@dc42 said in Duet3 6CH + 3CH expansion board - Missing steps.:

Thanks. I'll do that E drive position reporting check on my tool changer. It may be just a reporting issue.

@dc42 @Phaedrux

Here are promised videos. Use bookmarks to go directly to issue.

XY Motors connected to Duet 3 board

XY Motors connected to expansion board

Edit: attaching config files
xy_on_expansion.config.g
xy_on_duet3.config.g

Compressed gcode, renamed to *.txt
ZR_BearingTopMount_FR.zip.txt

Diagnostic after failed print (for M122 B1)

M122 B1
Diagnostics for board 1:
Duet EXP3HC firmware version 3.2 (2021-01-05)
Bootloader ID: not available
Never used RAM 154728, free system stack 154 words
HEAT 90 CanAsync 94 CanRecv 84 TMC 30 MAIN 315 AIN 257
Last reset 08:10:45 ago, cause: power up
Last software reset data not available
Driver 0: position -591153, 160.0 steps/mm,  standstill, reads 62793, writes 52 timeouts 0, SG min/max 0/1023
Driver 1: position -76259, 160.0 steps/mm,  standstill, reads 62795, writes 52 timeouts 0, SG min/max 0/1023
Driver 2: position 52354, 172.0 steps/mm,  standstill, reads 62807, writes 44 timeouts 0, SG min/max 0/156
Moves scheduled 4073, completed 4073, in progress 0, hiccups 218
No step interrupt scheduled
VIN: 24.7V, V12: 12.3V
MCU temperature: min 43.8C, current 44.0C, max 44.2C
Ticks since heat task active 245, ADC conversions started 29445736, completed 29445736, timed out 0
Last sensors broadcast 0x00000000 found 0 248 ticks ago, loop time 0
CAN messages queued 122, send timeouts 0, received 269109, lost 0, free buffers 36

Diagnostic after failed print (for M122)

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.2 running on Duet 3 MB6HC v1.01 or later (SBC mode)
Board ID: 08DJM-956L2-G43S8-6JKDL-3SJ6L-1802G
Used output buffers: 1 of 40 (11 max)
=== RTOS ===
Static ram: 149788
Dynamic ram: 63136 of which 68 recycled
Never used RAM 145840, free system stack 128 words
Tasks: Linux(ready,87) HEAT(blocked,296) CanReceiv(blocked,849) CanSender(blocked,344) CanClock(blocked,352) TMC(blocked,53) MAIN(running,673) IDLE(ready,19)
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 01:37:31 ago, cause: watchdog
Last software reset at 2021-01-11 20:53, reason: User, none spinning, available RAM 146296, slot 1
Software reset code 0x0012 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00400000 BFAR 0x00000000 SP 0x00000000 Task Linu Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
Aux1 errors 0,0,0
MCU temperature: min 35.9, current 37.4, max 38.4
Supply voltage: min 24.1, current 24.3, max 24.4, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.1, current 12.1, max 12.2, under voltage events: 0
Driver 0: position 70760, standstill, reads 54741, writes 24 timeouts 0, SG min/max 0/238
Driver 1: position 8428, standstill, reads 54741, writes 24 timeouts 0, SG min/max 0/236
Driver 2: position 1039, standstill, reads 54741, writes 24 timeouts 0, SG min/max 0/264
Driver 3: position 0, standstill, reads 54741, writes 24 timeouts 0, SG min/max 0/255
Driver 4: position 0, standstill, reads 54754, writes 11 timeouts 0, SG min/max 0/0
Driver 5: position 0, standstill, reads 54754, writes 11 timeouts 0, SG min/max 0/0
Date/time: 2021-01-11 22:30:54
Slowest loop: 187.54ms; fastest: 0.03ms
=== 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, maxWait 272324ms, bed compensation in use: mesh, comp offset 0.000
=== MainDDARing ===
Scheduled moves 1805, completed moves 1805, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 2], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed moves 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, chamberHeaters = -1 -1 -1 -1
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.3
=== GCodes ===
Segments left: 0
Movement lock held by null
HTTP* is doing "M122" 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
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.
=== CAN ===
Messages queued 25218, send timeouts 0, received 41, lost 0, longest wait 1ms for reply type 6018, free buffers 48
=== SBC interface ===
State: 4, failed transfers: 0
Last transfer: 2ms ago
RX/TX seq numbers: 13476/13476
SPI underruns 0, overruns 0
Number of disconnects: 0, IAP RAM available 0x2c8a8
Buffer RX/TX: 0/0-0
=== Duet Control Server ===
Duet Control Server v3.2.0
Code buffer space: 4096
Configured SPI speed: 8000000 Hz
Full transfers per second: 35.91
Maximum length of RX/TX data transfers: 2800/1684

@Phaedrux said in Duet 3 + Tool board stops mid-print and reports 100% complete:

Can you provide the M122 for the mainboard as well?

