Z axis makes loud noise and wont move

Jasonpgr

I finally got my firmware and everything updated (I think) and I can connect to the board again over the wifi, but I think some of my settings aren't compatible with the new firmware. Whenever I try to home any axis, it tries to move the Z axis first, and when it tries to move I just hear a grinding type noise and it doesn't move at all. I've got some fairly beefy Nema17 motors on the Z axis, and they're each driving two leadscrews, with pulleys to reduce the gearing down. I went this route because my build plate is a 550mm x 550mm sheet of 3/8" aluminum and I was worried about the weight. In retrospect, this is probably major overkill.

I originally thought I was trying to move it too fast, but I have the max z speed set pretty slow, and it's still doing it. I'm going to copy my config.g file here. If anyone with more experience could review it and see where I went wrong, I would greatly appreciate it.

; Configuration file for Duet WiFi (firmware version 1.20 or newer)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool on Mon May 07 2018 21:33:03 GMT-0700 (PDT)

; General preferences
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves
M555 P1 ; Set firmware compatibility to look like RepRapFirmare

M667 S1 ; Select CoreXY mode

; Network
M550 PDBOT_XL ; Set machine name
M552 S1 ; Enable network
M587 S"Jason-home" P"3382Rockwood" ; Configure access point. You can delete this line once connected
M586 P0 S1 ; Enable HTTP
M586 P1 S0 ; Disable FTP
M586 P2 S0 ; Disable Telnet

; Drives
M569 P0 S1 ; Drive 0 goes forwards
M569 P1 S1 ; Drive 1 goes forwards
M569 P2 S1 ; Drive 2 goes forwards
M569 P3 S1 ; Drive 3 goes forwards
M569 P4 S1 ; Drive 4 goes backwards
M350 I0 ; Configure microstepping without interpolation
M350 X16 Y16 Z16 E16:16 I1 ; Configure microstepping with interpolation
M92 X100 Y100 Z1500 E418:418 ; Set steps per mm
M566 X800 Y800 Z30 E100:100 ; Set maximum instantaneous speed changes (mm/min)
M203 X10000 Y10000 Z300 E1200:1200 ; Set maximum speeds (mm/min)
M201 X1000 Y1000 Z50 E250:250 ; Set accelerations (mm/s^2)
M906 X1100 Y1100 Z1400 E800:800 I60 ; Set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z-0.8 S1 ; Set axis minima
M208 X500 Y480 Z450 S0 ; Set axis maxima

; Endstops
M574 X1 Y2 S0 ; Set active low endstops

; Z-Probe
M574 Z1 S2 ; Set endstops controlled by probe
M307 H3 A-1 C-1 D-1 ;
M558 P9 X0 Y0 Z1 H5 F100 T2000 ; Set Z probe type to effector and the dive height + speeds
G31 P25 X-45 Y0 Z1.5 ; Set Z probe trigger value, offset and trigger height
M557 X45:450 Y45:450 S100 ; Define mesh grid

; Heaters
M305 P0 T100000 B3950 C0 R4700 ; Set thermistor + ADC parameters for heater 0
M143 H0 S160 ; Set temperature limit for heater 0 to 160C
M307 H1 A373.4 C264.8 D10 B0
M305 P1 T100000 B4725 C7.06e-8 R4700 ; Set thermistor + ADC parameters for heater 1
M143 H1 S300 ; Set temperature limit for heater 1 to 300C

; Fans
M106 P0 S1 I0 F500 H-1 ; Set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned off
M106 P1 S1 I0 F500 H1 T45 ; Set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned on

; Tools
M563 P0 D1 H1 ; Define tool 0
G10 P0 X0 Y0 Z0 ; Set tool 0 axis offsets
G10 P0 R0 S0 ; Set initial tool 0 active and standby temperatures to 0C

M501

; Automatic saving after power loss is not enabled

; Custom settings are not configured

fcwilt

@jasonpgr

Possibly the Z steppers are trying to move in opposite directions?

Frederick

Jasonpgr

@fcwilt
nah, they don't even visibly try to wiggle at all. They're not belted together so they would go askew at last a little bit before binding up.

fcwilt

@jasonpgr said in Z axis makes loud noise and wont move:

@fcwilt
nah, they don't even visibly try to wiggle at all. They're not belted together so they would go askew at last a little bit before binding up.

But you said you hear a grinding noise.

Can you disconnect them from the bed and see if the grinding noise is related?

Frederick

dc42

@jasonpgr check that you have the phases of the motors connected correctly. Do not swap wires over without identifying the phases first. See https://duet3d.dozuki.com/Wiki/Choosing_and_connecting_stepper_motors#Section_Identifying_the_stepper_motor_phases

Jasonpgr

@dc42 The printer was working just fine before installing the new firmware. So I don't belive it is a phase issue. Should it does sound similar. The grinding is probably just the machine vibrating as the motors shake/stall or something.

