Benbox Laser Machines/CO2 Lasers/3D Printers

Software => T2 Engraving => Topic started by: fvuichard on March 25, 2017, 02:42:02 PM

Title: Error on engraving
Post by: fvuichard on March 25, 2017, 02:42:02 PM
Hi,

I have some problems when I engrave a big picture.
T2 Laser returns an error after one or two hours of engraving.

You can see the error message and GRBL settings in attachement.

I'm using T2 Laser 1.3y registered and firmware GRBL 1.1e

All work perfect when i use "Robotlaser"

If somebody can help!

Title: Re: Error on engraving
Post by: Zax on March 25, 2017, 03:25:56 PM
It stops because Grbl reports an error, that was a new safety feature I added. It is called "Fail Safe Mode" and can be found in the Advanced Settings section on the Laser Control screen. I do not recommend disabling it.

There are many reasons, often caused by the computer sleep mode (USB power saving mode).

Sometimes the errors can be ignored but it's also possible the machine could stop responding with the laser on, causing a fire so this features disables the laser and stops when Grbl reports a potential problem.
Title: Re: Error on engraving
Post by: fvuichard on March 25, 2017, 04:29:56 PM
Thanks, I will test by changing the USB power settings.
If that does not change anything, I will try to disable the fail safe mode.
Title: Re: Error on engraving
Post by: Zax on March 25, 2017, 06:14:01 PM
You are using my Grbl 1.1e firmware, correct?

That will not only significantly enhance performance but it is required with newer version of T2Laser to use many of the features. When switching between programs also be sure to reset the Grbl parameters in T2Laser before running as other programs can change my compiled defaults.
Title: Re: Error on engraving
Post by: fvuichard on March 26, 2017, 02:23:03 AM
No change with USB or fail safe mode settings. Always the same error.

I use your firmware and I flash from laser T2.

I have tried to reflash the firmware and to make a reset on the GRBL parameters but it does not change anything.
Reinstall the driver did not change anything

I will still try to re install the software (Is there any particular instruction to follow for this?).
Title: Re: Error on engraving
Post by: Zax on March 26, 2017, 04:18:11 AM
Send me your image and settings, or zip the G-code file and email that to me.
Title: Re: Error on engraving
Post by: negativ on April 10, 2017, 09:26:12 AM
Is there any known solution to this problem? Because after an hour I get the same error when engraving a big picture. (latest Grbl firmware and T2Laser software, USB power saving mode disabled)
Title: Re: Error on engraving
Post by: Zax on April 10, 2017, 11:34:56 AM
I ran his file many times as well as my own test files. I could not replicate any issues.

Your situation may be different, so please e-mail me the file and instructions (size, settings, mode etc.) and I will check it.
Title: Re: Error on engraving
Post by: fvuichard on April 13, 2017, 05:39:51 AM
Hi!

I tried a lot of things:

- Disable USB power saving
- Test with and without "Speed Mode" or "photo mode"
- Disable Windows defender
- Disable Anti-virus
- Disable "Fail safe mode"
- Reinstall the software and the driver
- Update to version 1.3z
- Try different firmware

Finally, I formatted my computer and reinstall Windows 10, I also did the "update Creator" but no change.

For now, it still does not work. My only solution is to use another app. But I still use "T2 Laser" for small engraving because I find it more powerful than others.

I'll let you know if I can make it work.
Title: Re: Error on engraving
Post by: Zax on April 13, 2017, 08:22:25 AM
Try a different USB cable, I do remember someone having issues and a new cable fixed it.

Make sure no other programs are trying to access the USB/Serial when running as this will for sure cause Grbl errors.

I tested the files on 2 different Nano's and ran in standard and accelerated modes, it's a long job so I let it run overnight with the laser disconnected (I use an LED instead so I can see it working) and after multiple runs with no errors I determined it isn't a software issue. In addition I always run my test jobs on new releases, one is over 7.5 million lines of G-code and is an excellent stress test.

In the next release I will add a reduced buffer option, this will slow down the data flow to Grbl and potentially impact overall performance but may help if your Nano is having memory or overheating issues.
Title: Re: Error on engraving
Post by: nottingham82 on April 13, 2017, 12:49:54 PM
My USB cable failed! New USB cable and I was rocking and rollin
Title: Re: Error on engraving
Post by: fvuichard on April 13, 2017, 10:41:16 PM
So, I try with several USB cables but still the same problem ...
Title: Re: Error on engraving
Post by: Zax on April 14, 2017, 04:14:46 AM
I don't know what else could cause it, maybe a driver issue?

