PA calibration: wider PA range for TPU/TPE

PA_CALIBRATE takes PA_STEP (default 0.002, 0-0.098 over 50 lines).
_PA_CFG.material_pa_step uses 0.004 (0-0.196) for tpu/tpe/flex; soft TPU
measured 0.094, close to the old end. The "no result" rejection uses the
end of the range actually tested.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

README.md

@@ -42,7 +42,7 @@ everything below, grouped by topic. Comment out what you do not use there.
 | `purge_until_empty.cfg` | `PURGE_UNTIL_EMPTY`: purges a snapped filament out until there is no more nozzle pressure | same as `purge_check.cfg` |
 | **pressure_advance/** | | |
 | `bd_pressure.cfg` | `[bdpressure bd_pa]` (I2C on the Nitehawk) and the vendor macros `PA_CALIBRATE`, `PA_E`, `PA_RESET`, `PA_STATE`; `PA_CALIBRATE` no longer sets Z back to a value read before the test (wrong after a Z hop in `G28 XY`) | `bdpressure.py` from the bd_pressure repo |
-| `bd_pa_spoolman.cfg` + `bd_pa_*.sh` | `LANE_CALIBRATE_PA`, `PA_CALIBRATE_ALL_LANES`, `LANE_RECAL_PA`, `SET_SPOOL_ID`, `PA_STATUS`: pressure advance per lane/spool, cached locally and in Spoolman; before a calibration the lane's spool is assigned again so a temperature just changed in Spoolman is used; a calibration with no result, a pause during the test or too few/stuck sensor readings is rejected and not saved | bd_pressure, AFC, Spoolman, `gcode_shell_command` |
+| `bd_pa_spoolman.cfg` + `bd_pa_*.sh` | `LANE_CALIBRATE_PA`, `PA_CALIBRATE_ALL_LANES`, `LANE_RECAL_PA`, `SET_SPOOL_ID`, `PA_STATUS`: pressure advance per lane/spool, cached locally and in Spoolman; before a calibration the lane's spool is assigned again so a temperature just changed in Spoolman is used; flexible materials (TPU/TPE) calibrate at a lower flow (8 mm³/s) and over a wider PA range (0–0.196 in 0.004 steps instead of 0–0.098); a calibration with no result, a pause during the test or too few/stuck sensor readings is rejected and not saved | bd_pressure, AFC, Spoolman, `gcode_shell_command` |
 | **spoolman/** | | |
 | `active_spool.cfg` | `SET_ACTIVE_SPOOL`, `CLEAR_ACTIVE_SPOOL` | Spoolman in Moonraker |
 | **leds/** | | |

macros/pressure_advance/bd_pa_spoolman.cfg

@@ -203,12 +203,17 @@ variable_write_threshold: 0.002
 # A calibration is rejected (nothing cached or written to Spoolman, the
 # previous PA is kept) when:
 #  - its result is the last PA_CALIBRATE test value: bdpressure.py found no
-#    result and left the extruder at the end of its scan (0..49 x 0.002),
+#    result and left the extruder at the end of its scan (0..49 x the PA
+#    step: 0.098 at the default step, 0.196 for flexibles),
 #  - the printer paused during the test (e.g. an AFC filament fault),
 #  - bd_pressure gave fewer than min_points readings or fewer than
 #    min_distinct different ones (sensor silent or hung; needs
 #    bdpressure_check.py, otherwise this check is skipped).
-variable_sweep_end_pa: 0.098
+variable_pa_step: 0.002        # PA_CALIBRATE tests 50 values: 0..49 x step
+# Wider range for materials whose PA can be above 0.098 (soft TPU measured
+# 0.094): same 50 lines and test time, coarser steps. Key contained in the
+# lane's material (any case); with several matches the largest step wins.
+variable_material_pa_step: {"tpu": 0.004, "tpe": 0.004, "flex": 0.004}
 variable_min_points: 10
 variable_min_distinct: 8
 # PA applied when a rejected lane has no earlier cached value
@@ -464,7 +469,14 @@ gcode:
                 {% endif %}
             {% endfor %}
 
-            {action_respond_info("Calibrating PA for %s (spool %d) at %.0fC, %g mm3/s..." % (lane, spool_id, nozzle_temp, vol.max))}
+            {% set step = namespace(pa=cfg.pa_step|float) %}
+            {% for key, s in cfg.material_pa_step.items() %}
+                {% if key in material and s|float > step.pa %}
+                    {% set step.pa = s|float %}
+                {% endif %}
+            {% endfor %}
+
+            {action_respond_info("Calibrating PA for %s (spool %d) at %.0fC, %g mm3/s, PA 0-%.3f..." % (lane, spool_id, nozzle_temp, vol.max, 49 * step.pa))}
             M117 Calibrating PA: {lane}
 
