OctoPrint with Mk3 - Prints Stop Suddenly  

OctoPrint with Mk3 - Prints Stop Suddenly

I've had several problems with the Mk3 and OctoPrint, which makes OctoPrint essentially unusable. These all started after upgrading to firmware RC4 from RC1. I reverted to RC1 after I started having serious problems with RC4, but I then had a new, potentially even more severe problem with RC1.

With RC1, the print suddenly stops mid-print with the head not moving and filament still being extruded. It resumes movement after several seconds, dragging the nozzle through the glob of filament that has just been extruded. I've seen multiple other people who have the same issue in various forms.

With RC4, there are an excessive number of serial transmission errors. These cause the printer to stutter as if it's unable to receive data. This is usually followed by a full stop of the print where the printer sits with no motor movement but with the hotend and heatbed both on.

There's also a third issue that seems to happen occasionally; the printer detects a "crash" even though there does not appear to be one. It re-zeroes either the X or Y axis, sometimes both, and then starts printing again. In most cases it doesn't do much to affect the print (except for once where the Y axis re-zeroed about 1mm off). I've disabled crash detection temporarily to mitigate this.

Below are some excerpts from the OctoPrint logs.

RC1 issue - filament continues to extrude while head is stuck

Send: N30401 G1 X110.601 Y102.216 E0.0492*90
Recv: ok
Send: N30402 G1 X110.748 Y102.070 E0.0078*87
Recv: start
Printer sent 'start' while printing. External reset? Aborting job since printer lost state.
Changing monitoring state from 'Printing' to 'Operational'
Send: M84
Recv: echo:echo: Last Updated: Dec 5 2017 17:02:35 | Author: (none, default config)
Recv: Compiled: Dec 5 2017
Recv: echo: Free Memory: 1543 PlannerBufferBytes: 1392
Recv: echo:Hardcoded Default Settings Loaded
Recv: crashdet_disable
Recv: CrashDetect DISABLED
Recv: PAT9125_init:1
Recv: FSensor
Recv: DISABLED
Recv:
Recv: fsensor_disable
Recv:
Recv: tmc2130_init mode=0
Recv: initial zsteps on power up: 424
Recv: initial zsteps after reset: 1016
Recv: echo:SD init fail
Recv: echo:SD init fail
Recv: ok
Send: M104 T0 S0
Recv: ok
Send: M140 S0
Recv: ok
Send: M106 S0
Recv: ok
Send: N0 M110 N0*125
Recv: Invalid M code.
Recv: ok
Send: M105
Recv: ok T:210.2 /0.0 B:60.1 /0.0 T0:210.2 /0.0 @:0 B@:0 P:38.6 A:27.6


RC4 issue - head stops with no extrusion
(Note that the printer asks for a resend of an insane line number.)

Send: N1587 G1 X146.542 Y109.836 E0.0372*106
Recv: Full RX Buffer
Recv: Error:Line Number is not Last Line Number+1, Last Line: 1580
Recv: Resend: 1581
Send: N1581 G1 X124.683 Y85.591 E0.0280*95
Recv: ok
Send: N1582 G1 X146.542 Y107.450 E1.4458*103
Recv: Error:Line Number is not Last Line Number+1, Last Line: 1580
Recv: Resend: 1581
Send: N1583 G1 X146.542 Y108.245 E0.0372*97
Recv: ok
Send: N1584 G1 X124.430 Y86.134 E1.4626*85
Recv: ok
Send: N1585 G1 X124.177 Y86.676 E0.0280*94
Recv: ok
Send: N1586 G1 X146.542 Y109.041 E1.4793*109
Recv: Error:Line Number is not Last Line Number+1, Last Line: 540423990
Recv: Resend: 540423991
Printer requested line 540423991 but no sufficient history is available, can't resend
Changing monitoring state from 'Printing' to 'Error: Printer requested line 540423991 but no sufficient history is available, can't resend'
Recv: ok
Recv: Error:Line Number is not Last Line Number+1, Last Line: 825503790
Recv: Resend: 825503791
Printer requested line 825503791 but no sufficient history is available, can't resend
Recv: ok
Recv: ok
Recv: ok
Recv: start
Recv: echo:echo: Last Updated: Dec 29 2017 23:38:09 | Author: (none, default config)
Recv: Compiled: Dec 29 2017
Recv: echo: Free Memory: 1654 PlannerBufferBytes: 1392
Recv: echo:Hardcoded Default Settings Loaded
Recv: adc_init
Recv: crashdet_disable
Recv: CrashDetect DISABLED
Recv: tmc2130_init(), mode=STEALTH
Recv: PAT9125_init:1
Recv: FSensor
Recv: DISABLED
Recv:
Recv: initial zsteps on power up: 712
Recv: initial zsteps after reset: 1016
Recv: echo:SD init fail
Recv: echo:SD init fail