Bit late, but it was mechanical. Didn't see that my Y tower Idler pulley mount had a lose screw.
Fixed.

@cosmowave thanks again.
I did implement R-1 and that seemed to work just fine.
Once I did that I disassembled the filament sensor and added just a very small drop of med thick ca on the TAC switch to add a little height to help remove some space between the TAC switch and the 6mm bb that pushes on the switch when filament goes thru the tube.

Here are part of my config.g that relate to the 4th axis:
M584 X0 Y1 Z2 U4 E3 P3 ; U4 is the 4th tower axis which is E1 stepper driver on the Duet Wifi
M665 R244.500 L400.970:400.970:400.970:8019.4 B150.0 H448.37 X-0.072 Y0.021 Z0.000
M669 X0 Y0
M666 X-0.34 Y-0.31 Z0.66 A0.00 B0.00
;Drives
M569 P0 S0 ; Drive 0 goes forwards, X tower stepper
M569 P1 S0 ; Drive 1 goes forwards, y tower stepper
M569 P2 S0 ; Drive 2 goes forwards, Z tower stepper
M569 P3 S0 ; Drive 3 goes forwards, E0 stepper
M569 P4 S0 ; Drive 4 goes forwards, 4th tower stepper
M350 X16 Y16 Z16 U16 E16 I1 ; Configure microstepping with interpolation
M92 X200 Y200 Z200 U200 E2787 ; Set steps per mm
M566 X1200 Y1200 Z1200 U1200 E40 ; Set maximum instantaneous speed changes (mm/min)
M203 X18000 Y18000 Z18000 U18000 E1200 ; Set maximum speeds (mm/min)
M201 X1000 Y1000 Z1000 U1000 E120 ; Set accelerations (mm/s^2)
M906 X1600 Y1600 Z1600 U1400 E500 I40 ; Set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

; Endstops
M574 X2 Y2 Z2 U2 S1 ; Set active low endstops

;Tools
G10 P0 X0 Y0 Z0 U0 ; Set tool 0 axis offsets

M500

Config-override.g lines of code related to the 4th axis:
M665 L400.970:400.970:400.970:8019.400 R244.529 H447.421 B150.0 X0.044 Y-0.103 Z0.000

homedelta.g:
G91 ; relative positioning
M584 P4 ;unhide U4
;*** Slow homing has been configured. Change F180 to F1800 below when your configuration is working
G1 S1 X450 Y450 Z450 U450 F1400 ; move all towers to the high end stopping at the endstops (first pass)
G1 X-5 Y-5 Z-5 U-5 F1800 S2 ; go down a few mm
;*** Slow homing has been configured. Change F180 to F360 below when your configuration is working
G1 S1 X10 Y10 Z10 U10 F360 ; move all towers up once more (second pass)
G1 Z-5 F6000 ; move down a few mm so that the nozzle can be centred
G90 ; absolute positioning
G1 X0 Y0 F6000 ; move X+Y to the centre
M584 P3 ; hide U4

I believe that's it.
4th axis rod length is 20 times that of XYZ. I haven't tried changing it.

Thanks again, found a bad crimp, but took such time making good crimps, but I guess removing the plug a few times must of weaked it. So I am in the process of re- crimping all 6 crimps and will report back when working.
Thanks again.

/quadcells

Sorry it took so long to get you this video of the camera tracking the hotend:
https://youtu.be/NWMInhy16rM

just completed a 12 hr print no heat faults. Thanks again.

@Hergonoway
I did not as I saw that the 3 jams I experienced were caused by a faulty heat sink fan. I replaced the fan and no jams.

Ok I figured it out.
below is part of my gcode with the last bold to show where my error was, I had M106 H3 and should of been H103.
Now it all works as it should.

M305 P0 S"Bed" T100000 B3950 R4700 H0 L0 ; BOM thermistor values. Put your own H and/or L values here to set the bed thermistor ADC correction
M305 P1 S"E0" T100000 B4725 C7.06e-8 R4700 H0 L0 ; E3D Semitec 104GT2 thermistor values. Put your own H and/or L values here to set the first nozzle thermistor ADC correction
M305 P2 S"E1" T100000 B4725 C7.06e-8 R4700 H0 L0 ; E3D Semitec 104GT2 thermistor values. Put your own H and/or L values here to set the first nozzle thermistor ADC correction

M305 P101 X1001 S"Duet Drivers"
M305 P102 X1002 S"Duex5 Drivers"

M305 P103 X3 T100000 B4725 C7.06e-8 R4700 H0 L0 S"Chamber Temperature" ; Chamber Temperature sensor connected to Duex5 board

M305 P104 X405 T22 S"Filament DryBox Temperature"
M305 P105 X455 T22 S"Filament DryBox Humidity [%]"

M106 P3 S1 I0 T25 H103 ; Chamber fans 0.24amps 12v.

