Random overextrusion after 3+hours of printing FW 3.5.2

[gloomyandy]

@charliedrums Just to be clear, did the test with RC.4 also start to over extrude? If that was the case then it seems unlikely that it is anything in 3.5.2 that is causing the problems, especially if you were able to print ok with 3.5.0. Why did you choose to go back to 3.5-rc4 rather than 3.5.0? You might want to try 3.5.0 just to be sure, that the problem is not related to the firmware.

[charliedrums]

@droftarts said in Random overextrusion after 3+hours of printing FW 3.5.2:

ut without running a test print on a previous RRF version that was working for you, it's hard to say why this would happen at the same time as updating to RRF 3.5.2. If it happens again, can you send M350 and check the microstepping in use is still x16, as per your

Ok, so I went back to 3.4.6 and ran the file again and the same thing happened at around 2-3 hours in, so that takes out the possibility of being software related. I think?
Here is the diagnostics:

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.4.6 (2023-07-21 14:11:38) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 153252
Dynamic ram: 67620 of which 0 recycled
Never used RAM 126272, free system stack 128 words
Tasks: SBC(resourceWait:,0.8%,446) HEAT(notifyWait,0.0%,321) Move(notifyWait,2.5%,214) CanReceiv(notifyWait,0.0%,773) CanSender(notifyWait,0.0%,327) CanClock(delaying,0.0%,347) TMC(notifyWait,8.1%,56) MAIN(running,88.5%,923) IDLE(ready,0.0%,30), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 04:20:10 ago, cause: power up
Last software reset details not available
Error status: 0x04
Aux0 errors 0,0,0
Step timer max interval 131
MCU temperature: min 41.5, current 42.5, max 42.5
Supply voltage: min 23.8, current 24.0, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/64/64, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 917, reads 44703, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 860, reads 44703, writes 0 timeouts 0
Driver 2: standstill, SG min 0, mspos 792, reads 44703, writes 0 timeouts 0
Driver 3: standstill, SG min 0, mspos 168, reads 44703, writes 0 timeouts 0
Driver 4: standstill, SG min 0, mspos 488, reads 44703, writes 0 timeouts 0
Driver 5: standstill, SG min 0, mspos 408, reads 44703, writes 0 timeouts 0
Date/time: 2024-06-27 16:15:47
Slowest loop: 29.62ms; fastest: 0.04ms
=== Storage ===
Free file entries: 10
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 28, maxWait 204ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 224744, completed 224704, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== AuxDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 1
Movement lock held by null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X340.993011 Y297.888000 E0.105450" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause* is idle in state(s) 0
Code queue is empty
=== Filament sensors ===
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 10186, received 8489, lost 0, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 372, free buffers 50 (min 49), ts 1726/1726/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 19094/19094
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x2ab5c
Buffer RX/TX: 1392/2864-0, open files: 0
=== Duet Control Server ===
Duet Control Server v3.4.6
File /opt/dsf/sd/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
Executing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
> Next stack level
File:
Buffered code: G1 X340.993 Y297.888 E.10545
Buffered code: G1 X342.308 Y298.665 E.10599
Buffered code: G1 X343.57 Y299.538 E.10648
Buffered code: G1 X344.154 Y300.008 E.05202
Buffered code: G1 X344.773 Y300.507 E.05517
Buffered code: G1 X345.912 Y301.567 E.10797
Buffered code: G1 X346.982 Y302.707 E.10849
Buffered code: G1 X347.988 Y303.921 E.1094
Buffered code: G1 X348.928 Y305.199 E.11008
Buffered code: G1 X349.801 Y306.533 E.11063
Buffered code: G1 X350.614 Y307.927 E.11198
Buffered code: G1 X351.353 Y309.347 E.11108
Buffered code: G1 X352.021 Y310.789 E.11027
Buffered code: G1 X352.628 Y312.265 E.11074
Buffered code: G1 X353.165 Y313.751 E.10964
Buffered code: G1 X353.636 Y315.246 E.10876
Buffered code: G1 X354.039 Y316.739 E.10731
Buffered code: G1 X354.375 Y318.223 E.10558
Buffered code: G1 X354.641 Y319.687 E.10325
Buffered code: G1 X354.846 Y321.122 E.10058
Buffered code: G1 X354.995 Y322.53 E.09825
Buffered code: G1 X355.09 Y323.879 E.09384
Buffered code: G1 X355.137 Y325.313 E.09956
Buffered code: G1 X355.137 Y326.466 E.08001
Buffered code: G1 X355.088 Y327.775 E.09089
Buffered code: G1 X355.005 Y328.922 E.0798
Buffered code: G1 X354.754 Y330.938 E.14097
Buffered code: G1 X354.577 Y331.92 E.06924
Buffered code: G1 X354.355 Y332.922 E.07121
Buffered code: G1 X354.128 Y333.784 E.06185
Buffered code: G1 X353.652 Y335.265 E.10794
Buffered code: G1 X353.182 Y336.446 E.0882
==> 1536 bytes
Code buffer space: 1272
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 38.87, max time between full transfers: 43.7ms, max pin wait times: 56.7ms/1.0ms
Codes per second: 21.21
Maximum length of RX/TX data transfers: 3672/1664

