,2.7%,211) CanReceiv(6,nWait 1,0.0%,771) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,9.7%,53) MAIN(2,running,86.5%,101) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 03:26:07 ago, cause: software
Last software reset at 2024-06-26 18:23, reason: User, Platform spinning, available RAM 95692, slot 2
Software reset code 0x6000 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044a000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 40.9, current 43.2, max 43.2
Supply voltage: min 23.8, current 23.9, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/152/152, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 447, reads 34871, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 358, reads 34871, writes 0 timeouts 0
Driver 2: ok, SG min 0, mspos 337, reads 34871, writes 0 timeouts 0
Driver 3: ok, SG min 0, mspos 655, reads 34871, writes 0 timeouts 0
Driver 4: ok, SG min 0, mspos 463, reads 34871, writes 0 timeouts 0
Driver 5: ok, SG min 0, mspos 481, reads 34871, writes 0 timeouts 0
Date/time: 2024-06-26 21:49:16
Slowest loop: 51.41ms; fastest: 0.05ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 189738ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 106 ticks, disabled
Moves shaped first try 5639, on retry 5272, too short 6461, wrong shape 194305, maybepossible 1481
=== DDARing 0 ===
Scheduled moves 235144, completed 235107, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
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 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X354.319000 Y309.311005 E0.101450" 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 idle in state(s) 0
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 0x80000007
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 data received
=== CAN ===
Messages queued 317673, received 320618, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 379, free buffers 50 (min 49), ts 56240/56240/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 25733/25733
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 3024/512-4080, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X354.319 Y309.311 E.10145
Buffered code: G1 X355.033 Y311.045 E.13012
Buffered code: G1 X355.661 Y312.813 E.13019
Buffered code: G1 X356.205 Y314.607 E.13008
Buffered code: G1 X356.666 Y316.421 E.12987
Buffered code: G1 X357.045 Y318.247 E.12941
Buffered code: G1 X357.397 Y320.497 E.15803
Buffered code: G1 X357.563 Y321.95 E.10148
Buffered code: G1 X357.699 Y323.815 E.12976
Buffered code: G1 X357.75 Y325.703 E.13106
Buffered code: G1 X357.713 Y327.535 E.12715
Buffered code: G1 X357.541 Y329.761 E.15492
Buffered code: G1 X357.368 Y331.11 E.09437
Buffered code: G1 X357.015 Y333.005 E.13376
Buffered code: G1 X356.656 Y334.436 E.10237
Buffered code: G1 X356.222 Y335.812 E.10012
Buffered code: G1 X355.764 Y337.028 E.09016
Buffered code: G1 X355.384 Y337.898 E.06588
Buffered code: G1 X354.879 Y338.912 E.0786
Buffered code: G1 X353.981 Y340.442 E.1231
Buffered code: G1 X353.31 Y341.42 E.0823
Buffered code: G1 X352.698 Y342.217 E.06973
Buffered code: G1 X352.042 Y342.991 E.0704
Buffered code: G1 X351.344 Y343.741 E.07109
Buffered code: G1 X350.607 Y344.462 E.07154
Buffered code: G1 X349.22 Y345.659 E.12713
Buffered code: G1 X348.202 Y346.428 E.08853
Buffered code: G1 X347.349 Y347.011 E.07169
Buffered code: G1 X345.778 Y347.961 E.12739
Buffered code: G1 X344.865 Y348.446 E.07174
Buffered code: G1 X343.71 Y348.995 E.08874
Buffered code: G1 X342.01 Y349.696 E.1276
Buffered codes: 1536 bytes total
Code buffer space: 2512
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.20, max time between full transfers: 56.5ms, max pin wait times: 51.8ms/21.5ms
Codes per second: 20.63
Maximum length of RX/TX data transfers: 4440/1140

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3196, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,84) HEAT(2,nWait 6,0.4%,90) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.2%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,delaying,3.7%,52) MAIN(1,running,90.7%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.9%,112), total 100.0%
Owned mutexes:
Last reset 03:26:10 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 1, write errors 1, ifcnt 35, reads 48266, writes 40994, timeouts 4, DMA errors 0, CC errors 40994, failedOp 0x72, steps req 0 done 9378961
Moves scheduled 224153, completed 224150, in progress 1, hiccups 0, segs 27, step errors 0, maxLate 0 maxPrep 367, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/8, peak Rx sync delay 260, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 19.7, current 23.3, max 24.4
MCU temperature: min 40.0C, current 54.6C, max 56.1C
Last sensors broadcast 0x00000002 found 1 29 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 230643, send timeouts 0, received 362699, lost 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 390, adv 36112/109819
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 1 to 105us, poll 2 to 1701us
Driver 0: ok

I don't really understand it. The last thing that comes to mind is changing the 1LC board? I'm at a loss here. At this point it feels like I'm punching in the dark. If anybody has any info or what to try next I appreciate it.

*edit: The print separated from the build plate so I'm including some pictures of the how the print looks after the over extrusion. Also uploaded two videos. one at the start of the print and the other when it starts over extruding. Notice the sound of the retractions. It sounds off.

video_2024-06-26_22-01-48.mp4 video_2024-06-26_22-01-39.mp4