M122 is for both, main board starts at line 17

@Phaedrux said in Duet3 6CH + 3CH expansion board - Missing steps.:

We're not afraid of troubleshooting.

I spent 3 month troubleshooting exactly the same issue (inconsistent or under extrusion) on the tool-board, finally I had to remove it completely from my printer. And then I made the same mistake ordering expansion board....

@evomotors said in Duet 3 + Tool board stops mid-print and reports 100% complete:

@Phaedrux said in Duet 3 + Tool board stops mid-print and reports 100% complete:

Can you provide the M122 for the mainboard as well?

M122 is for both, main board starts at line 17

It doesn't happens on every print, the same gcode file did work when I started printing again from the beginning. It happened to me 3 or 4 times since I upgraded to Duet board few weeks ago.

I will enable diagnostics

Can I have some updates? Please...

@dc42

Got new tool board yesterday but haven't installed it yet. Currently trying to restore/ground my tooling plate and reapply PEI.

@dc42 said in Duet3 6CH + 3CH expansion board - Missing steps.:

@evomotors said in Duet3 6CH + 3CH expansion board - Missing steps.:

@dc42 Is it possible that pressure advance has the same issue on expansion and tool boards?

It's not pressure advance that triggers the problem I found today, it's DAA. Pressure advance will not trigger it. I ran the section of your test file that I have been using to replicate the problem with pressure advance enabled.

I can confirm that stuttering XY moves are gone with M593 disabled. No more layer shifts. I will still complete the print to see if issue with extrusions irregularity is gone as well.

@dc42 @T3P3Tony The issue is fixed in the last 3.3 build! Tested with DAA enabled and print looks great (didn't look into the diagnostic messages) . Thank you!

Do you want me to mark this as answered?

@T3P3Tony said in Duet3 6CH + 3CH expansion board - Missing steps.:

@evomotors Testing with your config with DAA enabled is not showing any errors on the bench setup. did you get a chance to test it on the printer?

I didn't update to latest that @dc42 uploaded. But on pervious early 3.3 betta issue stops only when DAA is disabled. And yes I'm testing life on the printer.

I will upgrade to fresh build little late today.

@dc42 said in Duet3 6CH + 3CH expansion board - Missing steps.:

@evomotors said in Duet3 6CH + 3CH expansion board - Missing steps.:

@dc42 Is it possible that pressure advance has the same issue on expansion and tool boards?

It's not pressure advance that triggers the problem I found today, it's DAA. Pressure advance will not trigger it. I ran the section of your test file that I have been using to replicate the problem with pressure advance enabled.

I can confirm that stuttering XY moves are gone with M593 disabled. No more layer shifts. I will still complete the print to see if issue with extrusions irregularity is gone as well.

@dc42 Is it possible that pressure advance has the same issue on expansion and tool boards?

@dc42 said in Duet3 6CH + 3CH expansion board - Missing steps.:

I've put new Duet 3 MB6HC firmware in https://www.dropbox.com/sh/wme9k0z86sytg33/AAAT6wrHp2eeJHK-dYoW1Um4a?dl=0. I expect it to work well with the EXP3HC firmware already there. I am testing with newer EXP3HC firmware, but it is still somewhat experimental.

I started the test print with the early 3.3beta that you are posted last week and DAA disabled. Then I will upgrade to the new 6CH and try again.

@dc42 said in Duet3 6CH + 3CH expansion board - Missing steps.:

I've located the problem and tested a provisional fix. It affects systems using CAN expansion boards that have DAA enabled.

When and how can I test?

Can I have some updates? Please...

@dc42 do you have any time estimates? I’m wondering when I’ll be able to print.

@dc42 Could my issue exists due to faulty Duet board ? I'm dead in the water. I cannot print at all for several weeks already.

@dc42 said in Duet3 6CH + 3CH expansion board - Missing steps.:

I was confusing you with the other guy having a problem with print quality when the extruder is on an expansion board. I searched through the 128 posts in this thread and eventually found your video. It looks like it's printing correctly most of the time, but occasionally there is a big jolt which results in a shift in X and/or Y. That ties in with the lost CAN messages that are reported by M122 B1.

The bottom line is when I connect XY motors to Duet3 board that problem disappears, but E steps still missing or not synchronized with XY movement and that produces bad quality print. Unfortunately I cannot connect extruder to duet3 as well as Duet3 has 6 stepper drivers, but I need 7.