Optimize Power-Loss Recovery (#12440)

Marlin/src/Marlin.cpp

@@ -924,11 +924,11 @@ void setup() {
   #endif
 
   #if DO_SWITCH_EXTRUDER
-    move_extruder_servo(0);  // Initialize extruder servo
+    move_extruder_servo(0);   // Initialize extruder servo
   #endif
 
   #if ENABLED(SWITCHING_NOZZLE)
-    move_nozzle_servo(0);  // Initialize nozzle servo
+    move_nozzle_servo(0);     // Initialize nozzle servo
   #endif
 
   #if ENABLED(PARKING_EXTRUDER)
@@ -936,11 +936,11 @@ void setup() {
   #endif
 
   #if ENABLED(POWER_LOSS_RECOVERY)
-    check_print_job_recovery();
+    recovery.check();
   #endif
 
-  #if ENABLED(USE_WATCHDOG) // Reinit watchdog after HAL_get_reset_source call
-    watchdog_init();
+  #if ENABLED(USE_WATCHDOG)
+    watchdog_init();          // Reinit watchdog after HAL_get_reset_source call
   #endif
 
   #if ENABLED(EXTERNAL_CLOSED_LOOP_CONTROLLER)

Marlin/src/feature/power_loss_recovery.cpp

@@ -29,247 +29,145 @@
 #if ENABLED(POWER_LOSS_RECOVERY)
 
 #include "power_loss_recovery.h"
+#include "../core/macros.h"
 
+bool PrintJobRecovery::enabled; // Initialized by settings.load()
+
+SdFile PrintJobRecovery::file;
+job_recovery_info_t PrintJobRecovery::info;
+
+#include "../sd/cardreader.h"
 #include "../lcd/ultralcd.h"
 #include "../gcode/queue.h"
+#include "../gcode/gcode.h"
 #include "../module/motion.h"
 #include "../module/planner.h"
 #include "../module/printcounter.h"
 #include "../module/temperature.h"
-#include "../sd/cardreader.h"
 #include "../core/serial.h"
 
 #if ENABLED(FWRETRACT)
   #include "fwretract.h"
 #endif
 
-// Recovery data
-job_recovery_info_t job_recovery_info;
-JobRecoveryPhase job_recovery_phase = JOB_RECOVERY_IDLE;
-uint8_t job_recovery_commands_count; //=0
-char job_recovery_commands[BUFSIZE + APPEND_CMD_COUNT][MAX_CMD_SIZE];
-
-extern uint8_t commands_in_queue, cmd_queue_index_r;
-
-#if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-  void debug_print_job_recovery(const bool recovery) {
-    SERIAL_PROTOCOLLNPGM("---- Job Recovery Info ----");
-    SERIAL_PROTOCOLPAIR("valid_head:", int(job_recovery_info.valid_head));
-    SERIAL_PROTOCOLLNPAIR(" valid_foot:", int(job_recovery_info.valid_foot));
-    if (job_recovery_info.valid_head) {
-      if (job_recovery_info.valid_head == job_recovery_info.valid_foot) {
-        SERIAL_PROTOCOLPGM("current_position: ");
-        LOOP_XYZE(i) {
-          SERIAL_PROTOCOL(job_recovery_info.current_position[i]);
-          if (i < E_AXIS) SERIAL_CHAR(',');
-        }
-        SERIAL_EOL();
-        SERIAL_PROTOCOLLNPAIR("feedrate: ", job_recovery_info.feedrate);
+PrintJobRecovery recovery;
 
-        #if HOTENDS > 1
-          SERIAL_PROTOCOLLNPAIR("active_hotend: ", int(job_recovery_info.active_hotend));
-        #endif
-
-        SERIAL_PROTOCOLPGM("target_temperature: ");
-        HOTEND_LOOP() {
-          SERIAL_PROTOCOL(job_recovery_info.target_temperature[e]);
-          if (e < HOTENDS - 1) SERIAL_CHAR(',');
-        }
-        SERIAL_EOL();
-
-        #if HAS_HEATED_BED
-          SERIAL_PROTOCOLLNPAIR("target_temperature_bed: ", job_recovery_info.target_temperature_bed);
-        #endif
+/**
+ * Clear the recovery info
+ */
+void PrintJobRecovery::init() { memset(&info, 0, sizeof(info)); }
 
-        #if FAN_COUNT
-          SERIAL_PROTOCOLPGM("fan_speed: ");
-          for (int8_t i = 0; i < FAN_COUNT; i++) {
-            SERIAL_PROTOCOL(job_recovery_info.fan_speed[i]);
-            if (i < FAN_COUNT - 1) SERIAL_CHAR(',');
-          }
-          SERIAL_EOL();
-        #endif
+/**
+ * Enable or disable then call changed()
+ */
+void PrintJobRecovery::enable(const bool onoff) {
+  enabled = onoff;
+  changed();
+}
 