I will send you a link to the one that I use, or you could try the one from EleksMaker site which is an updated version.


Title: Re: Error on engraving
Post by: Parnold on April 15, 2017, 09:19:49 AM
I have this same issue, and it seems to be related to the complexity of the image.  I was assuming that the laser was overheating, so I've been adding small fans around my Eleksmaker A3 hoping to cool things down.  My next test was going to be manually inserting pauses into the process using a timer and just giving the laser a chance to completely cool down.  Is this a possibility, or am I wasting my time?
Title: Re: Error on engraving
Post by: Administrator on April 15, 2017, 09:50:09 AM
My 2.5 watt laser got really hot on long cuts so I switched to a 1.6 watt and it never gets hot on long cuts.

I find I'm able to do everything with the 1.6 that I used to do with the 2.5. Others have told me their 2.5 does not get hot so maybe mine was going bad...I just don't use it anymore.
Title: Re: Error on engraving
Post by: ggallant571 on April 15, 2017, 09:53:42 AM
Are any of the components on the board hot. Particularity the large MOSFET. I have a POS nano that heats up badly. There is a degradation of the 5V which leads to the power transistor not completely turning on which leads to more heat and less laser. Took about 10 minutes. Measured 4.2V on the Nano +5V pin.

You might also check the modular power supply.
Title: Re: Error on engraving
Post by: Zax on April 15, 2017, 11:25:22 AM
@Parnold

A lot of thanks to fvuichard for his continued testing. I suggested disabling DTR in T2Laser advanced menu and that seems to have helped although I am not sure why it would make a difference.

He completed a 1.6 million lines file in 4 h and 30 m without errors and last I heard he was testing a >5 million lines file and was >9 hours in with no error.

Title: Re: Error on engraving
Post by: Parnold on April 26, 2017, 06:07:47 PM
I tried the DTR and it didn't have any effect.  If I turn off the failsafe, the burn still stops, but the program kind of freezes in limbo.  I can turn the laser on or off, but can't restart the job.  I am trying a different cable now, but don't have a lot of faith that it will fix the problem.  I'm pretty sure there's no issue with my system, my CPU utilization is at 22% with T2laser running, and I'm only using 4 gig of the 16 I have.  T2laser shows that it is using 249 mb in task manager.
When it crashes and I start closing down the program, I do get an "out of memory" error.  I will screen capture it next time it happens.  Tonight, my first burn attempt crapped out at about 2%.  This is the message I had on my screen tonight. (http://www.teartime.com/images/twlasererror.jpg)

I'm running in greyscale mode, speed 700 to 5000.  Laser power at 120. 

Does the machine throw out a code that could be posted by the software?  I would buy a lower power laser unit if I was sure it was going to stop the problem, but I would really hate to drop another 80 bucks and still not be able to print anything fairly complex.
Any comments, suggestions, questions????
Title: Re: Error on engraving
Post by: nottingham82 on April 26, 2017, 06:27:46 PM
What resolution are you printing at and can you share the image you are trying to print. I have gotten this error before. It happens when I open a huge image or high dpi image or when I am trying to print at a resolution lower than .1. The best solution when you get this error is a PC restart.
Title: Re: Error on engraving
Post by: Parnold on April 26, 2017, 06:41:22 PM
(http://www.teartime.com/images/burn.jpg)


Resolution .1

I'm actually up to 65% complete and it hasn't crapped out yet. 
Also, when it dies, I have touched all of the components on the board on top of the laser unit, as well as the cooling fins etc, and everything feels cool, or only just slightly warm.

This is just a random image, I have had the issue with several images, and I have successfully printed each of those images at least once.  It seems the damn machine knows when I put an expensive piece of wood under the laser. :(
Title: Re: Error on engraving
Post by: Parnold on April 26, 2017, 07:00:11 PM
Just died at 91%.  If I hit pause the program reports that it paused.  If I click stop, or emergency stop, nothing.  If I click the directional arrows, the unit does respond and move the carriage accordingly.  I can turn the laser on, can pulse, can turn the laser off.  I can adjust the pulse time and laser power.
Title: Re: Error on engraving
Post by: nottingham82 on April 26, 2017, 08:42:03 PM
258mb seems high as does 1062 minutes time estimation. How big are you trying to engrave this picture?
Title: Re: Error on engraving
Post by: fvuichard on April 26, 2017, 11:47:59 PM
Finally, I still have this error despite disabling the DTR.