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.4.6 (2023-07-21 14:17:33)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 2484, free system stack 25 words
Tasks: Move(notifyWait,0.6%,99) HEAT(notifyWait,0.5%,75) CanAsync(notifyWait,0.0%,65) CanRecv(notifyWait,0.1%,74) CanClock(notifyWait,0.0%,65) ACCEL(notifyWait,0.0%,61) TMC(delaying,2.9%,57) MAIN(running,90.9%,351) IDLE(ready,0.0%,26) AIN(delaying,5.0%,142), total 100.0%
Last reset 04:20:12 ago, cause: power up
Last software reset data not available
Driver 0: pos 7425929, 405.0 steps/mm,ok, SG min 0, read errors 0, write errors 1, ifcnt 238, reads 13513, writes 18073, timeouts 1, DMA errors 0, CC errors 18073, failedOp 0xec, steps req 281499 done 281503
Moves scheduled 215982, completed 215979, in progress 1, hiccups 0, step errors 0, maxPrep 584, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter 1/5, peak Rx sync delay 210, resyncs 0/0, next step interrupt due in 134 ticks, enabled
VIN voltage: min 20.9, current 23.7, max 24.3
MCU temperature: min 44.2C, current 53.7C, max 57.6C
Last sensors broadcast 0x00000002 found 1 152 ticks ago, 0 ordering errs, loop time 1
CAN messages queued 7108, send timeouts 0, received 10187, lost 0, free buffers 37, min 36, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 424, adv 36414/74668
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, other errors 0
=== Filament sensors ===
Interrupt 5 to 24us, poll 24 to 1733us
Driver 0: ok

I also ran M350 while printing with the over extrusion and it still says everything is a x16.

	M350
Microstepping - X:16(on), Y:16(on), Z:16(on), E:16(on)

As for the wire I tested all connections with multimeter and there doesn’t seem to be any shorts I could find. I however did not ground the hot end metal work, never did since I put it together around 2022 and it is mounted directly on the Hermes/Hemera which is mounted on a 0.25in SS bracket. While in the over extrusion face of the print I touched everything in the 1LC and nothing feels hot to the touch.

Completely missed that in the documentation. I’ve tried 3.4.6, 3.5.0RC4,3.5.1 and 3.5.2 and the same thing keeps happening. And up to this point everything was working fine even when jumping to unstable releases. I'm leaning towards a faulty 1LC unless there is something that I'm missing.

Here are the pictures requested:

*Edit:
Also, I live in Tampa Florida and these past couple of weeks we’ve seen some thunder storms for about two weeks straight. Don’t know if it is relevant but might as well mention it. I do not have the printer on an UPS.

[charliedrums]

@gloomyandy
Yes, so far I’ve tried 3.4.6, 3.5.0RC4,3.5.1 and 3.5.2 and the same thing keeps happening. I'm leaning towards a faulty 1LC unless there is something that I'm missing .

[droftarts]

@charliedrums said in Random overextrusion after 3+hours of printing FW 3.5.2:

I however did not ground the hot end metal work, never did since I put it together around 2022 and it is mounted directly on the Hermes/Hemera which is mounted on a 0.25in SS bracket.

