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V0.2 keeps getting klipper shutdown lost communication to MCU errors


WarHammerTF

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V0.2 keeps getting klipper shutdown lost communication to MCU errors - It also throws movement out of range errors once in a while. Klipper does not shutdown for those just stops.  I have swapped the Pi out, swapped the USB cable from Pi to Cheetah MCU board out and looked at all the wiring. It used to throw a lost communication to Display issue - I removed the display and commented out the display lines in printer.cfg - that decreased the number of of shutdowns somewhat. 

 

Any thoughts?

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14 minutes ago, WarHammerTF said:

V0.2 keeps getting klipper shutdown lost communication to MCU errors - It also throws movement out of range errors once in a while. Klipper does not shutdown for those just stops.  I have swapped the Pi out, swapped the USB cable from Pi to Cheetah MCU board out and looked at all the wiring. It used to throw a lost communication to Display issue - I removed the display and commented out the display lines in printer.cfg - that decreased the number of of shutdowns somewhat. 

Any thoughts?

Bad controller board perhaps? 

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I have another new controller on hand that I can try.

Before that I am trying to eliminate anything that might be a "silly" error before the adventure that flashing firmware usually ends up being.

I have a stupid amount of time into trying to troubleshoot this printer - way more than the build time. :o(

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14 minutes ago, WarHammerTF said:

Before that I am trying to eliminate anything that might be a "silly" error before the adventure that flashing firmware usually ends up being.

In this game there are no silly errors. I think before installing the new board - re flash the firmware on the current board, making sure of the settings specific to the board (Chip name, Clock reference and bootloader offset)

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Yup its looking like that is the next step.

On another not is looks like you might have a Switchwire in your group of Vorons? If so how do you like it?Is yours an ender conversion or total BOM sourced? I am interested as bed slingers can be handy to have at times.

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6 hours ago, WarHammerTF said:

Yup its looking like that is the next step.

On another not is looks like you might have a Switchwire in your group of Vorons? If so how do you like it?Is yours an ender conversion or total BOM sourced? I am interested as bed slingers can be handy to have at times.

It is a self sourced build. (To save postage, I self sourced a V0, V2.4r1 and the switchwire and had them shipped over together.) Not an Ender conversion. Don't use it as much as the other printers but it is a great printer none the less.

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You must have had a pretty big printer bill the month you had all three shipped over. 🐵

I have the V0.2 that is in troubleshooting phase and a second V2.4r2 that is about 75% assembled. After that I have all the parts on hand for a Micron 180. At that point maybe need a Switchwire or I am about done making printers until they come out with something that really moves things forward.

Seems like kind of a weird phase in 3d printers right now. Lots of "unique" printers - FL Sun and Positron come to mind here - that are interesting to look at but I don't think I would invest in or  proprietary Voron/core xy offshoots and semi clones - Bambu Labs, Sovol, Troodon etc.

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7 hours ago, WarHammerTF said:

You must have had a pretty big printer bill the month you had all three shipped over. 🐵

That was in Covid times when Aliexpress was still cheap. Probably cost less than a full kit would now.

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Well I got the MCU errors fixed. I changed the MCU controller out and re-flashed, redid the sd card for the Pi etc. I have about 6 hours of test printing on it.

That's the good news.

The not so good news is almost every time it completes a print it loses steps in X  on the next home or print start. It will indicate that it has homed  to 120 but it has only moved to 3 to 5mm from where it ended up after the print. A printer restart fixes it and it did not do this with the original SD card/MCU. 

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So for reference, after a print if I home Z, which also homes X oddly enough, then the V0.2 holds its coordinate position correctly and can then do other moves or print jobs without having to restart the printer. I ended up adding G28 Z as the last line in the print_end macro to automate the move. 

All in all I think I like limit switches over sensorless.

On to the next Voron.......

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59 minutes ago, WarHammerTF said:

I ended up adding G28 Z as the last line in the print_end macro to automate the move.

Just be careful that this does not destroy your print on the bed. Z- would normally home at your "safe homing" position which normally is in the middle of the bed, unless you have a [homing_override] specified in a corner of the bed.

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3 hours ago, WarHammerTF said:

if I home Z, which also homes X oddly

As you also suspect, that is not normal behaviour of a G28 Z.

If this happens, (I understand you have a sensorless setup), it might be because you have a homing override where it has set it up to do so. You might want to check that out.

A not-correct coordinate system at the end of a print, might suggest skipping of your stepper motors. This is mostly due to speeds it can't handle. The other, more painful one is a grub screw that has loosened. 

If you want to keep using this printer, you might want to check those few things out. I am sure the next time you are going to want to print something, it will give you more troubles than you would want at that moment.

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The last line of the Fysetc printer.cfg moves the printhead to X60 Y120 F3600 Z is not specified as it ilooks like it is calced a bit earlier in the macro. It does this move without fail at the end of a print. If I do not home Z or Y (Homing X here fails) it will lose its spot on the start of the next print. 

If I try to do a G28 Z on my Trident it says X and Y must be homed first. I wonder if the V0.2 is set somewhere to just throw in the XY home in a G28 Z. 

I will check the motor grub screws I can also adjust the speeds down. I am not sure what you mean by a homing override

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It is possible that the move at the end of the print, is the cause of skipping, even if it moves successfully, if it does this for example with a very high acceleration. But you would notice it as something strange.

A homing override is a macro that overrides the normal homing procedure, like is seen for example with sensorless homing.

If you can upload your latest klippy.log or your printer.cfg I can take a look if I can see what might be the culprit.

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Attached is the klipper log taken right after the printer loses its location and the printer.cfg file. 

The only way to get it to fail is to comment out the G28 Z comment I inserted at the end of the Print_End macro. 

The Print_End macro puts the printhead final move at  G0 X60 Y{max_y} F3600          ; park nozzle at rear - it does this correctly and shows the correct coordinates in klipper. Without the G28 Z whatever the next move is the printhead goes over a few millimeters, clunks and then stops and the screen reads that the printhead has moved to whatever X location was specified. On the picture uploaded Y and Z reflect correct positions X is still back at 60. With the G28 Z this failure cannot be duplicated. Without G28 Z it is repeatable. 

I looked at the motors and verified the grub screws were tight on the flat of the shaft and then sharpied a line across shaft and pulley gear. There is no movement during hours long prints including the final resting spot at the end of the print or during the failure when it thinks it has moved X but has not. 

Any insights you can share would be greatly appreciated.

 

Jeff

20240620_003702.jpg

PRINTERDORCFG 1ST V02.txt klippy.log

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