FLSUN S1 , Klipper Configuration files

Link https://github.com/flight505/FLSun_ConfigCode?tab=readme-ov-file#flsun-s1-pro-klipper-configuration 

### 🚀 New Features:
- **M141/M191 Commands** - Control outer bed zone like standard bed commands
- **BED_TEMPS Macro** - Set both bed zones with a single command
- **Enhanced Z-Offset Range** - Increased flexibility for different build surfaces
- **Full Fan Power** - Removed artificial 55% limitation on part cooling fan
- **Active Cooling System** - Chamber fan accelerates cool-down, saves 25 minutes during calibration
- **Optimized Calibration Order** - Delta calibration now runs before bed mesh for proper geometry
- **Enhanced Probe Accuracy** - 9x9 mesh grid with 3 samples per point for superior bed leveling
- **SPRO_ACTIVE_COOLDOWN** - New utility macro for temperature management operations

See the [Configuration Changes](#configuration-changes-2025-07-20) section below for detailed technical information.

## Important Printer-Specific Information

### Filament Path and Sensors
The FLSUN S1 PRO uses a dual-sensor system with a Direct Drive Extruder (DDE):
- **Filament Sensor Location**: Mounted near the filament spool holder at the top of the printer
- **Motion Sensor**: Detects filament movement to identify clogs or grinding
- **Switch Sensor**: Changes state when filament passes through
- **Filament Guide Tube**: Approximately 700-800mm long PTFE tube from sensor to direct drive extruder (NOT a bowden extruder - this is just a guide tube)
- **Direct Drive Extruder**: The extruder motor is mounted directly on the print head, providing precise filament control

### Build Specifications
- **Build Plate**: Textured PEI plate with maximum temperature of 120°C
- **Build Volume**: Φ320mm × 430mm (cylinder with 383mm maximum height)
- **Heating System**: Smart zone heating system for precise temperature control and improved print quality

### Critical Operating Procedures

#### To Unload Filament:
1. Heat the hotend to appropriate temperature
2. Open the filament guide tube connector located 10cm above the extruder
3. Run SMART_UNLOAD macro
4. Pull the filament out of the extruder when prompted
5. Close the filament guide tube connector

#### To Change Filament:
1. Open the filament guide tube connector 10cm above the extruder
2. Run SMART_UNLOAD macro and pull filament out
3. Cut the extracted filament at a 45-degree angle
4. Remove the 10cm piece from the extruder and discard
5. Manually retract remaining filament by rolling the spool
6. Insert new filament into the sensor at the top
7. Push filament through the guide tube past the connector into the extruder
8. Run SMART_LOAD macro
9. Close the filament guide tube connector

### Why Sensor Disabling is Critical
During filament loading/unloading operations, the sensors must be disabled because:
- Filament movement through the sensors during these operations would trigger false runout alarms
- The motion sensor would interpret the loading/unloading movement as normal printing, potentially masking real issues
- Without disabling, the printer would pause mid-operation thinking filament has run out

## Macro Overview

The configuration files contain comprehensive macros organized into the following categories:

### 1. **Configuration and Settings**
- _SPRO_SETTINGS - Central configuration for all macro parameters

### 2. **Filament Management**
- SMART_LOAD - Intelligent filament loading with sensor management
- SMART_UNLOAD - Safe filament unloading procedure
- LOAD_[MATERIAL] - Material-specific loading (PLA, PETG, ABS, ASA, TPU, PC)
- UNLOAD_[MATERIAL] - Material-specific unloading
- LOAD / UNLOAD - Quick access aliases for SMART_LOAD/UNLOAD
- CLEAN_FILAMENT - Purge 160mm of filament through nozzle (usage: CLEAN_FILAMENT S=240)
- M600 - Filament change pause

### 3. **Sensor Control**
- ENABLE_SENSORS - Enable both filament sensors
- DISABLE_SENSORS - Disable both sensors for maintenance
- CHECK_SENSORS / SENSOR_STATUS - Diagnostic tool for sensor status

### 4. **Temperature Management**
- SPRO_MATERIAL_SETTINGS - Apply material-specific temperatures and Z-offset
- SPRO_HEAT_ZONES - Smart dual-zone heating for materials
- PID_HOTEND - Hotend PID calibration
- PID_BED - Bed PID calibration (both zones)