It is really random but the small images (<100 x 100mm) does not seem to be affected.

Like @Parnold, the components are not too hot and the error occurs with different images and not always at the same time.
Title: Re: Error on engraving
Post by: ka4wwv on April 27, 2017, 04:09:45 AM
Similar but not exactly the same problem, set every thing in win10 like power sleep off.  "I think" it was screensaver on my system as I found the burn had stopped and bubbles were showing.  Looked at screensaver settings and couldn't find an off option so I set it to several​ thousand seconds.  Mutipule burns later and no problems.

Hope this helps

Ed
Title: Re: Error on engraving
Post by: Zax on April 27, 2017, 04:59:05 AM
I can only tell you that on my development and test systems (Win7 and 10, both 32 and 64-bit), which includes a very cheap tablet. I've processed G-code files in the millions of lines many, many times. The largest is 7.5 million lines and I've now ran that probably 20 or 30 times over the months and the sender is rock solid on several different Nano's and firmware.

We know the G-code itself isn't the problem, so that only leaves the hardware or some configuration.

T2Laser requests a "high priority" thread from Windows and attempts to prevent power saving, you can also enable "Keep Display On" in the settings menu. There are still other processes; like anti-virus, security, backup that can interfere with operation and other things on the USB bus that could potentially cause issues.

Make sure you are both using the latest version, install v1.4d or later so it's the online deployment version. The DTR setting is now static so it is remembered if you forget to disable it every time you startup.

Do not disable "Fail Safe" mode or you won't know that Grbl reported an error, and then things will just act strange like you describe and you'll wonder why. If Grbl sends an error it usually means the communications got messed up and it's out of sync, that could happen if the USB port goes to power saving mode or the Nano memory is corrupt or the cable is bad. So many reasons especially on a long burn, and certainly difficult to troubleshoot.
Title: Re: Error on engraving
Post by: Parnold on April 27, 2017, 04:17:43 PM
Thanks for all the ideas and input.  I'm determined to get this figured out.
Nottingham82. the image I am trying to burn was 250mm x 215mm.
Karwwv, I had my system set to never sleep, but the screen would black out at 20 minutes.  I've changed that now.
I also found a couple other settings that might have affected things.
(http://www.teartime.com/images/powersettings.jpg)
I bumped the hard drive sleep time up to 600 minutes, it was at 20 I think.  I also disabled the USB Selective Suspend Setting?  I'll report on my success hopefully.
Title: Re: Error on engraving
Post by: Zax on April 27, 2017, 04:42:21 PM
I checked my main development PC and it has similar settings to what you had (before changing them) so I don't think that's the fix, but still worth testing.

What's odd is sometimes you get almost all the way through a job, other times it errors early.

If you are using the latest version of T2Laser there's a menu option to install the most recent CH340 driver, maybe try that if you still have problems.
Title: Re: Error on engraving
Post by: carolynsdad on April 27, 2017, 10:10:40 PM
Have you possibly got a program or process running in the background that periodically makes unseen demands on processor time or memory at high priority such as attempting to access the internet for an update or some other servicing?

Have a look in Windows Task Manager on the Perfomance tab and then click the Resource Monitor button and see if there is any unexpected activity or memory usage.

Other ideas are:
Clearing caches
Defrag your hard drive
Check in Control Panel | Action Centre | Check for Solutions to unreported problems   see if there are any programs with memory leakage issues.

Hope you fnd something in there soon,
Mike
Title: Re: Error on engraving
Post by: Stonemull on April 28, 2017, 12:14:48 AM
Other devices plugged into the same USB controller can cause a loss of comms and a reconnection.

I was playing with Zadiq which is a USB bootloader for STM2 hardware and if I gpgave thst running then after a sleep, I can wake my PC with the mouse, then the mouse stops working till I cycle dongle power.

Not helping this issue, just saying that USB can be a finicky beast and it is not always the device you are suspecting that can be the sole cause if the problems.
It might be worth checking the windows error logs too, see if there is anything relevant.

Title: Re: Error on engraving
Post by: fvuichard on May 10, 2017, 06:13:06 AM
my stepper motor cable  has just broken. I was wondering if it was not possible that was causing me errors only on big picture because that was pulling on it and create bad contact.
I just order new cables and I keep you informed if there is change.
Title: Re: Error on engraving
Post by: Zax on May 10, 2017, 07:43:47 AM
I don't see how, it's an open loop system so Grbl has no idea the steppers didn't move when instructed to do so.