-        #if HAS_LEVELING
-          SERIAL_PROTOCOLPAIR("leveling: ", int(job_recovery_info.leveling));
-          SERIAL_PROTOCOLLNPAIR(" fade: ", int(job_recovery_info.fade));
-        #endif
-        #if ENABLED(FWRETRACT)
-          SERIAL_PROTOCOLPGM("retract: ");
-          for (int8_t e = 0; e < EXTRUDERS; e++) {
-            SERIAL_PROTOCOL(job_recovery_info.retract[e]);
-            if (e < EXTRUDERS - 1) SERIAL_CHAR(',');
-          }
-          SERIAL_EOL();
-          SERIAL_PROTOCOLLNPAIR("retract_hop: ", job_recovery_info.retract_hop);
-        #endif
-        SERIAL_PROTOCOLLNPAIR("cmd_queue_index_r: ", int(job_recovery_info.cmd_queue_index_r));
-        SERIAL_PROTOCOLLNPAIR("commands_in_queue: ", int(job_recovery_info.commands_in_queue));
-        if (recovery)
-          for (uint8_t i = 0; i < job_recovery_commands_count; i++) SERIAL_PROTOCOLLNPAIR("> ", job_recovery_commands[i]);
-        else
-          for (uint8_t i = 0; i < job_recovery_info.commands_in_queue; i++) SERIAL_PROTOCOLLNPAIR("> ", job_recovery_info.command_queue[i]);
-        SERIAL_PROTOCOLLNPAIR("sd_filename: ", job_recovery_info.sd_filename);
-        SERIAL_PROTOCOLLNPAIR("sdpos: ", job_recovery_info.sdpos);
-        SERIAL_PROTOCOLLNPAIR("print_job_elapsed: ", job_recovery_info.print_job_elapsed);
-      }
-      else
-        SERIAL_PROTOCOLLNPGM("INVALID DATA");
-    }
-    SERIAL_PROTOCOLLNPGM("---------------------------");
-  }
-#endif // DEBUG_POWER_LOSS_RECOVERY
+/**
+ * The enabled state was changed:
+ *  - Enabled: Purge the job recovery file
+ *  - Disabled: Write the job recovery file
+ */
+void PrintJobRecovery::changed() {
+  if (!enabled)
+    purge();
+  else if (IS_SD_PRINTING())
+    save(true);
+}
 