### 5. **Bed Leveling & Calibration**
- SPRO_BED_LEVEL - Enhanced bed leveling with temperature preservation
- BED_LEVEL_1 / bed_level_1 - Delta calibration
- BED_LEVEL_2 / bed_level_2 - Bed mesh calibration
- SPRO_MESH_MANAGER - Temperature-based mesh management
- SPRO_FULL_CALIBRATION - Complete calibration sequence
- ZUP / ZDOWN - Z-offset fine adjustment (±0.025mm)
- CALIBRATE_MOTOR - Motor calibration routine
- MEASURING_RESONANCES - Input shaper calibration

### 6. **Print Management**
- SPRO_PRINT_START - Comprehensive print initialization
- SPRO_PRINT_END - Safe print completion procedure
- SPRO_PRIME_LINE - Draw prime line for nozzle priming
- START_PRINT - Power loss recovery aware print start
- END_PRINT - Power loss recovery aware print end
- PAUSE / RESUME - Print pause/resume with position save
- CANCEL_PRINT - Cancel print with proper shutdown

### 7. **Dual-Zone Bed Control**
- M141 - Set outer bed zone temperature (usage: M141 S70)
- M191 - Wait for outer bed zone to reach temperature
- BED_TEMPS - Set both zones at once (usage: BED_TEMPS INNER=60 OUTER=55)

### 8. **LED & Output Control**
- screen_led_on / screen_led_off - Control screen RGB LEDs
- box_led_on / box_led_off - Control enclosure LED
- laser_on / laser_off - Control laser output
- relay_on / relay_off - Control relay output
- drying_box_1 / drying_box_off - Control filament dryer

### 9. **Maintenance & Utilities**
- SPRO_MAINTENANCE_MODE - Enter safe maintenance mode
- TMC - Dump TMC driver information
- save_time - Track total print time
- WAIT_FOR - Wait with progress updates
- SPRO_ACTIVE_COOLDOWN - Active cooling with chamber fan for faster temperature reduction

### 10. **Power Loss Recovery**
- SAVE_POWER_LOSS_PARAMS - Save print state
- RESUME_INTERRUPTED - Resume after power loss
- PRE_RESUME_INTERRUPTED - Prepare for resume
- START_PRINT_RESUME - Complete resume process
- SHUTDOWN - Emergency shutdown

## Detailed Macro Descriptions

### _SPRO_SETTINGS
**Purpose**: Centralized configuration storage for all macro parameters  
**Variables**:
- extruder_temp_*: Temperature settings for each material
- bed_temp_*: Bed temperature settings for each material  
- z_offset_*: Material-specific Z-offset adjustments
- Load/unload distances and speeds for multi-stage operations
- Prime line configuration for delta printer

### SMART_LOAD
**Purpose**: Intelligently loads filament with automatic sensor management  
**Parameters**: 
- TEMP (optional): Override temperature (default: 220°C)
**Process**:
1. Heats extruder to specified temperature
2. Automatically disables sensors to prevent false triggers
3. Multi-stage loading sequence optimized for direct drive:
  - Initial feed (10mm @ 5mm/s)
  - Prime extruder (15mm @ 10mm/s)
  - Final extrusion (5mm @ 2.5mm/s)
4. Disables extruder motor (signals completion to screen)
5. Maintains hotend temperature for subsequent operations
6. Prompts user to re-enable sensors after completion

### SMART_UNLOAD
**Purpose**: Safely unloads filament with enhanced tip-forming to prevent jams  
**Parameters**:
- TEMP (optional): Override temperature (default: 235°C)
**Process**:
1. Heats extruder to specified temperature
2. Disables sensors automatically
3. Enhanced 4-stage unloading with tip forming:
  - Tip forming: Small push (2mm) and retract to prevent stringing
  - Cooling moves: Multiple retracts/pushes to shape tip properly
  - Clear hotend: Controlled retraction (10mm @ 30mm/s)
  - Final retract: Fast movement away from gears (10mm @ 50mm/s)
4. Prompts for manual sensor re-enabling
**Key Improvement**: Prevents "mushroom" tip formation that causes gear jams

### LOAD_[MATERIAL] / UNLOAD_[MATERIAL]
**Purpose**: Material-specific wrappers for smart load/unload with preset temperatures  
**Available Materials**: PLA, PETG, ABS, ASA, TPU, PC  
**Features**:
- Automatically uses optimal temperature for each material
- Ensures consistent loading/unloading conditions
- Reduces user error in temperature selection