Is the SS bracket grounded? If not, I don't think it would hurt to try, or make sure the motor is grounded, particularly if the alternative is replacing the 1LC. May be the hot, humid, thundery weather, and a particular filament is enough to make it more susceptible to static discharge. I'd imagine it's discharging through the motor wires, into the driver, and messing that up. To reiterate our advice:

We recommend connecting the hot end metalwork to ground on the toolboard via a resistor (10k to 1M Ohm), if it is not grounded through its mounting system. This will prevent the hot end building up static charge, which might otherwise occur as filament is extruded and may then flash over to the tool board thermistor input, causing damage.

https://docs.duet3d.com/Duet3D_hardware/Duet_3_family/Duet_3_Toolboard_1LC#wiring-notes

Ian

[gloomyandy]

@charliedrums Is there any chance this could be related to temperature of your extruder or extruder motor? I wonder if after a long time your are getting "heat creep" that impacts the ability for the extruder to perform a retract, perhaps the filament is softened and so the extruder fails to grip it? You mentioned earlier that you needed to reboot for the problem to go away. Couple of tests you could try....

1. Wait for the problem to happen, reboot the computer and start the print again (do not allow any time for things to cool down).
2. Wait for the problem to happen, do not reboot, but allow the printer to cool down completely, then start the print again.

If in case 1 the problem does not happen for a few hours we can probably ignore heat. If in case 2 it takes a couple of hours for the problem to appear, then maybe heat is involved.

When you fitted the SZP, did you make any other changes? Is there any chance that the way the SZP is fitted that the airflow around the extruder has been reduced/changed?

[charliedrums]

@droftarts
It was not grounded but it is now. Since it takes a couple of days to get here I went and ordered a 1LC v1.3 board to see if that changes anything.

I updated the bootloader on the 1LC and I have grounded the bracket and now the screws and the hemera are grounded. This time I started a print and it started over extruding right from the start. Maybe now with the updated bootloader and grounded everything, updaye everything to 3.5.2 and see what happens? I'll keep trying stuff until the new 1LC gets here. I'll keep the thread updated to my findings.

[charliedrums]

@gloomyandy
I don't think it is heat related. I do a lot of hueforge, so the way I have the pause script is to turn off the extruder and park the extruder. So at least twice of the tests have been, set the print and go to bed, when I wake up it has been paused for a couple of hours letting the extruder cool down. I proceed to bring it up to temperature remove filament, trim it, and finally purge filament before resuming the print. After this the problem persists. But I'll give ot a try.

I bought a new 1lcv1.3 from filastruder so I have a couple of days before it gets here where I can keep investigating to see if I can pinpoint the problem.

[charliedrums]

Small update. While waiting for the new 1LCv1.3 to get here I decided to remake all the cable harnesses that connect to the 1LC board I got the correct crimper and crimped everything correctly with new JST-PH connectors (trying to get these perfect is not that easy). After this I tried again but same thing After a couple of hours the extruder randomly starts over extruding. So this eliminates any bad crimps or harness connections.

I also took the board off the extruder and inspected everything to see if there was any visible damage. But there was nothing that I could see. Is there any test to see if the board is busted in any way?

[OwenD]

@charliedrums
Have you scanned the Gcode at that area?
I once had a similar issue that was doing my head in.
It turned out that in one of the settings in PrusaSlicer, I had a value entered as a percentage when it should have been an 1 based factor.
So instead of be 75% of the extrusion value, it was 75X the value.
I never figured out if I made an error, or there was a change in the software (unlikely), or if it was me caopying configs between prusa slicer and super slicer.
I think it was in overhangs.
In any case, maybe check for sudden increases in the E values for moves in that area.

[deckingman]

I haven't read this entire thread so I might have missed something but another option/thing to check is if the Z axis is moving properly. If the Z axis has some "stiction" or other movement related issue which prevents it from moving the full layer height, then this can seem like over extrusion. i.e. if you extrude enough filament for (say) 0.3mm layer height but the Z axis has only moved (say) 0.1mm, then this can seem like over extrusion.

[charliedrums]

@OwenD I have printed the gcode before. Probably like 30 t50 times and it has always worked. Still gave it a look but found nothing out of the ordinary.

[charliedrums]

Ok, so the new 1LC (v1.3) board came in today. I decided to start everything with a new install on a Pi5. using
image_2024-04-19-DuetPi-arm64. Once I built the image and assembled everything I updated all the boards thought putty. Interesting that when I do a toolboard diagnostics it says that the toolboard is version 1.1 not 1.3.