             G1 Z50 F3000
@@ -473,7 +485,7 @@ gcode:
             G4 P400
             G1 Z0 F3000
             G4 P400
-            PA_CALIBRATE NOZZLE_TEMP={nozzle_temp} MAX_VOLUMETRIC={vol.max} ACC_WALL={cfg.acc_wall} TRAVEL_SPEED={cfg.travel_speed} ACC_TO_DECEL_FACTOR={cfg.acc_to_decel_factor}
+            PA_CALIBRATE NOZZLE_TEMP={nozzle_temp} MAX_VOLUMETRIC={vol.max} ACC_WALL={cfg.acc_wall} TRAVEL_SPEED={cfg.travel_speed} ACC_TO_DECEL_FACTOR={cfg.acc_to_decel_factor} PA_STEP={step.pa}
 
             # IMPORTANT: we do NOT read printer.extruder.pressure_advance
             # here. Klipper fully evaluates a macro's Jinja2 template
@@ -493,7 +505,7 @@ gcode:
             # triggered (and its own template is rendered), PA_CALIBRATE
             # above has already finished and printer.extruder.pressure_advance
             # is current.
-            _PA_AFTER_CALIBRATE LANE={lane} SPOOL_ID={spool_id} CACHE_FOUND={1 if cache_found else 0} CACHED_PA={cached_pa}
+            _PA_AFTER_CALIBRATE LANE={lane} SPOOL_ID={spool_id} CACHE_FOUND={1 if cache_found else 0} CACHED_PA={cached_pa} SWEEP_END={49 * step.pa}
             BLOBIFIER_CLEAN
             G4 P400
             G1 Z10 F3000
@@ -504,13 +516,14 @@ gcode:
 
 [gcode_macro _PA_AFTER_CALIBRATE]
 description: Internal -- runs immediately after PA_CALIBRATE completes; reads the fresh PA value and caches it
-# LANE=<lane_name> SPOOL_ID=<int> CACHE_FOUND=<0|1> CACHED_PA=<float>
+# LANE=<lane_name> SPOOL_ID=<int> CACHE_FOUND=<0|1> CACHED_PA=<float> SWEEP_END=<last PA tested>
 gcode:
     {% set lane = params.LANE|default("")|string %}
     {% set spool_id = params.SPOOL_ID|default(0)|int %}
     {% set cache_found = params.CACHE_FOUND|default(0)|int %}
     {% set cached_pa = params.CACHED_PA|default(0.0)|float %}
     {% set cfg = printer["gcode_macro _PA_CFG"] %}
+    {% set sweep_end = params.SWEEP_END|default(49 * cfg.pa_step|float)|float %}
 
     # This template is evaluated only once this macro is actually
     # triggered -- which happens after PA_CALIBRATE (queued earlier by
@@ -519,7 +532,7 @@ gcode:
 
     # Reject runs where the sensor or the printer had a problem
     {% set problems = [] %}
-    {% if new_pa >= cfg.sweep_end_pa|float - 0.0001 %}
+    {% if new_pa >= sweep_end - 0.0001 %}
         {% set _ = problems.append("no result (PA left at the end of the test range, %.3f)" % new_pa) %}
     {% endif %}
     {% if printer.pause_resume.is_paused %}
@@ -538,7 +551,7 @@ gcode:
 
     {% if problems %}
         # A cached value at the end of the scan is an earlier failed run, not a PA
-        {% set use_cache = cache_found and cached_pa < cfg.sweep_end_pa|float - 0.0001 %}
+        {% set use_cache = cache_found and cached_pa < sweep_end - 0.0001 %}
         {% set keep = cached_pa if use_cache else cfg.fallback_pa|float %}
         _WARN MSG="PA calibration for {lane} (spool {spool_id}) rejected: {problems|join('; ')}. Nothing saved; using PA={'%.4f' % keep} ({'cached' if use_cache else 'fallback'}). Fix the cause, then LANE_CALIBRATE_PA LANE={lane} FORCE=1" DISPLAY="PA cal rejected: {lane}, see console"
         SET_PRESSURE_ADVANCE ADVANCE={keep}

macros/pressure_advance/bd_pressure.cfg

@@ -131,7 +131,10 @@ gcode:
     G4 P1000
     {% set y_step = 38.75 %}
     {% set pressure_ad = 0 %}
-    {% set pressure_step = 0.002 %}
+    # PA_STEP: PA increase per test line, 50 lines (0..49 x step); the
+    # vendor value 0.002 tests 0-0.098. bdpressure.py reports the VALUE
+    # sent with each reading, so a larger step widens the range.
+    {% set pressure_step = params.PA_STEP|default(0.002)|float %}
     
     G1 F{high_speed}
     G1 X78 Y{y_step} E9.92204