### ENABLE_SENSORS / DISABLE_SENSORS
**Purpose**: Unified control of both filament sensors  
**Affected Sensors**:
- filament_sensor: Primary runout detection
- filament_motion_sensor: Movement/clog detection
**Usage Notes**:
- Always disable before filament changes
- Re-enable before starting prints
- Both sensors controlled simultaneously for safety

### CHECK_SENSORS
**Purpose**: Diagnostic tool for troubleshooting sensor issues  
**Information Provided**:
- Sensor enable/disable state
- Filament detection status
- Motion sensor status
- Helpful for debugging false triggers or missed detections

### CLEAN_FILAMENT
**Purpose**: Purge filament through the nozzle for cleaning or color changes  
**Parameters**:
- S (required): Temperature in Celsius (e.g., CLEAN_FILAMENT S=240)
**Process**:
1. Heats extruder to specified temperature
2. Extrudes 100mm at moderate speed
3. Extrudes additional 60mm at slower speed (total 160mm)
4. Turns off hotend after completion
**Usage**: Perfect for purging old colors or materials after filament change

### SPRO_MATERIAL_SETTINGS
**Purpose**: Applies comprehensive material-specific settings  
**Parameters**:
- MATERIAL: One of PLA, PETG, ABS, ASA, TPU, PC
**Settings Applied**:
- Extruder temperature
- Bed temperature (both inner and outer zones)
- Z-offset adjustment for material characteristics
**Usage**: Call before printing or when switching materials

### SPRO_BED_LEVEL
**Purpose**: Enhanced bed leveling routine preserving temperatures  
**Parameters**:
- BED_TEMP (optional): Override bed temperature
- EXTRUDER_TEMP (optional): Override extruder temperature  
**Features**:
- Saves current temperatures before leveling
- Performs delta calibration and bed mesh
- Restores original temperatures
- Shows bed mesh visualization

### SPRO_PRINT_START
**Purpose**: Comprehensive print preparation sequence  
**Parameters**:
- BED_TEMP: Target bed temperature
- EXTRUDER_TEMP: Target extruder temperature
- MATERIAL (optional): Material type for automatic settings
**Sequence**:
1. Initial heating to 80% of target
2. Home and QGL/bed mesh
3. Final heating to target
4. Sensor enablement check
5. Prime line routine (delta-optimized)
6. Ready for print

### SPRO_PRINT_END
**Purpose**: Safe print completion and cooldown  
**Features**:
- Coordinated retraction
- Safe Z-lift within delta limits
- Park position at X0 Y-140
- Controlled cooldown of all heaters
- Motor idle timeout

### SPRO_FULL_CALIBRATION
**Purpose**: Complete automated calibration sequence for the S1 PRO - performs ALL calibrations  
**Process** (optimized order for delta printers):
1. **Motor Calibration** - Calibrates all three delta motors
2. **Delta Calibration** - Establishes delta geometry (MUST be done before bed mesh)
3. **Hotend PID Tuning** - Tunes PID values at 240°C with active cooling
4. **Bed PID Tuning** - Tunes both bed zones at 60°C with active cooling
5. **Input Shaper Calibration** - Measures resonances and configures input shaping
6. **Bed Mesh Profiles** - Creates high-accuracy 9x9 meshes for 60°C, 70°C, 80°C, 90°C, 100°C
  - Each temperature includes 2-minute heat soak
  - Uses enhanced probe settings (3 samples, slower speed)
**Duration**: Approximately 65 minutes (reduced from 90 with active cooling)
**When to use**:
- Initial printer setup
- After mechanical changes
- Weekly maintenance (recommended)
- If print quality degrades
**Note**: Requires Klipper restart after completion to apply all calibrations

### SPRO_MAINTENANCE_MODE
**Purpose**: Enter safe maintenance mode for manual operations  
**Actions**:
- Disables all filament sensors
- Turns off all heaters
- Sets conservative motion limits (100mm/s velocity, 1000mm/s² acceleration)
- Disables extruder stepper
**Usage**: Run before performing manual maintenance like nozzle changes or cleaning

