Z stalling or not moving part way through print
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@engikeneer
While I don't disagree that the change is significant, I see it as more of a change to a starting point rather than looking at it from A to B being a big jump percentage-wise.
I do have a small z hop of .1mm in my slicer but I've always had that and my layer heights are much more than that.You could be right though, a combination of z hop movements, heat, acceleration,
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Try reducing your z acceleration to 200.
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@phaedrux
I tried to do some testing and got inconsistent results.
I wrote a gcode to change acceleration and move z up and down several times at different speeds. Acceleration between 100-600mm/s^2 and speeds between 30 and 600mm/min(0.5mm/s to 10mm/s). I don't think the low speed really solidified any findings but I wanted to see if it'd fail because of the acceleration value alone.
The z axis would stop intermittently at all acceleration values, mostly at high movement speed but sometiems at 100mm/min. If it failed, I'd just turn it off, wait for the motors to cool then retry.I settled on the highest acceleration value and movement speeds that failed the least - 300mm/s^2 acceleration and max speed of 250 mm/min.
So far so good after 50+ hours of prints.I'm marking this solved but still not clear to me why it was failing .
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undefined skhotso has marked this topic as solved
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undefined skhotso has marked this topic as unsolved
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Back again. I must be sh*t at crimping as well as the factories that made two of my stepper cables, or something funky is going on with my board.
It was stalling/grinding again with the "phase 2 disconnected" error so checked my cables at the stepper motors, plugged them back in, restarted the duet...still grinding.
Unplugged the cables from the board to check continuity to the motors, checked out good so I plugged it back in and it started working again.Printed for another 20+ hours, came back to a failed print due to z stalling as well as the phase 2 error. unplugged cable and just put it right back to see if it just needed to be "re-seated". z worked again.
Instead of wasting plastic I just simulated prints (gcode movements only) for 8 hours at a time.
Got 3 more stalled z-axes and both we fixed by reseating the cable.Before reseating the cable after the 3rd stall, I unplugged the z cables from the motors and plugged one into the x motor. The stalled-motor status moved to the x-axis and caused grinding. Reseated the cable at the board and back to normal.
SO far, I've recrimped 3 times and used cables from the other axes. It seems to stick with the z axis motor ports.
Is it possible I just need to reflow the solder on the header pins or is there something I can do to keep the pins and cables in uninterrupted contact? -
As you problem moves with the z axis steppers I would not reflow anything on the board. I am curious if you steppers are failing(slim chance but maybe) or if you’re still having problems with crimped wires.
Do you have consistent resistance between phases of the steppers when disconnected from the duet?
Have you tried lubing the lead screws lately?
How much are the steppers heating up? -
@alex-cr
I wasn't thinking of reflowing the whole board, probably just ensure good solder connection on the z headers.Consistent as in not fluctuating while measuring or consistent as in the same resistance between phases?
I didn't really watch the values as I was measuring, just measured and they were close to each other so I moved on.One of the first steps when troubleshooting this was cleaning and applying teflon dry lube to the lead screws.
steppers are hot but I can hold my hand on there all day if needed. Sorry, I haven't actually measured the temp.
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Consistent as same resistance between phases. Sounds like you checked that box.
In terms of stepper temp, that should be sufficient. Just making sure they aren't too hot. If you can hold your hand there, that's not the problem.
My only other thought is disconnecting the lead screw and ensuring the whole Z axis moves freely.
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@skhotso said in Z stalling or not moving part way through print:
Is it possible I just need to reflow the solder on the header pins or is there something I can do to keep the pins and cables in uninterrupted contact?
Can you post a photo of the solder joints and connector for the Z axis?
Does the problem follow the Z motor, or the Z driver?
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@phaedrux
I'll take a pic when I have time to unmount it from the printer.The problem appears to follow the driver -- as mentioned above, switching the cable from the z motor to the x motor caused the grinding. I did not plug the z motor into the x axis/driver pins though.
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Tried to take a picture but it was dark so I took a video. Snapshot from video attached. It doesn't look like there are any soldering issues here.
I bought 2 new motors just for the hell of it, even though both motors' phases tested around 6 (k?)ohms or so.
I decided to just split the z axis motors into separate drivers so I can see which motor keeps getting a "phase disconnected".
I also soldered the wires to the connector pieces after crimping, just for good measure.Haven't seen the issue yet so I'll just keep on printing until the issue pops up.
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@skhotso said in Z stalling or not moving part way through print:
It doesn't look like there are any soldering issues here.
Agreed, those look like good joints from what I can see.
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undefined skhotso has marked this topic as solved