Now whoever I'm having a new problem. After updating everything on FW3.5.2, I go to start the print everything looks good and is heating up as it should but once heating up finishes and it starts to move to the the homing routine a couple of things happen. *Edit Before I start any print or anything I can probe and scan the bed without any problems.

Error: Expansion board 120 reconnected
Error: Expansion board 121 reconnected

then the scanning z probe starts scanning the bed and in every pass I get this error.

Error: Board 120 does not have input handle 3040

and in DWC this is how the teperature is reported after this happens

I have no Idea whats going on now. All I did is change the 1LC board.
Here are the diagnostics. of all boards.

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 11 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91860 of which 3080 recycled
Never used RAM 92188, free system stack 136 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,rWait:,0.9%,801) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,1.8%,211) CanReceiv(6,nWait 1,0.0%,794) CanSender(5,nWait 7,0.0%,334) CanClock(7,delaying,0.0%,348) TMC(4,nWait 6,9.6%,53) MAIN(2,running,87.4%,101) IDLE(0,ready,0.2%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 00:23:03 ago, cause: power up
Last software reset at 2024-07-01 18:02, reason: MemoryProtectionFault mmarValid daccViol, Platform spinning, available RAM 92476, slot 1
Software reset code 0x4160 HFSR 0x00000000 CFSR 0x00000082 ICSR 0x0440f804 BFAR 0x00000000 SP 0x204198e8 Task IDLE Freestk 20 ok
Stack: 20419968 00000000 2041999c 20419960 a5a5a5a5 0049a485 0049a0e0 61000000 61000000 a5a5a5a5 2041999c fffc0000 20425daf 20419958 2041995c 43f8e92d 20419960 00000000 ffffffff 004999a9 43f8e92d 00000000 20419960 00000000 00000001 204199e0 4e49414d
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 33.6, current 42.0, max 42.1
Supply voltage: min 23.7, current 24.0, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/72/72, gc cycles 0
Events: 2 queued, 2 completed
Driver 0: ok, SG min 0, mspos 628, reads 55863, writes 17 timeouts 0
Driver 1: ok, SG min 0, mspos 913, reads 55863, writes 17 timeouts 0
Driver 2: standstill, SG min 0, mspos 520, reads 55863, writes 17 timeouts 0
Driver 3: standstill, SG min 0, mspos 936, reads 55863, writes 17 timeouts 0
Driver 4: standstill, SG min 0, mspos 952, reads 55863, writes 17 timeouts 0
Driver 5: standstill, SG min 0, mspos 104, reads 55864, writes 17 timeouts 0
Date/time: 2024-07-01 18:25:49
Slowest loop: 77.42ms; fastest: 0.04ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 27, maxWait 199391ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 1 ticks, disabled
Moves shaped first try 1321, on retry 722, too short 604, wrong shape 12745, maybepossible 120
=== DDARing 0 ===
Scheduled moves 17499, completed 17443, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X336.225006 Y327.441986 E0.046660" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 28613, received 21465, lost 0, errs 641, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 250, free buffers 50 (min 48), ts 6920/6919/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 53966/53966
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 3248/48-4096, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X336.225 Y327.442 E.04666
Buffered code: G1 X336.573 Y327.959 E.05293
Buffered code: G1 X336.881 Y328.464 E.05023
Buffered code: G1 X337.357 Y329.369 E.08267
Buffered code: G1 X337.635 Y329.988 E.05459
Buffered code: G1 X337.85 Y330.524 E.04646
Buffered code: G1 X338.183 Y331.522 E.08229
Buffered code: G1 X338.49 Y332.75 E.09722
Buffered code: G1 X338.669 Y333.816 E.08108
Buffered code: G1 X338.748 Y334.521 E.05168
Buffered code: G1 X338.797 Y335.606 E.07913
Buffered code: G1 X338.763 Y336.843 E.08942
Buffered code: G1 X338.686 Y337.585 E.05172
Buffered code: G1 X338.569 Y338.329 E.0515
Buffered code: G1 X338.414 Y339.049 E.04953
Buffered code: G1 X338.163 Y339.93 E.06047
Buffered code: G1 X337.864 Y340.77 E.05791
Buffered code: G1 X337.827 Y340.861 E.00612
Buffered codes: 864 bytes total
Code buffer space: 3200
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 38.34, max time between full transfers: 64.4ms, max pin wait times: 34.9ms/3.8ms
Codes per second: 12.04
Maximum length of RX/TX data transfers: 8176/1140