HI,
I converted my (not being used) Linksys router into an AP wired it to the Mesh node that is in the area.
made a macro M587 to add my network and IP address,gateway,netmask.
Now my Duet starts up with a specific IP and connects only to the linksys router(AP).
When I look at the mesh app it shows the duet connected as wired. perfect.
So far I haven't lost connection to the duet since I made these changes.

Thanks to all for your help.

I swapped Y and E1 to help with the heat, I redesigned my Duet Wifi and Duex5 mounting brackets so that a 40mm x 40mm x 10mm fan mounting at one end of the control boards so that the fan is half below and half above the Duet boards and air flows across the drivers per dc42's suggestion. I also added heatsinks on the drivers and align them so the fins of the heatsinks allow air to flow unrestricted.
I have completed 4 30 hour prints without any over heat warnings.
Thanks for your help and saving me $$.
Some day I'll switch to Duet 3.

@quadcells followed the instructions for motion. I now have live video working and on the DWC .
Thanks

@cosmowave thanks again.
I did implement R-1 and that seemed to work just fine.
Once I did that I disassembled the filament sensor and added just a very small drop of med thick ca on the TAC switch to add a little height to help remove some space between the TAC switch and the 6mm bb that pushes on the switch when filament goes thru the tube.

@cosmowave oh, I was wondering why there was a R-1 to disable the triggers.
That seems easy and clean. I will try that.
Thanks

@jay_s_uk I was trying to install motion plugin but something went wrong and didn't work.
I haven't tried videostream.
I will take another stab at Motion and will look at videostream too.
I'll report back.
Thanks.

@markz Hi, thanks for the reply.
I have a Orbiter 2.0 with the Filament Sensor installed. There is an "Unload" button and there is another button that is triggered when there is filament inserted into the sensor.
All was working fine for a long time then I started getting unloading during prints.
I then changed the M581 R0 to R2 to prevent unloading and loading during a print. That worked.
But I still get unwanted loading during calibration which I think is do to the filament moving around as the carriage moves about. So there might be a problem with the pcb board in the sensor housing that I need to investigate, but I thought writing some kind of code to prevent this from happening as an added safety.
Here is the code for the triggers:

trigger2.g:

T0 ; select tool 0
M300 S2000 P100 ; play beep sound
M291 P"Filament autoloading!" S0 T3 ; display message
M302 P1 ; enable cold extrusion
G4 S1 ; wait for one second
G1 E15 F500 ; load filament inside the gears
G10 P0 S240 R0 ; set hotend temperature to 240
M116 ; wait for hotend to reach 240
G1 E150 F300 ; extrude 150mm, you may need to reduce speed for very soft TPU
M104 S0 T0 ; set hotend temperature to 0
M302 P0 ; disable cold extrusion
M291 P"Filament autoload complete!" S0 T3 ; display message

trigger3.g:

T0 ; select tool 0
M300 S4000 P100 ; play beep sound
M291 P"Filament unloading!" S0 T3 ; display message
G10 P0 S235 R0 ; set hotend temperature to 235
M116 ; wait for hotend to reach 235
G0 E-5 F3600 ; extract filament to cold end
G4 S3 ; wait for 3 seconds
G0 E5 F3600 ; push back the filament to strive stringing
G0 E-15 F3600 ; Extract fast in the cold zone
G0 E-100 F300 ; continue extraction slow allow filament to be cooled enough before reaches the gears
M104 S0 T0 ; set hotend temperature to 0
M291 P"Filament unload complete!" S0 T3 ; display message

@phaedrux Getting the camera working was easy, just have to figure out how to get the video over to the DWC.

I have 2 triggers, trigger2.g (Loading filament) trigger3.g (Unloading filament).
I have this code in my config.g :

M950 J1 C"io4.in" ; define input for filament auto load, connects to the FS pin of the Orbiter 2.0 Filament Sensor
M581 P1 T2 S0 R2 ; define trigger for filament auto load triggers trigger2.g
M950 J2 C"io5.in" ; define input for filament unload, connects to FU pin of the Orbiter 2.0 Filament Sensor
M581 P2 T3 S0 R2 ; define trigger for filament auto load triggers trigger3.g

I use R2 in the M581 to prevent loading and unloading triggers during a print job and it works great.
The problem is that I have seen unwanted loading and unloading triggers during bed calibration.
I figured I should write a meta script that would see that the printer is busy with another task or command and not let the triggers execute or query while the printer is busy, but I do not know how.
Can I get some direction on how to write this:

If printer is busy
abort

@phaedrux The Raspberry Pi High Quality 12.3 megapixel 1080p @ 30hz.

I have a Duet 3 MB6HC connected to a SBC (Pi4).
Is it possible to connect a HQ camera to the Pi4, will this be too much of a burden for the Pi4?
If it is possible, can someone point me in the right direction for information on how to?

@phaedrux thank you for the reply.