### SPRO_HEAT_ZONES
**Purpose**: Smart dual-zone bed heating based on material type  
**Parameters**:
- MATERIAL: Material type (PLA, PETG, ABS, ASA, TPU, PC)
**Features**:
- Automatically sets appropriate inner and outer bed temperatures
- Waits for both zones to reach temperature
- Uses material-specific temperature profiles from _S1_PRO_SETTINGS

### SPRO_MESH_MANAGER
**Purpose**: Automatically load or create bed mesh for current temperature  
**Parameters**:
- BED_TEMP: Target bed temperature
**Process**:
1. Checks if mesh profile exists for current temperature
2. Loads existing profile if available
3. Creates and saves new profile if not found
**Naming**: Profiles saved as s1pro_[temp]c (e.g., s1pro_60c)

### SPRO_PRIME_LINE
**Purpose**: Draw a prime line to prepare nozzle before printing  
**Process**:
1. Moves to safe position at edge of bed (Y-145)
2. Draws line while extruding ~26mm of filament
3. Creates consistent pressure in nozzle
4. Removes any oozing or old material
**Note**: Automatically called by SPRO_PRINT_START

### WAIT_FOR
**Purpose**: Wait for specified time with progress updates  
**Parameters**:
- WAIT_TIME: Time to wait in seconds (default: 60)
**Features**:
- Shows remaining time every 30 seconds
- Useful for heat soaking or time-based operations

### SPRO_ACTIVE_COOLDOWN
**Purpose**: Active cooling using chamber fan for faster temperature reduction  
**Parameters**:
- TARGET: Target temperature in °C (default: 40)
- SENSOR: Temperature sensor to monitor (default: heater_bed)
**Process**:
1. Activates part cooling fan at 100%
2. Activates chamber fan (box_fan) at 100%
3. Waits for specified sensor to reach target temperature
4. Automatically turns off both fans when target is reached
**Usage Examples**:
- SPRO_ACTIVE_COOLDOWN - Cool bed to 40°C
- SPRO_ACTIVE_COOLDOWN TARGET=30 SENSOR=extruder - Cool hotend to 30°C
- SPRO_ACTIVE_COOLDOWN TARGET=50 SENSOR="heater_generic HotBed1" - Cool outer bed to 50°C
**Benefits**: Reduces cooling time by up to 75% compared to passive cooling

## Best Practices

1. **Always verify sensor state** before starting prints using CHECK_SENSORS
2. **Follow the exact filament change procedure** - the filament guide tube connector must be opened
3. **Don't skip the 45-degree cut** - ensures smooth filament insertion
4. **Re-enable sensors** after any filament operation before printing
5. **Use material-specific macros** for optimal results
6. **Monitor first layer** after material changes due to Z-offset differences

## Troubleshooting

### Filament Won't Load
1. Ensure filament guide tube connector is closed
2. Check filament is cut at 45-degree angle
3. Verify filament reached extruder gears
4. Confirm correct temperature for material

### Screen Stuck During Load/Unload
If the printer screen animation doesn't complete:
1. The macro properly disables the extruder motor to signal completion
2. Check console for any error messages
3. Verify the macro completed (look for "Load complete" message)
4. If stuck, you can manually run SET_STEPPER_ENABLE STEPPER=extruder ENABLE=0

### Interface Locked/Unresponsive
If the web interface becomes unresponsive or "Unlock" button doesn't work:
1. **Common with embedded browsers** - OrcaSlicer, PrusaSlicer built-in browsers often have issues
2. **Use external browser** - Open Fluidd/Mainsail in Chrome, Firefox, or Safari
3. **Clear browser cache** - Force refresh with Ctrl+F5 (Cmd+Shift+R on Mac)
4. **Check resources** - Run free -h in SSH to check if system is low on memory
5. **Restart interface** - sudo service nginx restart or sudo service moonraker restart
6. **Last resort** - Restart Klipper: sudo service klipper restart

### False Sensor Triggers
1. Run CHECK_SENSORS to verify state
2. Ensure sensors were disabled during last filament change
3. Check for partial clogs causing inconsistent movement

### Filament Guide Tube Issues
- If resistance is felt during manual push, check for:
 - Kinks in filament guide tube
 - Debris in tube
 - Incorrect tube routing
 - Worn tube requiring replacement
- Note: Unlike bowden systems, the guide tube doesn't affect retraction settings