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 3832, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,90) HEAT(2,nWait 6,0.1%,126) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,91.3%,412) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.5%,112), total 100.0%
Owned mutexes:
Last reset 00:18:59 ago, cause: power up
Last software reset data not available
Driver 0: pos 0, 80.0 steps/mm, ok, SG min 0, read errors 0, write errors 0, ifcnt 55, reads 21490, writes 0, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 660061
Moves scheduled 15214, completed 15210, in progress 1, hiccups 0, segs 26, step errors 0, maxLate 0 maxPrep 210, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 1/6, peak Rx sync delay 245, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 11.9, current 24.6, max 24.6
MCU temperature: min 36.0C, current 38.5C, max 38.8C
Last sensors broadcast 0x00000000 found 0 137 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 6671, send timeouts 0, received 20102, lost 0, errs 0, boc 0, free buffers 18, min 17, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 369, adv 36213/74673
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0

Zprobe

M122 B120
Diagnostics for board 120:
Duet SZP firmware version 3.5.2 (2024-06-10 13:23:26)
Bootloader ID: SAMC21 bootloader version 2.10 (2023-11-16)
All averaging filters OK
Never used RAM 14188, free system stack 110 words
Tasks: HEAT(2,nWait 6,0.1%,132) CanAsync(5,nWait 4,0.0%,54) CanRecv(3,nWait 1,0.0%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) MAIN(1,running,64.7%,430) IDLE(0,ready,0.0%,26) AIN(2,nWait 4,35.1%,72), total 100.0%
Owned mutexes: I2C(AIN)
Last reset 00:19:13 ago, cause: power up
Last software reset at 2024-03-12 06:08, reason: StackOverflow, available RAM 14136, slot 0
Software reset code 0x0100 ICSR 0x0041a00e SP 0x20007f34 Task ACCE Freestk 5138 ok
Stack: 20002e70 20002ea4 00014913 200029a4 20002ac0 20002998 000139f1 20002ac0 fffffffd 0000002a 00000000 20007f8c 00000000 20007f8c 00014677 00000000 200010a4 20001028 00013eb7 20001028 200010a4 00000032 454c4449 00019000 00012683 200011c0 200011c0
Peak sync jitter 1/6, peak Rx sync delay 216, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 4.4, current 5.0, max 5.0
MCU temperature: min 27.5C, current 30.1C, max 30.2C
Last sensors broadcast 0x00000000 found 0 165 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 5518, send timeouts 0, received 11275, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
Accelerometer: LIS2DW, status: 00
Inductive sensor: raw value 39288477, frequency 3.66MHz, current setting 13, ok
I2C bus errors 0, naks 3, contentions 0, other errors 0

any help would be greatly appreciated.

[charliedrums]

Ok so I narrowed down the tool Expansion board 121 reconnected error to the harness connection between the scanning z probe and the tool board harness. I mystically did not plug it in all the way. Having plugged it in correctly I started a new test print with the new 1LC board but still I’m having the same over extrusion problem at random times. Sometimes is at the start of the print, sometimes is at layer 5, sometimes its 3+ hours into the print.

So I decided to go back to the basics I disconnected the scanning z probe and the filament sensor and updated the config.g file to comment out the scanning z probe and the filament sensor. So the only things that are plugged in to the 1LC are the extruder & cooling fan, the extruder heater, thermistor, motor, vin power and the can connection. With this configuration I started a test print to see if I keep getting the over extrusion issue. Hopefully I have a successful print on this one I really don’t want to ditch duet for Klipper and a Chinese board.