 /**
  * Check for Print Job Recovery during setup()
  *
- * If a saved state exists, populate job_recovery_commands with
- * commands to restore the machine state and continue the file.
+ * If a saved state exists send 'M1000 S' to initiate job recovery.
  */
-void check_print_job_recovery() {
-  memset(&job_recovery_info, 0, sizeof(job_recovery_info));
-  ZERO(job_recovery_commands);
-
-  if (!card.cardOK) card.initsd();
-
-  if (card.cardOK) {
-
-    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-      SERIAL_PROTOCOLLNPAIR("Init job recovery info. Size: ", int(sizeof(job_recovery_info)));
-    #endif
-
-    if (card.jobRecoverFileExists()) {
-      card.openJobRecoveryFile(true);
-      card.loadJobRecoveryInfo();
-      card.closeJobRecoveryFile();
-      //card.removeJobRecoveryFile();
-
-      if (job_recovery_info.valid_head && job_recovery_info.valid_head == job_recovery_info.valid_foot) {
-
-        uint8_t ind = 0;
-
-        #if HAS_LEVELING
-          strcpy_P(job_recovery_commands[ind++], PSTR("M420 S0 Z0"));               // Leveling off before G92 or G28
-        #endif
-
-        strcpy_P(job_recovery_commands[ind++], PSTR("G92.0 Z0"));                   // Ensure Z is equal to 0
-        strcpy_P(job_recovery_commands[ind++], PSTR("G1 Z2"));                      // Raise Z by 2mm (we hope!)
-        strcpy_P(job_recovery_commands[ind++], PSTR("G28 R0"
-          #if ENABLED(MARLIN_DEV_MODE)
-            " S"
-          #elif !IS_KINEMATIC
-            " X Y"                                                                  // Home X and Y for Cartesian
-          #endif
-        ));
-
-        char str_1[16], str_2[16];
-
-        #if HAS_LEVELING
-          if (job_recovery_info.fade || job_recovery_info.leveling) {
-            // Restore leveling state before G92 sets Z
-            // This ensures the steppers correspond to the native Z
-            dtostrf(job_recovery_info.fade, 1, 1, str_1);
-            sprintf_P(job_recovery_commands[ind++], PSTR("M420 S%i Z%s"), int(job_recovery_info.leveling), str_1);
-          }
-        #endif
-
-        #if ENABLED(FWRETRACT)
-          for (uint8_t e = 0; e < EXTRUDERS; e++) {
-            if (job_recovery_info.retract[e] != 0.0)
-              fwretract.current_retract[e] = job_recovery_info.retract[e];
-              fwretract.retracted[e] = true;
-          }
-          fwretract.current_hop = job_recovery_info.retract_hop;
-        #endif
-
-        dtostrf(job_recovery_info.current_position[Z_AXIS] + 2, 1, 3, str_1);
-        dtostrf(job_recovery_info.current_position[E_AXIS]
-          #if ENABLED(SAVE_EACH_CMD_MODE)
-            - 5
-          #endif
-          , 1, 3, str_2
-        );
-        sprintf_P(job_recovery_commands[ind++], PSTR("G92.0 Z%s E%s"), str_1, str_2); // Current Z + 2 and E
-
-        uint8_t r = job_recovery_info.cmd_queue_index_r, c = job_recovery_info.commands_in_queue;
-        while (c--) {
-          strcpy(job_recovery_commands[ind++], job_recovery_info.command_queue[r]);
-          r = (r + 1) % BUFSIZE;
-        }
-
-        if (job_recovery_info.sd_filename[0] == '/') job_recovery_info.sd_filename[0] = ' ';
-        sprintf_P(job_recovery_commands[ind++], PSTR("M23 %s"), job_recovery_info.sd_filename);
-        sprintf_P(job_recovery_commands[ind++], PSTR("M24 S%ld T%ld"), job_recovery_info.sdpos, job_recovery_info.print_job_elapsed);
+void PrintJobRecovery::check() {
+  if (enabled) {
+    if (!card.cardOK) card.initsd();
+    if (card.cardOK) {
+      load();
+      if (!valid()) return purge();
+      enqueue_and_echo_commands_P(PSTR("M1000 S"));
+    }
+  }
+}
 
-        job_recovery_commands_count = ind;
+/**
+ * Delete the recovery file and clear the recovery data
+ */
+void PrintJobRecovery::purge() {
+  init();
+  card.removeJobRecoveryFile();
+}
 
-        #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-          debug_print_job_recovery(true);
-        #endif
-      }
-      else {
-        if (job_recovery_info.valid_head != job_recovery_info.valid_foot)
-          LCD_ALERTMESSAGEPGM("INVALID DATA");
-        memset(&job_recovery_info, 0, sizeof(job_recovery_info));
-      }
-    }
+/**
+ * Load the recovery data, if it exists
+ */
+void PrintJobRecovery::load() {
+  if (exists()) {
+    open(true);
+    (void)file.read(&info, sizeof(info));
+    close();
   }
+  #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+    debug(PSTR("Load"));
+  #endif
 }
 
 /**
  * Save the current machine state to the power-loss recovery file
  */
-void save_job_recovery_info() {
+void PrintJobRecovery::save(const bool force/*=false*/) {
+
   #if SAVE_INFO_INTERVAL_MS > 0
-    static millis_t next_save_ms; // = 0;  // Init on reset
+    static millis_t next_save_ms; // = 0
     millis_t ms = millis();
   #endif
-  if (
-    // Save on every command
-    #if ENABLED(SAVE_EACH_CMD_MODE)
-      true
-    #else
-      // Save if power loss pin is triggered
-      #if PIN_EXISTS(POWER_LOSS)
-        READ(POWER_LOSS_PIN) == POWER_LOSS_STATE ||
+
+  if (force
+    #if DISABLED(SAVE_EACH_CMD_MODE)      // Always save state when enabled
+      #if PIN_EXISTS(POWER_LOSS)          // Save if power loss pin is triggered
+        || READ(POWER_LOSS_PIN) == POWER_LOSS_STATE
       #endif
-      // Save if interval is elapsed
-      #if SAVE_INFO_INTERVAL_MS > 0
-        ELAPSED(ms, next_save_ms) ||
+      #if SAVE_INFO_INTERVAL_MS > 0       // Save if interval is elapsed
+        || ELAPSED(ms, next_save_ms)
       #endif
-      // Save on every new Z height
-      (current_position[Z_AXIS] > 0 && current_position[Z_AXIS] > job_recovery_info.current_position[Z_AXIS])
+      // Save every time Z is higher than the last call
+      || current_position[Z_AXIS] > info.current_position[Z_AXIS]
     #endif
   ) {
+
     #if SAVE_INFO_INTERVAL_MS > 0
       next_save_ms = ms + SAVE_INFO_INTERVAL_MS;
     #endif
 
