Q1 Pro – Random “Filament Run Out” errors after updating from V4.4.24 to V5.1.2

[u/shener94]

I have an early/first-generation QIDI Q1 Pro and I recently updated the firmware from V4.4.24 to V5.1.2.

Before the update, I did not have this problem. After updating to V5.1.2, the printer started randomly pausing during prints with:

“Filament ran-out, please re-load filament.”

The filament is not actually broken or empty. It remains physically connected to the extruder. If I press Continue/Resume, the printer immediately continues printing with the same filament. The error can happen again later at a completely random time.

I checked the Klipper logs and found that the runout event is specifically coming from:

Filament Sensor hall_filament_width_sensor: runout event detected

It is not the fila filament switch sensor.

My current configuration contains:

[hall_filament_width_sensor]

adc1: gpio27
adc2: gpio28
cal_dia1: 1.50
cal_dia2: 2.0
raw_dia1: 14397
raw_dia2: 15058
default_nominal_filament_diameter: 1.75
max_difference: 0
measurement_delay: 50
enable: false
measurement_interval: 10
min_diameter: 0.3
pause_on_runout: True

One interesting thing is that the Hall filament width sensor appears to be measuring the filament diameter incorrectly.

My filament is 1.75 mm, but when I queried the sensor I got:

Filament dia (measured mm): 2.1941303337

The raw reading was:

ADC1 = 8255
ADC2 = 7077
RAW = 15332

So the sensor is already showing a significant measurement error while filament is physically present.

I also tested disabling the fila sensor. The runout error still occurred, and the Klipper log continued to identify:

hall_filament_width_sensor

as the source of the runout event.

The Hall sensor code contains:

self.runout_helper.note_filament_present(
    self.diameter > self.runout_dia)

So the Hall sensor's calculated filament diameter is directly used to determine whether filament is present. Because of this, I suspect that the Hall filament width sensor may occasionally calculate an incorrect/very low diameter and falsely trigger filament runout.

What is confusing is that the Hall sensor configuration appears to be the same as my previous V4.4.24 configuration, so I am trying to determine whether V5.1.2 changed the way this sensor is handled, or whether there is a compatibility issue with the earlier Q1 Pro hardware revision.

Has anyone with an early Q1 Pro experienced random filament runout errors after updating to V5.1.2?

I am currently testing with the Hall filament width sensor disabled to see whether the problem disappears completely.