Here are my diagnostics:
MB6HC

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 11 of 40 (29 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 89888 of which 5072 recycled
Never used RAM 92192, free system stack 136 words
Tasks: SBC(2,rWait:,0.9%,821) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,1.9%,211) CanReceiv(6,nWait 1,0.0%,794) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,348) TMC(4,nWait 6,9.7%,53) MAIN(2,running,87.1%,101) IDLE(0,ready,0.3%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 00:19:02 ago, cause: software
Last software reset at 2024-07-01 22:29, reason: User, Gcodes spinning, available RAM 95744, slot 0
Software reset code 0x6003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0043c000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU temperature: min 37.2, current 42.1, max 42.2
Supply voltage: min 23.8, current 24.0, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/48/48, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 366, reads 41818, writes 17 timeouts 0
Driver 1: ok, SG min 0, mspos 1010, reads 41818, writes 17 timeouts 0
Driver 2: ok, SG min 0, mspos 277, reads 41818, writes 17 timeouts 0
Driver 3: ok, SG min 0, mspos 59, reads 41818, writes 17 timeouts 0
Driver 4: ok, SG min 0, mspos 859, reads 41818, writes 17 timeouts 0
Driver 5: ok, SG min 0, mspos 229, reads 41818, writes 17 timeouts 0
Date/time: 2024-07-01 22:48:14
Slowest loop: 1369.34ms; fastest: 0.05ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 99861ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 383 ticks, disabled
Moves shaped first try 1182, on retry 654, too short 544, wrong shape 10891, maybepossible 117
=== DDARing 0 ===
Scheduled moves 15092, completed 15032, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.2
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X329.549988 Y341.337006 E0.083270" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 24111, received 22784, lost 0, errs 1, boc 0
Longest wait 2ms for reply type 6026, peak Tx sync delay 323, free buffers 50 (min 49), ts 5711/5710/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 45007/45007
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 3264/752-4080, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X329.55 Y341.337 E.08327
Buffered code: G1 X328.919 Y341.965 E.06177
Buffered code: G1 X328.509 Y342.594 E.0521
Buffered code: G1 X328.222 Y343.222 E.04791
Buffered code: G1 X328.016 Y343.85 E.04586
Buffered code: G1 X327.906 Y344.479 E.04431
Buffered code: G1 X327.95 Y344.793 E.022
Buffered code: G1 X328.205 Y345.107 E.02807
Buffered code: G1 X329.428 Y345.735 E.0954
Buffered code: G1 X330.45 Y346.364 E.08327
Buffered code: G1 X330.63 Y346.543 E.01761
Buffered code: G1 X331.455 Y346.422 E.05786
Buffered code: G1 X331.908 Y346.306 E.03245
Buffered code: G1 X332.359 Y346.157 E.03296
Buffered code: G1 X333.06 Y345.853 E.05302
Buffered code: G1 X333.762 Y345.466 E.05562
Buffered code: G1 X334.184 Y345.184 E.03522
Buffered code: G1 X334.598 Y344.867 E.03618
Buffered code: G1 X335.255 Y344.267 E.06174
Buffered code: G1 X334.577 Y343.85 E.05523
Buffered code: G1 X333.945 Y343.222 E.06182
Buffered code: G1 X333.536 Y342.594 E.052
Buffered code: G1 X333.249 Y341.965 E.04797
Buffered code: G1 X333.042 Y341.337 E.04588
Buffered code: G1 X332.933 Y340.708 E.0443
Buffered code: G1 X332.976 Y340.394 E.02199
Buffered code: G1 X333.232 Y340.08 E.02811
Buffered code: G1 X334.455 Y339.452 E.0954
Buffered code: G1 X335.476 Y338.823 E.08321
Buffered code: G1 X336.108 Y338.195 E.06182
Buffered code: G1 X336.518 Y337.567 E.05204
Buffered code: G1 X336.805 Y336.938 E.04797
Buffered codes: 1536 bytes total
Code buffer space: 2512
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.60, max time between full transfers: 50.4ms, max pin wait times: 35.8ms/5.4ms
Codes per second: 13.53
Maximum length of RX/TX data transfers: 4436/1124

1LC

	Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 3372, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,90) HEAT(2,nWait 6,0.3%,98) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,90.8%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.8%,112), total 100.0%
Owned mutexes:
Last reset 00:19:06 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, standstill, SG min 0, read errors 0, write errors 1, ifcnt 26, reads 48051, writes 13, timeouts 0, DMA errors 0, CC errors 0, steps req 0 done 850185
Moves scheduled 13946, completed 13943, in progress 1, hiccups 27, segs 26, step errors 0, maxLate 0 maxPrep 335, maxOverdue 102, maxInc 37, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/5, peak Rx sync delay 228, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 19.7, current 23.7, max 24.6
MCU temperature: min 34.6C, current 45.0C, max 46.0C
Last sensors broadcast 0x00000002 found 1 205 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 22882, send timeouts 0, received 24273, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 403, adv 36312/74663
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0

[charliedrums]

Ok this time it was 1h 1m 28s when the over extrusion started. Any Ideas of what I could try next? Would making a new RJ11 cable from the tool distribution board help? Or re cabling the whole thing? At this point I’ll try anything.