-    // Head and foot will match if valid data was saved
-    if (!++job_recovery_info.valid_head) ++job_recovery_info.valid_head; // non-zero in sequence
-    job_recovery_info.valid_foot = job_recovery_info.valid_head;
+    // Set Head and Foot to matching non-zero values
+    if (!++info.valid_head) ++info.valid_head; // non-zero in sequence
+    //if (!IS_SD_PRINTING()) info.valid_head = 0;
+    info.valid_foot = info.valid_head;
 
     // Machine state
-    COPY(job_recovery_info.current_position, current_position);
-    job_recovery_info.feedrate = feedrate_mm_s;
+    COPY(info.current_position, current_position);
+    info.feedrate = uint16_t(feedrate_mm_s * 60.0f);
 
     #if HOTENDS > 1
-      job_recovery_info.active_hotend = active_extruder;
+      info.active_hotend = active_extruder;
     #endif
 
-    COPY(job_recovery_info.target_temperature, thermalManager.target_temperature);
+    COPY(info.target_temperature, thermalManager.target_temperature);
 
     #if HAS_HEATED_BED
-      job_recovery_info.target_temperature_bed = thermalManager.target_temperature_bed;
+      info.target_temperature_bed = thermalManager.target_temperature_bed;
     #endif
 
     #if FAN_COUNT
-      COPY(job_recovery_info.fan_speed, fan_speed);
+      COPY(info.fan_speed, fan_speed);
     #endif
 
     #if HAS_LEVELING
-      job_recovery_info.leveling = planner.leveling_active;
-      job_recovery_info.fade = (
+      info.leveling = planner.leveling_active;
+      info.fade = (
         #if ENABLED(ENABLE_LEVELING_FADE_HEIGHT)
           planner.z_fade_height
         #else
@@ -279,35 +177,238 @@ void save_job_recovery_info() {
     #endif
 
     #if ENABLED(FWRETRACT)
-      COPY(job_recovery_info.retract, fwretract.current_retract);
-      job_recovery_info.retract_hop = fwretract.current_hop;
+      COPY(info.retract, fwretract.current_retract);
+      info.retract_hop = fwretract.current_hop;
     #endif
 
     // Commands in the queue
-    job_recovery_info.cmd_queue_index_r = cmd_queue_index_r;
-    job_recovery_info.commands_in_queue = commands_in_queue;
-    COPY(job_recovery_info.command_queue, command_queue);
+    info.cmd_queue_index_r = cmd_queue_index_r;
+    info.commands_in_queue = commands_in_queue;
+    COPY(info.command_queue, command_queue);
 
     // Elapsed print job time
-    job_recovery_info.print_job_elapsed = print_job_timer.duration();
+    info.print_job_elapsed = print_job_timer.duration();
 
     // SD file position
-    card.getAbsFilename(job_recovery_info.sd_filename);
-    job_recovery_info.sdpos = card.getIndex();
+    card.getAbsFilename(info.sd_filename);
+    info.sdpos = card.getIndex();
+
+    write();
 
-    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-      SERIAL_PROTOCOLLNPGM("Saving...");
-      debug_print_job_recovery(false);
+    // KILL now if the power-loss pin was triggered
+    #if PIN_EXISTS(POWER_LOSS)
+      if (READ(POWER_LOSS_PIN) == POWER_LOSS_STATE) kill(MSG_OUTAGE_RECOVERY);
     #endif
+  }
+}
 
-    card.openJobRecoveryFile(false);
-    (void)card.saveJobRecoveryInfo();
+/**
+ * Save the recovery info the recovery file
+ */
+void PrintJobRecovery::write() {
 