## Advanced Features

### Exclude Object Support
The printer now supports excluding individual objects during multi-part prints:
- **Enable in Slicer**: Turn on "Label objects" in PrusaSlicer/OrcaSlicer
- **During Print**: Use the web interface to exclude failed objects
- **G-code Commands**:
 - EXCLUDE_OBJECT NAME=object_name - Exclude specific object
 - EXCLUDE_OBJECT_DEFINE - Define objects (handled by slicer)
- **Benefits**: Save time and material when one object fails in a multi-part print

### Enhanced Filament Change (M600)
Improved M600 implementation with proper delta positioning:
- **Usage**: M600 or M600 X=0 Y=-140 Z=10
- **Features**:
 - Saves current position and state
 - Moves to safe change position
 - Performs enhanced unload with tip forming
 - Waits for user to load new filament
 - Restores position after change

### TMC5160 Advanced Features
The extruder motor now uses advanced TMC5160 features:
- **StealthChop**: Ultra-quiet operation
- **CoolStep**: Automatic current reduction for efficiency
- **Interpolation**: 256 microstep interpolation for smooth motion

### Thermal Protection
Enhanced thermal runaway protection for all heaters:
- Monitors temperature rise rates
- Prevents runaway conditions
- Automatic shutdown on anomalies

## Best Practices

### G-code Filename Requirements
Klipper and its web interfaces have specific filename requirements:
- **Use underscores** instead of spaces (e.g., test_print_PLA.gcode not test print PLA.gcode)
- **Avoid special characters**: No °, ®, ™, or Unicode characters
- **Stick to**: Letters, numbers, underscores (_), and hyphens (-)
- **Slicer Output Format**: Configure your slicer to use underscores:
 
 [input_filename_base]_[layer_height]mm_[filament_type].gcode
 

### Why Filename Rules Matter
- Prevents errors when downloading files
- Avoids thumbnail generation issues
- Ensures compatibility with Linux filesystem
- Prevents Klipper crashes from special characters

## Safety Notes

- Never force filament if resistance is encountered
- Always wait for proper temperature before load/unload
- The delta printer has limited safe parking areas - macros use tested positions
- Dual-zone bed requires both zones to reach temperature for optimal adhesion

## Configuration Changes (2025-07-20)

### Critical Issues Resolved

#### 1. **Pressure Advance Configuration** (printer.cfg)
- **Issue**: Configuration was set for bowden system (PA=0.6) when the printer has a Direct Drive Extruder
- **Fix**: Set pressure advance to 0.05 (optimal for direct drive systems)
- **Why**: Direct drive systems require much lower PA values (0.02-0.08) compared to bowden systems (0.5-1.0)

#### 2. **Power Loss Recovery** (flsun_func.cfg)
- **Issue**: G4 P5000 (5-second wait) commands after SHUTDOWN would never execute
- **Fix**: Removed all wait commands after SHUTDOWN
- **Why**: System cannot execute commands after shutdown, making recovery impossible

#### 3. **relay_off Macro** (flsun_func.cfg)
- **Issue**: Incorrectly disabled extruder stepper when turning off relay
- **Fix**: Removed SET_STEPPER_ENABLE STEPPER=extruder ENABLE=0 from relay_off
- **Why**: This could cause missed steps or position loss during prints

#### 4. **Motion Sensor Detection** (flsun_func.cfg)
- **Issue**: Detection length was set for bowden system characteristics
- **Fix**: Set to 10mm for direct drive operation
- **Why**: Direct drive systems have immediate response and lower detection length prevents false triggers

#### 5. **Z-Offset Range** (printer.cfg)
- **Issue**: Limited to ±0.1mm, too restrictive for different surfaces
- **Fix**: Increased to ±0.2mm range
- **Why**: Different build surfaces and materials need more adjustment range

### New Features Added

#### 1. **Dual-Zone Bed Control** (s1_pro_macros.cfg)
- Added M141 command to set outer bed zone temperature
- Added M191 command to wait for outer bed zone
- Added BED_TEMPS macro for easy dual-zone control
- Modified heating routines to properly use both zones

#### 2. **Fan Power Control** (printer.cfg)
- Removed 55% power limitation on part cooling fan
- Now allows full power control via slicer or macros

#### 3. **Legacy Macro Handling** (printer.cfg)
- Converted old bed_level_1/2 and LOAD/UNLOAD_FILAMENT to aliases
- Now redirect to enhanced SPRO versions with proper sensor management