Do all the speeds and accelerations and everything look correct? Is there another config or setting file that could be conflicting somehow?

SIam

@jasonpgr I don't think that this solves your problem, but the following things makes the config file clean

This you can remove

M350 I0 ; Configure microstepping without interpolation

Here you have defined two extruders, but you don't have a second tool in your config defined

M350 X16 Y16 Z16 E16:16 I1 ; Configure microstepping with interpolation
M92 X100 Y100 Z1500 E418:418 ; Set steps per mm
M566 X800 Y800 Z30 E100:100 ; Set maximum instantaneous speed changes (mm/min)
M203 X10000 Y10000 Z300 E1200:1200 ; Set maximum speeds (mm/min)
M201 X1000 Y1000 Z50 E250:250 ; Set accelerations (mm/s^2)
M906 X1100 Y1100 Z1400 E800:800 I60 ; Set motor currents (mA) and motor idle factor in per cent

Here I would say remove the second E Values or define a second tool

I can't find further Errors so far, did you have your old config.g file ? If yes, can you post it here?

jay_s_uk

@jasonpgr said in Z axis makes loud noise and wont move:

M587 S"Jason-home" P"3382Rockwood" ; Configure access point. You can delete this line once connected

you shouldn't include the above in your firmware as it will get written to the ESP on every boot and wear the flash out.

What firmware are you running? post the output of M115

Jasonpgr

@jay_s_uk

FIRMWARE_NAME: RepRapFirmware for Duet 2 WiFi/Ethernet FIRMWARE_VERSION: 2.0(RTOS) ELECTRONICS: Duet WiFi 1.02 or later FIRMWARE_DATE: 2018-06-05b3

As for the M587 line, would it be better to comment it out using ; before the M587 part, or should I delete the line all together? I don't want to lose information I might need for trouble shooting later if I don't need to.

jay_s_uk

@jasonpgr it's your WiFi details so just delete it.

And really, I recommend if you're starting a rebuild to move up to version 3.3.
If you'd rather not do that then I recommend at least upgrading to 2.05.1

Jasonpgr

@jay_s_uk
I just did a firmware upgrade last month, and I'm still trying to get it all back up and working again since then. Did I not use the latest version? That's a little frustrating, but it seems like it's going to be the best route. Guess I'll be doing a whole new upgrade tonight.

jay_s_uk

@jasonpgr I think 2.0 is from around the time I got into using RRF (about 2 1/2 years ago).
If you do for for 3.3, I would go the route of generating a new set of config files using the config tool rather than trying to adjust yours to suit.
Always worth reading the release notes too

Jasonpgr

@jay_s_uk

Yeah. You're definitely right about that. I really struggle with the gcode and programming of stuff, so I've been putting it off again and again. I'm also guessing my firmware upgrade from a few months ago didn't work if it's a version that old.

Well, I'll take some good notes from my old config file, and see if I can't get it going from scratch. Probably the best thing in the long run anyway.

Stand by for a bunch of panicked posts from me over the next couple weeks asking questions with very obvious answers I've managed to overlook.

Phaedrux

If you still have access to DWC. Upload these 3 zip files, one at a time in the system tab. Don't extract them. Reboot after each. Use M115 to verify the firmware has been applied.
https://github.com/Duet3D/RepRapFirmware/releases/download/2.05.1/Duet2Firmware-2.05.1.zip
https://github.com/Duet3D/RepRapFirmware/releases/download/3.0/Duet2and3Firmware-3.0.zip
https://github.com/Duet3D/RepRapFirmware/releases/download/3.3/Duet2and3Firmware-3.3.zip
That will get your firmware and DWC up to date.

You can see the change logs here:
https://github.com/Duet3D/RepRapFirmware/wiki/Changelog-RRF-3.x

For your config, might be a good idea to run through the configurator tool and generate a fresh set for RRF3.
https://configtool.reprapfirmware.org/Start

Backup your existing config files in the sys folder in case you want to switch back to RRF3. IT’s easy to switch back and forth, just upload the zip file for the version you want and then upload your config files.

These documents will come in handy during the conversion.
https://duet3d.dozuki.com/Wiki/RepRapFirmware_3_overview
https://duet3d.dozuki.com/Wiki/Gcode

Jasonpgr

@phaedrux
Thanks for the step by step, I really appreciate it. I have the firmware all updated I believe, and I'm working on the config tool now. I think I've got all the parameters entered correctly, except for some about the probe/z endstop under the io section. You can see the post I made last night with a screenshot of the part of the config I'm talking about.

https://forum.duet3d.com/topic/23842/config-tool-question

Jasonpgr

Sooooo I'm super dumb. I finally got around to trying to troubleshoot this problem again, and it looks like the cat had chewed through one of the wires going to one of the Z stepper motors..... Soooooo all that frustration took 30 seconds and one drop of solder to fix. At least I have an upgraded set of firmware at least I guess.