-    // If power-loss pin was triggered, write just once then kill
-    #if PIN_EXISTS(POWER_LOSS)
-      if (READ(POWER_LOSS_PIN) == POWER_LOSS_STATE) kill(MSG_POWER_LOSS_RECOVERY);
+  #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+    debug(PSTR("Write"));
+  #endif
+
+  open(false);
+  file.seekSet(0);
+  const int16_t ret = file.write(&info, sizeof(info));
+  #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+    if (ret == -1) SERIAL_ECHOLNPGM("Power-loss file write failed.");
+  #endif
+}
+
+/**
+ * Resume the saved print job
+ */
+void PrintJobRecovery::resume() {
+
+  #define RECOVERY_ZRAISE 2
+
+  #if HAS_LEVELING
+    // Make sure leveling is off before any G92 and G28
+    gcode.process_subcommands_now_P(PSTR("M420 S0 Z0"));
+  #endif
+
+  // Set Z to 0, raise Z by 2mm, and Home (XY only for Cartesian) with no raise
+  // (Only do simulated homing in Marlin Dev Mode.)
+  gcode.process_subcommands_now_P(PSTR("G92.0 Z0|G1 Z" STRINGIFY(RECOVERY_ZRAISE) "|G28 R0"
+    #if ENABLED(MARLIN_DEV_MODE)
+      " S"
+    #elif !IS_KINEMATIC
+      " X Y"
     #endif
+  ));
+
+  // Pretend that all axes are homed
+  axis_homed = axis_known_position = xyz_bits;
+
+  char cmd[40], str_1[16], str_2[16];
+
+  // Select the previously active tool (with no_move)
+  #if EXTRUDERS > 1
+    sprintf_P(cmd, PSTR("T%i S"), info.active_hotend);
+    gcode.process_subcommands_now(cmd);
+  #endif
+
+  #if HAS_HEATED_BED
+    const int16_t bt = info.target_temperature_bed;
+    if (bt) {
+      // Restore the bed temperature
+      sprintf_P(cmd, PSTR("M190 S%i"), bt);
+      gcode.process_subcommands_now(cmd);
+    }
+  #endif
+
+  // Restore all hotend temperatures
+  HOTEND_LOOP() {
+    const int16_t et = info.target_temperature[e];
+    if (et) {
+      #if HOTENDS > 1
+        sprintf_P(cmd, PSTR("T%i"), e);
+        gcode.process_subcommands_now(cmd);
+      #endif
+      sprintf_P(cmd, PSTR("M109 S%i"), et);
+      gcode.process_subcommands_now(cmd);
+    }
   }
+
+  // Restore print cooling fan speeds
+  for (uint8_t i = 0; i < FAN_COUNT; i++) {
+    uint8_t f = info.fan_speed[i];
+    if (f) {
+      sprintf_P(cmd, PSTR("M106 P%i S%i"), i, f);
+      gcode.process_subcommands_now(cmd);
+    }
+  }
+
+  // Restore retract and hop state
+  #if ENABLED(FWRETRACT)
+    for (uint8_t e = 0; e < EXTRUDERS; e++) {
+      if (info.retract[e] != 0.0)
+        fwretract.current_retract[e] = info.retract[e];
+        fwretract.retracted[e] = true;
+    }
+    fwretract.current_hop = info.retract_hop;
+  #endif
+
+  #if HAS_LEVELING
+    // Restore leveling state before 'G92 Z' to ensure
+    // the Z stepper count corresponds to the native Z.
+    if (info.fade || info.leveling) {
+      dtostrf(info.fade, 1, 1, str_1);
+      sprintf_P(cmd, PSTR("M420 S%i Z%s"), int(info.leveling), str_1);
+      gcode.process_subcommands_now(cmd);
+    }
+  #endif
+
+  // Restore Z (plus raise) and E positions with G92.0
+  dtostrf(info.current_position[Z_AXIS] + RECOVERY_ZRAISE, 1, 3, str_1);
+  dtostrf(info.current_position[E_AXIS]
+    #if ENABLED(SAVE_EACH_CMD_MODE)
+      - 5 // Extra extrusion on restart
+    #endif
+    , 1, 3, str_2
+  );
+  sprintf_P(cmd, PSTR("G92.0 Z%s E%s"), str_1, str_2);
+  gcode.process_subcommands_now(cmd);
+
+  // Move back to the saved XY
+  dtostrf(info.current_position[X_AXIS], 1, 3, str_1);
+  dtostrf(info.current_position[Y_AXIS], 1, 3, str_2);
+  sprintf_P(cmd, PSTR("G1 X%s Y%s F3000"), str_1, str_2);
+  gcode.process_subcommands_now(cmd);
+
+  // Move back to the saved Z
+  dtostrf(info.current_position[Z_AXIS], 1, 3, str_1);
+  sprintf_P(cmd, PSTR("G1 Z%s F200"), str_1);
+  gcode.process_subcommands_now(cmd);
+
+  // Restore the feedrate
+  sprintf_P(cmd, PSTR("G1 F%d"), info.feedrate);
+  gcode.process_subcommands_now(cmd);
+
+  // Process commands from the old pending queue
+  uint8_t r = info.cmd_queue_index_r, c = info.commands_in_queue;
+  for (; c--; r = (r + 1) % BUFSIZE)
+    gcode.process_subcommands_now(info.command_queue[r]);
+
+  // Resume the SD file from the last position
+  char *fn = info.sd_filename;
+  while (*fn == '/') fn++;
+  sprintf_P(cmd, PSTR("M23 %s"), fn);
+  gcode.process_subcommands_now(cmd);
+  sprintf_P(cmd, PSTR("M24 S%ld T%ld"), info.sdpos, info.print_job_elapsed);
+  gcode.process_subcommands_now(cmd);
 }
 