Diagnostics:
MB6HC

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (29 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 89912 of which 5048 recycled
Never used RAM 92192, free system stack 136 words
Tasks: SBC(2,nWait 7,0.9%,821) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,2.5%,211) CanReceiv(6,nWait 1,0.0%,794) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,9.7%,53) MAIN(2,running,86.7%,101) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 01:00:13 ago, cause: software
Last software reset at 2024-07-01 22:29, reason: User, Gcodes spinning, available RAM 95744, slot 0
Software reset code 0x6003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0043c000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU temperature: min 41.9, current 44.6, max 44.7
Supply voltage: min 23.7, current 23.9, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/48/48, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 444, reads 10183, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 867, reads 10184, writes 0 timeouts 0
Driver 2: ok, SG min 0, mspos 508, reads 10184, writes 0 timeouts 0
Driver 3: ok, SG min 0, mspos 852, reads 10184, writes 0 timeouts 0
Driver 4: ok, SG min 0, mspos 628, reads 10184, writes 0 timeouts 0
Driver 5: ok, SG min 0, mspos 460, reads 10184, writes 0 timeouts 0
Date/time: 2024-07-01 23:29:26
Slowest loop: 31.88ms; fastest: 0.05ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 991ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 166 ticks, disabled
Moves shaped first try 2755, on retry 1709, too short 1471, wrong shape 35430, maybepossible 500
=== DDARing 0 ===
Scheduled moves 61679, completed 61619, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X337.981995 Y325.506012 E0.063910" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 65895, received 49465, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 254, free buffers 50 (min 48), ts 12359/12359/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 11409/11409
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 1920/3424-0, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X337.982 Y325.506 E.06391
Buffered code: G1 X338.172 Y326.122 E.04473
Buffered code: G1 X338.373 Y326.988 E.06169
Buffered code: G1 X338.475 Y327.605 E.04339
Buffered code: G1 X338.532 Y328.208 E.04203
Buffered code: G1 X338.576 Y329.165 E.06648
Buffered code: G1 X338.54 Y329.812 E.04496
Buffered code: G1 X338.477 Y330.421 E.04248
Buffered code: G1 X338.404 Y330.875 E.03191
Buffered code: G1 X338.17 Y331.76 E.06352
Buffered code: G1 X337.971 Y332.224 E.03503
Buffered code: G1 X337.819 Y332.486 E.02102
Buffered code: G1 X337.248 Y333.118 E.0591
Buffered code: G1 X336.888 Y333.48 E.03543
Buffered code: G1 X336.109 Y334.03 E.06617
Buffered code: G1 X335.767 Y334.23 E.02749
Buffered code: G1 X335.59 Y333.679 F15000
Buffered code: G1 F1500
Buffered code: G1 X334.92 Y333.853 E.04803
Buffered code: G1 X334.282 Y333.984 E.04519
Buffered code: G1 X333.634 Y334.091 E.04557
Buffered code: G1 X332.588 Y334.206 E.07302
Buffered code: G1 X331.473 Y334.279 E.07753
Buffered code: G1 X328.705 Y334.286 E.19207
Buffered code: G1 X327.414 Y334.206 E.08975
Buffered code: G1 X326.38 Y334.093 E.07218
Buffered code: G1 X325.719 Y333.984 E.04649
Buffered code: G1 X324.531 Y333.728 E.08433
Buffered code: G1 X324.202 Y333.548 E.02602
Buffered code: G1 X323.572 Y333.103 E.05352
Buffered code: G1 X322.915 Y332.457 E.06394
Buffered codes: 1472 bytes total
Code buffer space: 1920
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.44, max time between full transfers: 54.9ms, max pin wait times: 54.5ms/4.6ms
Codes per second: 19.17
Maximum length of RX/TX data transfers: 4436/1124

