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Not sure what initially caused your issue but try throwing a G92 E0 into your start gcode right after homing and also after any purge line you may have setup.
I've encountered this same error when trying to recover failed prints by restarting them at the failed layer. If you don't tell the extruder it should already be some distance through the print, it throws out the exact same error. Since you're starting at '0' it needs to be told that.
I was having a similar problem with my printer as well, and this is what solved it. I wasn't able to print 2 things back-to-back without restarting the firmware first.
Thanks for the suggestion. Just tested by adding G92 E0 right after the PRINT_START and PURGE_LINE macros and it still has the same error at the same spot; right as it goes around the circle part of the elbow on the second layer.
Might be something wrong with the slicer. Try a different slicer and if that doesn't work try a different file. I've had Cura updates break my gcode in the past.
You might manually look through the gcode file and see if you see anything out of the ordinary at that layer.
Move exceeds maximum extrusion (1.531mm^2 vs 1.440mm^2)
This was solved by reinstalling slicer (Cura in that case) for one guy on the internet.
So maybe just install cura and try
I'm not really looking to change slicers at this point. I've used Cura in the past and have landed on PrusaSlicer for a variety of reasons and would like to get it working properly again ideally.
Thats cool, but installing cura takes few mins and it might prove that you have a slicer issue. I just thought its easier to install cura instead of reinstalling prusaslicer
Could you share the top few lines (including the first few G1 ... Lines) of a gcode file that fails?
sure thing, here is the start of it.
Hmm, can't see anything wrong with it unfortunately. I'm also not used to Klipper G-Code (yet).
You could also have a look at the few lines of G-Code that seem to trigger it. Although finding that line is not so easy. I'm just wondering if you would find an unexpected jump in the E coordinate ie. E jumping to E. That would at least make sure that the slicer is the culprit. If you don't find such a thing, I guess your printer is badly configured somehow.
What method did you use to determine the pressure advance value and what value did you select? If the number is too large you will get very odd behavior.
Hmm good thinking, that would make sense that could impact it... maybe I'll try reducing that although I am on the low end for that setting compared to the recommended values. Pressure advance is 0.0425 and was determined using the method described in the klipper docs
0.04 seems reasonable. Does the problem go away if you set it to 0?
Just tested it, setting pressure advance to 0 still triggers the exact same error.
Purge line too long moving out of print space?
Also this is probably a problem in your printer.cfg