+#if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+
+  void PrintJobRecovery::debug(PGM_P const prefix) {
+    serialprintPGM(prefix);
+    SERIAL_ECHOPAIR(" Job Recovery Info...\nvalid_head:", int(info.valid_head));
+    SERIAL_ECHOLNPAIR(" valid_foot:", int(info.valid_foot));
+    if (info.valid_head) {
+      if (info.valid_head == info.valid_foot) {
+        SERIAL_ECHOPGM("current_position: ");
+        LOOP_XYZE(i) {
+          SERIAL_ECHO(info.current_position[i]);
+          if (i < E_AXIS) SERIAL_CHAR(',');
+        }
+        SERIAL_EOL();
+        SERIAL_ECHOLNPAIR("feedrate: ", info.feedrate);
+
+        #if HOTENDS > 1
+          SERIAL_ECHOLNPAIR("active_hotend: ", int(info.active_hotend));
+        #endif
+
+        SERIAL_ECHOPGM("target_temperature: ");
+        HOTEND_LOOP() {
+          SERIAL_ECHO(info.target_temperature[e]);
+          if (e < HOTENDS - 1) SERIAL_CHAR(',');
+        }
+        SERIAL_EOL();
+
+        #if HAS_HEATED_BED
+          SERIAL_ECHOLNPAIR("target_temperature_bed: ", info.target_temperature_bed);
+        #endif
+
+        #if FAN_COUNT
+          SERIAL_ECHOPGM("fan_speed: ");
+          for (int8_t i = 0; i < FAN_COUNT; i++) {
+            SERIAL_ECHO(int(info.fan_speed[i]));
+            if (i < FAN_COUNT - 1) SERIAL_CHAR(',');
+          }
+          SERIAL_EOL();
+        #endif
+
+        #if HAS_LEVELING
+          SERIAL_ECHOPAIR("leveling: ", int(info.leveling));
+          SERIAL_ECHOLNPAIR(" fade: ", int(info.fade));
+        #endif
+        #if ENABLED(FWRETRACT)
+          SERIAL_ECHOPGM("retract: ");
+          for (int8_t e = 0; e < EXTRUDERS; e++) {
+            SERIAL_ECHO(info.retract[e]);
+            if (e < EXTRUDERS - 1) SERIAL_CHAR(',');
+          }
+          SERIAL_EOL();
+          SERIAL_ECHOLNPAIR("retract_hop: ", info.retract_hop);
+        #endif
+        SERIAL_ECHOLNPAIR("cmd_queue_index_r: ", int(info.cmd_queue_index_r));
+        SERIAL_ECHOLNPAIR("commands_in_queue: ", int(info.commands_in_queue));
+        for (uint8_t i = 0; i < info.commands_in_queue; i++) SERIAL_ECHOLNPAIR("> ", info.command_queue[i]);
+        SERIAL_ECHOLNPAIR("sd_filename: ", info.sd_filename);
+        SERIAL_ECHOLNPAIR("sdpos: ", info.sdpos);
+        SERIAL_ECHOLNPAIR("print_job_elapsed: ", info.print_job_elapsed);
+      }
+      else
+        SERIAL_ECHOLNPGM("INVALID DATA");
+    }
+    SERIAL_ECHOLNPGM("---");
+  }
+
+#endif // DEBUG_POWER_LOSS_RECOVERY
+
 #endif // POWER_LOSS_RECOVERY

Marlin/src/feature/power_loss_recovery.h

@@ -26,7 +26,6 @@
  */
 
 #include "../sd/cardreader.h"
-#include "../core/millis_t.h"
 #include "../inc/MarlinConfigPre.h"
 
 #define SAVE_INFO_INTERVAL_MS 0
@@ -37,7 +36,9 @@ typedef struct {
   uint8_t valid_head;
 
   // Machine state
-  float current_position[NUM_AXIS], feedrate;
+  float current_position[NUM_AXIS];
+
+  uint16_t feedrate;
 
   #if HOTENDS > 1
     uint8_t active_hotend;
@@ -74,26 +75,45 @@ typedef struct {
   millis_t print_job_elapsed;
 
   uint8_t valid_foot;
+
 } job_recovery_info_t;
 
