UM3E will not store z offset properly, plus other active leveling failures

[ddrsarah 0]

I've gone through lots of debugging scenarios for this and I'm hoping someone can help pinpoint how to fix this. Running a UM3E 5.3.1 with Cura 4.11.

 

The tl;dr is active leveling constantly fails before a print, but I also can't turn it off because the z offset is not being stored or remembered with the printer. 

 

Scenario 1: Active levelling fails when set to "Always" before a print. Error of unrealistic value between print cores. However, active levelling can be performed as normal through the build plate menu.

 

Scenario 2: Active levelling is set to "Never". Set manual levelling, perform active leveling. Print 1 prints sucessfully. Print 2 - same print, same settings, same everything - fails because the nozzle is trying to print about 2-3mm above where it should.  

 

Scenario 3: Active levelling set to never. Perform manual levelling. Did not perform active levelling. Print fails because print head is 2-3mm above the configured z offset.

 

What do I do? This seems to be some sort of firmware issue because active leveling works 100% of the time form the build plate menu and 0% of the time before a print. And I can't turn the whole thing off because the z offset never gets set correctly with manual levelling. 

Edited October 16, 2021 by ddrsarah

[CarloK 203]

@ddrsarah Sorry to hear about your problems. Thanks for writing down you analysis so clearly. In firmware 5.2.17 we fixed several problems related to Active Leveling and I hoped we fixed them all, but from your report it turns out we overlooked something.
Could you dump your log files to usb and send them to me for analysis? I'm especially interested in the configuration files. On the printer you can find the dump option in the system/diagnostic menu. Send the files to me by clicking my avatar, and then on my personal info page you see the 'message' button on top.