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 3372, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,88) HEAT(2,nWait 6,0.3%,90) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,90.7%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.9%,112), total 100.0%
Owned mutexes:
Last reset 01:00:15 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 0, write errors 2, ifcnt 168, reads 27122, writes 16826, timeouts 4, DMA errors 0, CC errors 16827, failedOp 0x71, steps req 0 done 2205650
Moves scheduled 57511, completed 57507, in progress 1, hiccups 80, segs 26, step errors 0, maxLate 0 maxPrep 354, maxOverdue 106, maxInc 52, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/6, peak Rx sync delay 252, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 11.6, current 24.2, max 24.5
MCU temperature: min 34.6C, current 45.2C, max 46.0C
Last sensors broadcast 0x00000002 found 1 143 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 49415, send timeouts 0, received 65795, lost 0, errs 0, boc 0, free buffers 18, min 18, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 398, adv 36262/74666
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0

[deckingman]

@charliedrums Looking at this logically, any print move looks like this. G1 Xnn Ynn Enn. Which means move a certain distance in X and/or Y while extruding a certain amount of filament. What you are saying is that at random times, when printing a gcode that you have printed many times before, that Enn becomes something greater. I.e, the fimant moving through the extruder randomly moves further or faster than it should do. There are many reasons why it might move less (partial blockage, temperature too low, motor or wring issue, missed steps, etc), but none that I can think of that would make the filament move further than it should. So the only logical conclusion is that something else is happening which gives the appearance of over extrusion when in fact it isn't. My best guess, as I've stated before, is that your Z axis isn't moving the full layer height.

[charliedrums]

@deckingman @deckingman

I would have guessed the same but I have checked all 4 Z motors and their harnesses. Here is what leads me to determine it is over extrusion. First once the issue begins, I remove the print from under the extruder and let it print in air for a while and visibly one can tell the more amount of plastic is being forces through the nozzle.

Second, I am using the Orthus Filament Monitor. The orthus has a light that flashes intermittently when filament is running through it. The faster the blink of the light the faster the filament if passing through the sensor, when the problem begins the light flashes faster as in filament is passing faster trough the sensor/extruder. I can move the printer to the max height(365mm) and home without any problems.

I’m going one thing at a time right now I eliminated the z scanning probe and the filament sensor. Still happening. This time around I re did the harness that powers the tool distribution board (two cables 24v Vin ground) and am currently running the print to see if the problem continues after this, I’ll re do the RJ11 cable. Then continue from there.

[deckingman]

@charliedrums If you are certain that it is genuine over extrusion after some seemingly random period of time, then the only explanation I can think of is that somehow, something is changing the G1 Xnn Ynn Enn commands that exist in the gcode file to something like G1 Xnn Ynn E(some other value that is always higher). I note that you are using a SBC. Is there any chance that you could run stand alone mode and print directly form an SD card?

[deckingman]

@charliedrums One other suggestion - try a print without input shaping. I can't offhand think why it should make a difference but who knows?

[charliedrums]

@deckingman
Yes, I can I don’t see why not. The only reason I have SBC is so I could get WIFI. Looking through the documentation I see that I can connect to the board directly with an ethernet cable. Next thing Ill do is that go Direct an eliminate the SBC and see. Thanks for the idea.

[OwenD]

@charliedrums said in Random overextrusion after 3+hours of printing FW 3.5.2:

@OwenD I have printed the gcode before. Probably like 30 t50 times and it has always worked. Still gave it a look but found nothing out of the ordinary.

Good that you're keeping an open mind.
Having printed the code before may not prove anything.
For example in my case the Gcode extrusion values were far above the capabilities of the extruder, but I wasn't getting skipped steps because my maximum extruder speed values were limiting it to achievable amounts (albeit way over extruded).
If in the interim you had for example increased your max extruder speeds then a problem that wasn't obvious before may now appear.
Loading the code into Prusa Slicer and viewing it by volumetric flow rate would show up any odd areas most likely a lot more than just scanning the code by eye.

Have you tried swapping the drivers around that the extruder is on?
That should rule out a hardware fault on the board at least.

EDIT: Just saw that you're using a tool board and have swapped it.