-extern job_recovery_info_t job_recovery_info;
+class PrintJobRecovery {
+  public:
+    static SdFile file;
+    static job_recovery_info_t info;
 
-enum JobRecoveryPhase : unsigned char {
-  JOB_RECOVERY_IDLE,
-  JOB_RECOVERY_MAYBE,
-  JOB_RECOVERY_YES,
-  JOB_RECOVERY_DONE
-};
-extern JobRecoveryPhase job_recovery_phase;
+    static void init();
+
+    static bool enabled;
+    static void enable(const bool onoff);
+    static void changed();
+
+    static void check();
+    static void resume();
 
-#if HAS_LEVELING
-  #define APPEND_CMD_COUNT 9
-#else
-  #define APPEND_CMD_COUNT 7
-#endif
+    static inline bool exists() { return card.jobRecoverFileExists(); }
+    static inline void open(const bool read) { card.openJobRecoveryFile(read); }
+    static inline void close() { file.close(); }
 
-extern char job_recovery_commands[BUFSIZE + APPEND_CMD_COUNT][MAX_CMD_SIZE];
-extern uint8_t job_recovery_commands_count;
+    static void purge();
+    static void load();
+    static void save(const bool force=
+      #if ENABLED(SAVE_EACH_CMD_MODE)
+        true
+      #else
+        false
+      #endif
+    );
+
+  static inline bool valid() { return info.valid_head && info.valid_head == info.valid_foot; }
+
+    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+      static void debug(PGM_P const prefix);
+    #endif
+
+  private:
+    static void write();
+};
 
-void check_print_job_recovery();
-void save_job_recovery_info();
+extern PrintJobRecovery recovery;

Marlin/src/gcode/feature/powerloss/M1000.cpp

@@ -0,0 +1,65 @@
+/**
+ * Marlin 3D Printer Firmware
+ * Copyright (C) 2016 MarlinFirmware [https://github.com/MarlinFirmware/Marlin]
+ *
+ * Based on Sprinter and grbl.
+ * Copyright (C) 2011 Camiel Gubbels / Erik van der Zalm
+ *
+ * This program is free software: you can redistribute it and/or modify
+ * it under the terms of the GNU General Public License as published by
+ * the Free Software Foundation, either version 3 of the License, or
+ * (at your option) any later version.
+ *
+ * This program is distributed in the hope that it will be useful,
+ * but WITHOUT ANY WARRANTY; without even the implied warranty of
+ * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  See the
+ * GNU General Public License for more details.
+ *
+ * You should have received a copy of the GNU General Public License
+ * along with this program.  If not, see <http://www.gnu.org/licenses/>.
+ *
+ */
+
+#include "../../../inc/MarlinConfig.h"
+
+#if ENABLED(POWER_LOSS_RECOVERY)
+
+#include "../../gcode.h"
+#include "../../../feature/power_loss_recovery.h"
+#include "../../../module/motion.h"
+#include "../../../lcd/ultralcd.h"
+
+void menu_job_recovery();
+
+#if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+
+  inline void plr_error(PGM_P const prefix) {
+    SERIAL_ECHO_START();
+    serialprintPGM(prefix);
+    SERIAL_ECHOLNPGM(" Power-Loss Recovery Data");
+  }
+
+#endif
+
+/**
+ * M1000: Resume from power-loss (undocumented)
+ *   - With 'S' go to the Resume/Cancel menu
+ *   - With no parameters, run recovery commands
+ */
+void GcodeSuite::M1000() {
+
+  if (recovery.valid()) {
+    if (parser.seen('S'))
+      ui.goto_screen(menu_job_recovery);
+    else
+      recovery.resume();
+  }
+  else {
+    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+      plr_error(recovery.info.valid_head ? PSTR("No") : PSTR("Invalid"));
+    #endif
+  }
+
+}
+
+#endif // POWER_LOSS_RECOVERY

