3.5.1 - 'Error: Pop(): stack underflow on Aux'

gloomyandy

@gnydick If you can get a set of commands that is reproducible and they are issued via the panelDue it might also be useful to check if the same set of commands produces an error if they are issued via the DWC console or perhaps via a USB connection.

omtek

@gloomyandy It seems like if the command from the PanelDue runs a predefined macro, then it's likely to generate the error message.

So far I've encountered the error when doing the following:

Pausing a print (runs pause.g)
Putting an active tool into standby (runs the toolchange macros)

What other commands besides those two trigger a predefined macro? The only other one I can think of is 'Cancel', but that won't show up unless the printer is paused.

oliof

@omtek any homing command (G28 X/Y/Z), as well as triggering a bed level (G32) or a bed mesh (G29). Main difference between these and pause/tool change is that pause and tool change may interact with the extruder for retract/unretracts?

omtek

@oliof You're right. I hadn't considered the homing macros. That's something else to try.

Getting the error when pausing during print seems to occur fairly consistently, as does putting a tool into standby. So far the printer appears to be unaffected, and the only additional error messages I'm getting in DWC appear to be when the PanelDue manages to correct itself and sends the commands that were queued up from the then non-working buttons.

droftarts

@omtek as this is on an SBC setup, @chrishamm could you have a look at this?

Ian

gnydick

@gloomyandy I issue those same commands from DWC all of the time and it hasn't happened.

omtek

Right now I can consistently get the error by doing the following:

Heating the tool to print temp (205C in this case)
Use the PanelDue to extrude 20mm of material.
Tap the tool icon on the PanelDue to put the tool into standby and deselect

I've been able to get a single 'Error: Pop(): stack underflow on Aux' with five out of five attempts.

If I perform the same actions in DWC, I don't get the error.

Additionally the error doesn't occur when doing the following:

Extruding in DWC and putting the tool into standby on the PanelDue.
Extruding on the PanelDue and putting the tool into standby in DWC

And aside from this error, the printer has been working great.

droftarts

@omtek how is the PanelDue wired to the Duet, ribbon cable or 4-wire cable? Is it particularly long?

You also have the PanelDue serial comms speed set higher than we normally suggest. From your config:

M575 P1 S1 B115200

Try M575 P1 S1 B57600

I suggest checking the wiring, crimps and connectors for good connections, and make sure they are not running close to motor or heater wires, which could be sources of interference.

Ian

omtek

@droftarts I'm using the 4-pin Molex KK cable. The original cable length was ~711mm long but I spent the morning re-crimping and shortening the length to ~400mm. I also updated the M575 line in my config.g per your suggestion. However, I'm still getting the single 'Error: Pop(): stack underflow on Aux' when performing the troubleshooting steps I outlined here.

droftarts

@omtek is there anyway you could setup in standalone mode (no RPi/SBC) and test if you have the same behaviour? That might help point out if it’s a firmware issue, or DSF. Is there anything else unique about your setup?

Ian

omtek

@droftarts My setup is nothing too exotic I hope: Duet 3 Mini 5+, Raspberry Pi 4b+ 4GB with external M.2 SSD (no SD card), RRF36 toolboard and a CannedERCF board (sitting on the canbus as passthrough, but no gcode configuration sent during this); all boards are running v3.5.1. I do have 5VEXT connected via an external power supply for a servo-powered filament cutter and the jumper set to disable the internal 5V.

I removed the jumper that disables the internal 5V power supply, but received the same error.
I copied my /sys folder to a microSD card flashed with image_2024-04-19-DuetPi-lite.zip, and I no longer get the Error: Pop(): stack underflow on Aux error using my troubleshooting steps. Several attempts over the last half-hour and the error has not occurred once.

My current setup was running the older ~~Jessie~~Buster image, and the only additional software I was running on the Pi was a uStreamer instance for the webcam (this was before Spyglass came out).

Is it worth trying out the new Bookworm image for troubleshooting now that it appears the error is specific to SBC mode?

droftarts

@omtek said in 3.5.1 - 'Error: Pop(): stack underflow on Aux':

Is it worth trying out the new Bookworm image for troubleshooting now that it appears the error is specific to SBC mode?

You can certainly give it a go, if you want! As it seems to be related to SBC mode, I'll ask @chrishamm to look at this.

Ian

omtek

@droftarts I used the same microSD card that I tested standalone mode to boot the raspberry pi and moved my configuration files over, however I still receive the Error: Pop(): stack underflow on Aux error when performing the troubleshooting steps.

Additionally, and probably out of the scope of this post, but I had issues booting my external M.2 drive when flashed with image_2024-04-19-DuetPi-lite.zip. The pi runs headless, but the green LED would flash 3x (missing start.elf iirc), and the M.2 drive activity would flash for a time, and then stop. I didn't feel like troubleshooting past that, but I was able to boot from the official Raspberry Pi OS (64-bit, lite) using the same drive and enclosure and following the instructions here I was able to get the repos added and DWC, DSF, et al installed. Unfortunately, the Error: Pop(): stack underflow on Aux error occurred using the official Raspberry Pi OS image and performing the troubleshooting steps.

chrishamm

@omtek I've got a bug fix ready for v3.5.2 which we will release sometime soon.

gnydick

This post is deleted!

omtek

This appears to be fixed with v3.5.2. I'm no longer getting the error message using the above steps. Additionally the 3 macros in the upper right corner of the 'Control' page have returned.

Marking as solved.