I may have found the culprit, I went back to my last backup of the config and config override file and that didn't help. But afterwards I checked each tower and if it is moving as it should. After measuring the X and Y towers are both moving 100mm when asked to but when the Z is asked to move 100mm it only moves about 96mm. Has anyone seen this before? how is that possible if all are using the same belts, same spec motors and M122 is not showing any step errors or anything. I am hesitant to change anything on the Steps per mm for just 1 axis if everything else matches for them...

@dc42 Works fine up to 3.4.4 and breaks again on the update to 3.4.5

@Phaedrux
So good news and maybe bad news with it. I redid the homing files and tried uploading the 3.4.5 firmware again. That did not fix anything.

But I thought I would try downgrading back to 3.4.1 and the issue is now no longer there...

Planning to now upload each new release until it starts again. At least then we could figure out which update caused the issue...

@Phaedrux config (1).g homeall (1).g
see homeall and config files above.

This still happens when sent from the console or with G28 X and G28 Y individually

Nothing else has changed recently. The last print was successful a few weeks ago and it has sat dormant since then.

M119 returns correctly
Endstops - X: not stopped, Y: not stopped, Z: not stopped, Z probe: not stopped ----- when all switchs are open
Endstops - X: at max stop, Y: at max stop, Z: not stopped, Z probe: not stopped ---- when X and Y are taped down

M122 Output:
M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.4.5 (2022-11-30 19:41:16) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: HBPBN-X396U-D65J0-40KMS-2903Z-Z05H4
Used output buffers: 1 of 40 (14 max)
=== RTOS ===
Static ram: 103652
Dynamic ram: 110712 of which 0 recycled
Never used RAM 27204, free system stack 122 words
Tasks: NETWORK(notifyWait,14.7%,223) HEAT(notifyWait,0.0%,358) Move(notifyWait,0.3%,290) CanReceiv(notifyWait,0.0%,942) CanSender(notifyWait,0.0%,336) CanClock(delaying,0.0%,341) TMC(notifyWait,0.7%,115) MAIN(running,83.3%,411) IDLE(ready,0.1%,30) AIN(delaying,0.9%,272), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 00:22:59 ago, cause: power up
Last software reset at 2022-04-03 10:29, reason: User, GCodes spinning, available RAM 26888, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 1379777, completed 1379775, timed out 0, errs 0
Step timer max interval 1488
MCU temperature: min 18.9, current 29.6, max 29.6
Supply voltage: min 24.1, current 24.2, max 24.3, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0, read errors 0, write errors 0, ifcnt 14, reads 7050, writes 14, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 0, ifcnt 12, reads 7052, writes 12, timeouts 0, DMA errors 0, CC errors 0
Driver 2: ok, SG min 0, read errors 0, write errors 0, ifcnt 13, reads 7051, writes 13, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 0, ifcnt 9, reads 7054, writes 9, timeouts 0, DMA errors 0, CC errors 0
Driver 4: ok, SG min 0, read errors 0, write errors 0, ifcnt 14, reads 7050, writes 14, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2022-12-10 19:45:44
Cache data hit count 2459183563
Slowest loop: 49.32ms; fastest: 0.11ms
=== Storage ===
Free file entries: 9
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 3.2ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 83, segments created 6, maxWait 373468ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 20, completed 18, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 2, 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, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 0
Movement lock held by HTTP
HTTP is idle in state(s) 54 15, running macro
Telnet is idle in state(s) 0
File is idle 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
=== CAN ===
Messages queued 12416, received 0, lost 0, boc 0
Longest wait 0ms for reply type 0, peak Tx sync delay 0, free buffers 18 (min 18), ts 6899/0/0
Tx timeouts 0,0,6898,0,0,5516 last cancelled message type 4514 dest 127
=== Network ===
Slowest loop: 17.57ms; fastest: 0.00ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
= WiFi =
Network state is active
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.27
WiFi MAC address f0:08:d1:03:e3:47
WiFi Vcc 3.34, reset reason Power up
WiFi flash size 2097152, free heap 23152
WiFi IP address 192.168.1.143
WiFi signal strength -41dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

And
M98 P"config.g"
Warning: Heater 1 predicted maximum temperature at full power is 508°C

After a few busy weeks of not using my printer, I went to work on another new print and after ironing out the wifi connection issues and upgrading to 3.4.5 from 3.4, I am running into an issue during homing

My homeall script is below
G91 ; relative positioning
G1 H2 Z5 F8000 ; lift Z relative to current position
G1 H1 X365 Y365 F1800 ; move quickly to X and Y axis endstops and stop there (first pass)
G91
G1 H2 X-5 Y-5 F6000 ; go back a few mm
G1 H1 X365 Y365 F360 ; move slowly to X and Y axis endstops once more (second pass)
G90 ; absolute positioning
G1 X225.5 Y178.5 F8000 ; move probe to center of bed and home Z
G30 ; home Z by probing the bed
G1 X180 Y180 F6000 ; Move nozzel to center

It looks like after the first pass for X and Y it leaves relative positioning (that's why I added another G91) and goes to absolute coords x=-5 and y=-5

Then takes forever to move slowly across the entire build plate to do the second pass. Once completed there the Z probe (BL Touch) hits on the first pass then never does the probing move...

Not sure where to go or why this all of a sudden no longer works after it worked fine in the past... Any help would be greatly appreciated

That's what I am trying to do but running into blocks, I visually can't see anythign wrong. Checked all towers are 90 degrees to the bed and all appear evenly spread. I did a slightly more accurate measure and after I removed and A,B corrections in the config override and reseting the printer the Z tower moved 49.22mm instead of 50mm and the X and Y towers move move 50.23mm instead of 50mm. Is there anything specific I should be checking mechanically, motor, idler pully, belt and carriage all appear fine?

I may have found the culprit, I went back to my last backup of the config and config override file and that didn't help. But afterwards I checked each tower and if it is moving as it should. After measuring the X and Y towers are both moving 100mm when asked to but when the Z is asked to move 100mm it only moves about 96mm. Has anyone seen this before? how is that possible if all are using the same belts, same spec motors and M122 is not showing any step errors or anything. I am hesitant to change anything on the Steps per mm for just 1 axis if everything else matches for them...

I adjusted and ran some calibrations with just S4 and fewer prob points and that seems to have made it much worse...
Some more info on the printer, it has the injection molded barbells and spring joints from SeemeCNC (https://www.seemecnc.com/collections/parts-accessories/products/replacement-ball-joints) so the spacing between top and bottom joints should all match. I am thinking it is an FSR issue and will start looking into those i guess

I have a custom DIY Kossel delta type printer modified to make it bigger and use 3030 extrusion instead of 2020. I have had and used it for a few years and all of a sudden the auto calibration is way off and never had issues with bed levelness in the past. It used FSRs for probing under the bed, has a duet3d wifi control board, and linear rails for the movement. I am guessing it is an issue with either one towers movement or an FSR issue but dont see anything that could be wrong. Belts are tight and fine, each FSR will trigger easily etc.

Anyone have any thoughts on where to start looking basaed on the bed probing results attached?

At work discussing 3d printing with someone they mentioned the new 3MF file format is starting to take over for STL within the organization. Upon a quick look up online it looks pretty interesting but haven't heard of it before. Anyone have any clue if this format will start to leak into desktop 3D printing as well? I understand some of the advantages for big manufacturing organizations but can it have similar benefits to RepRap and similar users? Is there any discussion for slicers to start to handle these files? Just pure curiosity at this point.

Thanks bot! That helps a lot and will give me a good place to start.