The "error" you were getting is an actual code back from Grbl telling T2Laser there was a problem, which means it must have detected something wrong. I can only assume that's a USB data error or something failing with the microcontroller.
Title: Re: Error on engraving
Post by: nottingham82 on May 10, 2017, 10:18:06 PM
was it grounding out causing a surge in the board when the broken wire was moving around?
Title: Re: Error on engraving
Post by: fvuichard on May 11, 2017, 02:01:35 AM
I do not know, but the end of some wire look naked and the red one is broken

In any way I have to change it. So I will see if this eliminates the problem.
Title: Re: Error on engraving
Post by: Zax on May 11, 2017, 04:29:37 AM
@nottingham82 That would likely cause it, good call, perhaps it does make sense.
Title: Re: Error on engraving
Post by: wild.bill on May 11, 2017, 10:26:33 AM
I think that bouncing broken motor wires will cause a surge that will cause GRBL to report an error.
Both times I have had broken motor wires I saw a string of errors which is what got me to go looking for a break.

Title: Re: Error on engraving
Post by: Stonemull on May 11, 2017, 12:47:44 PM
The pololus carry a warning in that disconnecting a motor while it is in use can destroy the pololu driver, I think high voltage inductive spikes would be the likely culprit in that case blowing the mosfets.
(think car coil .. )
It is quite possibly putting out a lot of RF interference as it will be arcing at some point, very tiny probably invisible arcs, but they are probably enough to upset a USB in close proximity.
Title: Re: Error on engraving
Post by: fvuichard on May 23, 2017, 01:33:03 AM
So, I just received my new cable, but that does not change anything. I managed to send an engraving of more than 18 hours but I had an error after one hour on the second try. :-[
Title: Re: Error on engraving
Post by: Zax on May 23, 2017, 04:14:24 AM
Can you recap what you've tried?

USB cable, Nano, run the g-code in Check mode, run without motors and laser connected (just the board) etc.

Title: Re: Error on engraving
Post by: fvuichard on May 23, 2017, 06:46:24 AM
I have test without the laser connected but not without the motors.

I will test this before to change my Nano board.
Title: Re: Error on engraving
Post by: Zax on May 23, 2017, 09:31:31 AM
You can also select Check Mode (Settings menu on the Laser Control screen), this just runs the Grbl interpreter and does not send any signals out of the Nano.
Title: Re: Error on engraving
Post by: fvuichard on May 29, 2017, 07:48:55 AM
I carried several test with the motors (or motors and laser) unplug, with the motor (or motor and laser) plugged but not powered. Also test  in check mode.

In check mode, I have no problem .. all process is ok.
But impossible to finish an engraving with the motor (or motor and laser) disconnect or not powered.

I have always this error. :'( :'( :'(
Title: Re: Error on engraving
Post by: Stonemull on May 29, 2017, 08:35:31 AM
Havevyou trued another Nano ?
Perhaps it has a random reboot issue.

I think if check mode is fine then there is no issue with the gcode. I assume it is very fast to check though.

Title: Re: Error on engraving
Post by: Zax on May 29, 2017, 10:49:41 AM
Check mode processes the g-code the same except no motor output. Sounds like it could be electrical noise causing an error in the Nano.
Title: Re: Error on engraving
Post by: mrehmus on May 29, 2017, 12:44:42 PM
I am starting to think that a UPS is a good idea with the lasers as well as with 3D printers. Especially if making long runs where power glitches or loss will mess up the work. Since most decent UPS units also do a fairly good job of filtering the power, it may make some sense.

Don't know if these products will work on a simulated sine wave power or if they need a pure sine wave.
Title: Re: Error on engraving
Post by: Zax on May 29, 2017, 01:13:00 PM
Since power for the Nano comes from the USB it will be OK, and the motors / laser run from the DC power supply so even a cheap smoothed square wave would be fine.
Title: Re: Error on engraving
Post by: mrehmus on May 29, 2017, 03:17:15 PM
Think I'll pull an old one out and try it. I have car battery-sized gel cells that should power the laser for many hours. I'm also going to plug in a Kill-a-Watt and see what kind of power the whole thing requires. Not much I think, maybe 75 watts or so.