Z-axis crashes into bottom of machine after upgrade to SailFish 7.8

[Phillip Moffatt]

Okay, I've probably overlooked something completely obvious here, but I'm not sure what, I've just updated my Rep1 Dual clone to 7.8 Beta - in order to get the shudder/hammerfix in as they were causing serious print issues - it's now much better, not perfect, it still changes speed, but without the hammering stops.

However, the Z-axis crashes every time when it goes down after a print, it seems to think the axis is 200+mm long, rather than the actual 150mm.
 Now, I've tried flashing the firmware twice to check it wasn't an error, made sure I reset all the defaults, etc, and I've checked I have the correct machine selected driver in RepG - (Replicator Dual, Sailfish), and, if I check the machine information, I can see it comes up with the right axis lengths - I've even tried changing to another machine and then changing back to force it to update the EEPROM, this is what shows up, which is correct:

System Information
 ReplicatorG version: Sailfish - 40r33
 Java version: 1.6.0_16

Machine
 Profile Name: The Replicator Dual (Sailfish)
 Driver Type: MightySailfish
 Name: Shiny Maker
 Motherboard firmware version: Unknown v7.8
 Motherboard communication statistics
  Number of packets received from the USB interface:0
  Number of packets sent over the RS485 interface:0
  Number of packets sent over the RS485 interface that were not responded to:0
  Number of packet retries attempted:0
  Number of bytes received over the RS485 interface that were discarded as noise:0

Machine Driver XML:
<machine experimental="0">
        <name>The Replicator Dual (Sailfish)</name>
        <geometry type="cartesian">
            <!-- different pulleys on X and Y axii -->
            <axis endstops="max" homingfeedrate="2500" id="x" length="227" maxfeedrate="18000" stepspermm="94.139704"/>  <!-- Pulley dia: 10.82mm / 1/8 step = 1/(10.82 * pi / 1600) -->
            <axis endstops="max" homingfeedrate="2500" id="y" length="148" maxfeedrate="18000" stepspermm="94.139704"/>  <!-- Pulley dia: 10.82mm / 1/8 step = 1/(10.82 * pi / 1600) -->
            <axis endstops="min" homingfeedrate="1100" id="z" length="150" maxfeedrate="1170" stepspermm="400"/> <!-- Actual length is 157mm, we reserve ~5mm for safety. TR-8x8 Z axis = 1/(8/1600) -->
            <axis endstops="none" id="a" length="100000" maxfeedrate="1600" stepspermm="96.275201870333662468889989185642"/> <!-- stepspermm is incoming filament length, see comment at bottom for explanation -->
            <axis endstops="none" id="b" length="100000" maxfeedrate="1600" stepspermm="96.275201870333662468889989185642"/> <!-- stepspermm is incoming filament length, see comment at bottom for explanation -->
        </geometry>
        <tools>
            <tool default_rpm="3" diameter="0.4" fan="true" heatedplatform="false" heater="true" index="1" model="Mk8" motor="true" motor_steps="3200" name="Mk8 Left" stepper_axis="b" type="extruder"/>
            <tool default_rpm="3" diameter="0.4" fan="true" heatedplatform="true" heater="true" index="0" model="Mk8" motor="true" motor_steps="3200" name="Mk8 Right" stepper_axis="a" type="extruder"/>
        </tools>
        <wipes>
            <wipe X1="-135.0" X2="-135.0" Y1="55.0" Y2="45.0" index="0" purge_duration="1000" purge_rpm="5.0" reverse_duration="15" reverse_rpm="35.0" wait="1000.0"/>
            <wipe X1="-135.0" X2="-135.0" Y1="55.0" Y2="45.0" index="1" purge_duration="1000" purge_rpm="5.0" reverse_duration="15" reverse_rpm="35.0" wait="1000.0"/>
        </wipes>
        <offsets>
            <offset xNozzle="33.0" yNozzle="0.0" zNozzle="0.0"/>
        </offsets>
        <clamps/>
        <driver name="mightysailfish">
            <!-- optional: <portname>COM1</portname> -->
            <rate>115200</rate>
        </driver>
        <warmup>
        </warmup>
        <cooldown>
M18 (Turn off steppers after a build.)
        </cooldown>
        <bookend dualstart="machines/replicator/Dualstrusion_start.gcode" end="machines/replicator/Dual_Head_end.gcode" start="machines/replicator/Dual_Head_start.gcode"/>
    </machine>


However, every time it finishes a print and drops the Z-axis, it tries to move 200+mm - roughly what the Clone R1 machine profile has - so I'm wondering if somehow it's picking up the settings from that, but I can't see how?

[Phillip Moffatt]

Actually just letting it run instead of hitting the e-stop, it looks like it tries to home the z-axis twice the length it's actually set at.

It's not doubled z-steps or similar because it prints perfectly.

[wirlybird]

Could it be the slicer doing it?  I had a profile update from Simplify 3D for one of my printers and after that it would drive the bed into the bottom of the machine when a print ended.  I found that in the "ending script" it told it to move "Z" 150mm.  I changed it to 145mm and it is fine.

[Phillip Moffatt]

The slicer - (S3D) is the exact same setup as I was using previously - in fact even x3g files generated previously that were already on the SD card crash.

The ending script for my S3D doesn't have a distance, it just homes the axis:

M73 P100 ; end build progress

G162 Z F6000; home Z axis

G162 X Y F10000; home X and Y axes

M18; disable all stepper motors

M109 S0 T0; set bed temperature to 0

M104 S0 T0; set extruder temperature to 0

M70 P5; "I Made A Shiny!"

[wirlybird]

You could try replacing

G162 Z F6000; home Z axis  with

G1 Z145 F6000 ; Send Z to bottom

I am not in front of S3D so I can't look at some stuff.  What is the build volume for Z set at in the gcode tab?

[Dan Newman]

You're homing Z max at the end with "G162 Z". Unless you have a Z-max
endstop, that drives the Z platform into the bottom of the bed. Very,
very few people have ever bothered to install a Z max endstop.

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[Dan Newman]

Note that MakerBot's firmware always stopped moving Z when Z reached
~150 mm. And hence why, when the community designed the Rep XL, they
couldn't use MakerBot's firmware. Sailfish imposes no such limit: it
runs Z as far as you tell it to. And if you tell it to home Z max --
which you should never do unless you have a Z max endstop -- then the
platform will grind into the bottom and continue to until the homing
command times out (30s?)

Dan

On 4/24/18 7:19 AM, 'Phillip Moffatt' via Jetty Firmware wrote:

[Phillip Moffatt]

That's never been an issue on 7.7 before though Dan - G162 has always just homed to the max axis travel (~147mm) set in the .xml previously - that ending script has been used for about 18 months or more before the 7.8 upgrade.

[Phillip Moffatt]

147mm.
 This is the exact same s3d setup, exact same .x3g files I've been using for months/years, the only change has been from Sailfish 7.7 to 7.8.

I have changed that already to that just to sort it temporarily, but I'd rather find out why it's suddenly doing it when it didn't on 7.7 and whether there's a workaround, rather than go through all my profiles and previously generated files to update them all.