Erratic Behavior on Z1 Axis with TMC2209 – Incorrect Motor Movements

General Discussion
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Basic Information:

Printer Model: DYI custom MakerFR I3-RS32 - Prusa Like
MCU / Printerboard: BTT Manta M5P + CB1 + TMC2209
Stepper motors: Nema 17 Bipolar 45Ncm(63.74oz.in) 2A 42x42x40mm https://www.omc-stepperonline.com/nema-17-bipolar-45ncm-64oz-in-2a-42x42x40mm-4-wires-w-1m-cable-connector-17hs16-2004s1

Hello Klipper community,

I’m encountering a strange issue with the TMC2209 driver on the Z1 axis of my 3D printer. The printer has been working flawlessly for months, but recently, I’ve noticed erratic and incorrect movements on the Z1 motor. Instead of stopping or responding to commands normally, the motor continuously moves, but in the wrong directions. It keeps oscillating back and forth as if receiving incorrect rotation instructions.

Issue Description:

  • The motor doesn’t stop moving, but instead switches directions randomly, moving right to left and left to right, without following the expected commands.
  • This behavior appears randomly and persists even after multiple resets.
  • The problem began without any recent configuration changes and affects only the Z1 axis, with other axes functioning as expected.

Driver Replacement Attempts:

  • I’ve replaced the TMC2209 driver on the Z1 axis three times. Each time, the issue is temporarily resolved, but after a few minutes of operation, the motor starts behaving erratically again.
  • After waiting several hours to ensure the driver is completely cooled down, the issue still persists, leading me to believe the driver might be getting damaged or malfunctioning.

Configuration Overview:

Here is my current configuration:
printer.cfg (24.6 KB)

Possible Causes?

  • The drivers have adequate cooling and ventilation, and no visible issues with the wiring or connections.
  • I’m unsure if this is a problem with overheating, wrong UART communication, or possibly firmware issues.
  • The run_current is set to 0.5A for the Z1 axis, which has worked well in the past. Could this be too low or too high for the motor, leading to incorrect behavior?

What I’ve Tried:

  • Replaced the driver three times, with the problem coming back each time after a few minutes of use.
  • Double-checked all wiring and connections for loose cables or poor contacts.
  • Monitored temperatures, and everything seems to be well within safe limits.

Has anyone experienced similar issues with the TMC2209 driver and erratic motor behavior like this? Could this be a sign that the driver is damaged, or could there be a deeper issue with the configuration or hardware? I’d really appreciate any suggestions or troubleshooting advice!

Thank you!

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This is quite a lengthy question with lots of information - can I ask why you’re not including the klippy.log like you were requested?

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@mykepredko Sorry, as a new user I can only post 2 links per post and I completely forgot to forward the klippy.log file. here it is
klippy.log (21.0 KB)
If necessary I can also take a video of the problem.

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Super weird, I just tried to swap my drivers between z0 and z1 to see if the problem was really coming from the drivers and if the problem was reflected on z0 but there both work correctly. I will launch a print and see if the problem reappears.

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I don’t think so. The headers (board) and pins (driver) are low quality (price). They corrode and that causes a bad electrical connection. When you changed the drivers, you “polished” the connection.

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