Mid print error traverse

Hi all!

I have been fighting with my machine for many months now and it is pretty much ready finally so it's time to fight with the mysterious problems I have absolutely no idea where they come from.

This time it's this mysterious mid-print move that does not show on G-code when I try to locate the error afterwards with online gcode viewer. I have quite big pieces to do. They are appr. 600 grams' cases for speakers that have now failed. There is one corner in my print where the extruder just pulls off to the Y max and tries to go through the build envelope's boundaries. This sounds like there would be an error in the file, BUT the two times this crazyness has happened it has happened on different layers that are 3mm far from each other. Also the first time the extruder moved less, and just stuck there in the middle of nowhere pushing plastic like there's no tomorrow. The mutual thing in these two cases are the same corner and approximately same height, 24mm and 27.4mm. I am extruding in 0.4mm layers since the pieces a big and I will surface treat them later.

These errors have occured when running the same file from the SD-card. I have checked the Rhino-file that it is a closed solid without any openings in the surface, it is valid by every mean before exporting. I use Cura to slice. Nothing gets too hot in my printer, electronics are cooled with fans.

My setup is 3Drag controller (Velleman's K8200 is the same board) with Reprap discount full graphic display (that has the SD-slot that I use for printing allways), Longs DM 542A Drivers and Marlin as the firmware. My machine is Corexy. To remove any glitches from the electricity I use a APC Smart-Ups 1500. The controller electronics are shielded in a aluminum lined case. I also have several ferrite choces on the voulnerable wires, that are also twisted appr 1 turn per inch instead of being "straight" for reducing the RFI-efect.

What have I missed? My kingdom for the solution for all the weirdo problems regarding the printers!

Thanks

Edited 2 time(s). Last edit at 04/14/2015 11:06AM by PropellerHat.

OMG.... Now happened something even worse!!! The machine was lifting the build platform with a 6cm tall object on it, nearly destroying the gantry :O Totally uncalled for. What!?

It may have twisted my X-linears. I think it's time to try with Repetier firmware if this same crap continues.

Edited 2 time(s). Last edit at 04/14/2015 11:03AM by PropellerHat.

Did you used the same SD card in both files?
How old is the card and have you format it lately?
Have you tried a different SD card?

A little misreading it's all it takes for disaster to strike.

Are you using Marlin development firmware?

Yes it is the same card in both cases. I formatted it just yesterday to eliminate the possibilities of that kind of problems. The card is not new so maybe I should get another. I am using Marlin 1.0.2, I tried 1.0.3 Dev but the extruder won't go with that. It looks like the firmware just randomly takes an axle and direction and pushes through anything. The softwre endstops don't stop the moves.

Edited 1 time(s). Last edit at 04/14/2015 12:49PM by PropellerHat.

I changed now Arduino Mega + Ramps 1.4 in the machine instead of the 3Drag. Let's see if anything changes.