Marlin/src/gcode/feature/powerloss/M413.cpp

@@ -0,0 +1,58 @@
+/**
+ * Marlin 3D Printer Firmware
+ * Copyright (C) 2016 MarlinFirmware [https://github.com/MarlinFirmware/Marlin]
+ *
+ * Based on Sprinter and grbl.
+ * Copyright (C) 2011 Camiel Gubbels / Erik van der Zalm
+ *
+ * This program is free software: you can redistribute it and/or modify
+ * it under the terms of the GNU General Public License as published by
+ * the Free Software Foundation, either version 3 of the License, or
+ * (at your option) any later version.
+ *
+ * This program is distributed in the hope that it will be useful,
+ * but WITHOUT ANY WARRANTY; without even the implied warranty of
+ * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  See the
+ * GNU General Public License for more details.
+ *
+ * You should have received a copy of the GNU General Public License
+ * along with this program.  If not, see <http://www.gnu.org/licenses/>.
+ *
+ */
+
+#include "../../../inc/MarlinConfig.h"
+
+#if ENABLED(POWER_LOSS_RECOVERY)
+
+#include "../../gcode.h"
+#include "../../../feature/power_loss_recovery.h"
+#include "../../../module/motion.h"
+#include "../../../lcd/ultralcd.h"
+
+/**
+ * M413: Enable / Disable power-loss recovery
+ *
+ * Parameters
+ *   S[bool] - Flag to enable / disable.
+ *             If omitted, report current state.
+ */
+void GcodeSuite::M413() {
+
+  if (parser.seen('S'))
+    recovery.enable(parser.value_bool());
+  else {
+    SERIAL_ECHO_START();
+    SERIAL_ECHOPGM("Power-loss recovery ");
+    serialprintln_onoff(recovery.enabled);
+  }
+
+  #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+    if (parser.seen('R') || parser.seen('L')) recovery.load();
+    if (parser.seen('W')) recovery.save(true);
+    if (parser.seen('P')) recovery.purge();
+    if (parser.seen('E')) serialprintPGM(recovery.exists() ? PSTR("BIN Exists\n") : PSTR("No BIN\n"));
+    if (parser.seen('V')) serialprintPGM(recovery.valid() ? PSTR("Valid\n") : PSTR("Invalid\n"));
+  #endif
+}
+
+#endif // POWER_LOSS_RECOVERY

Marlin/src/gcode/gcode.cpp

@@ -695,6 +695,11 @@ void GcodeSuite::process_parsed_command(
 
       case 999: M999(); break;                                    // M999: Restart after being Stopped
 
+      #if ENABLED(POWER_LOSS_RECOVERY)
+        case 413: M413(); break;                                  // M413: Enable/disable/query Power-Loss Recovery
+        case 1000: M1000(); break;                                // M1000: Resume from power-loss
+      #endif
+
       default: parser.unknown_command_error(); break;
     }
     break;

Marlin/src/gcode/gcode.h

@@ -196,7 +196,8 @@
  * M406 - Disable Filament Sensor flow control. (Requires FILAMENT_WIDTH_SENSOR)
  * M407 - Display measured filament diameter in millimeters. (Requires FILAMENT_WIDTH_SENSOR)
  * M410 - Quickstop. Abort all planned moves.
- * M412 - Enable / Disable filament runout detection. (Requires FILAMENT_RUNOUT_SENSOR)
+ * M412 - Enable / Disable Filament Runout Detection. (Requires FILAMENT_RUNOUT_SENSOR)
+ * M413 - Enable / Disable Power-Loss Recovery. (Requires POWER_LOSS_RECOVERY)
  * M420 - Enable/Disable Leveling (with current values) S1=enable S0=disable (Requires MESH_BED_LEVELING or ABL)
  * M421 - Set a single Z coordinate in the Mesh Leveling grid. X<units> Y<units> Z<units> (Requires MESH_BED_LEVELING, AUTO_BED_LEVELING_BILINEAR, or AUTO_BED_LEVELING_UBL)
  * M422 - Set Z Stepper automatic alignment position using probe. X<units> Y<units> A<axis> (Requires Z_STEPPER_AUTO_ALIGN)
@@ -822,6 +823,11 @@ private:
 
   static void M999();
 
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    static void M413();
+    static void M1000();
+  #endif
+
   static void T(const uint8_t tool_index);
 
 };

Marlin/src/gcode/queue.cpp

@@ -809,22 +809,6 @@ inline void get_serial_commands() {
     }
   }
 
-  #if ENABLED(POWER_LOSS_RECOVERY)
-
-    inline bool drain_job_recovery_commands() {
-      static uint8_t job_recovery_commands_index = 0; // Resets on reboot
-      if (job_recovery_commands_count) {
-        if (_enqueuecommand(job_recovery_commands[job_recovery_commands_index])) {
-          ++job_recovery_commands_index;
-          if (!--job_recovery_commands_count) job_recovery_phase = JOB_RECOVERY_DONE;
-        }
-        return true;
-      }
-      return false;
-    }
-
-  #endif
-
 #endif // SDSUPPORT
 
 /**
@@ -840,11 +824,6 @@ void get_available_commands() {
 
   get_serial_commands();
 
-  #if ENABLED(POWER_LOSS_RECOVERY)
-    // Commands for power-loss recovery take precedence
-    if (job_recovery_phase == JOB_RECOVERY_YES && drain_job_recovery_commands()) return;
-  #endif
-
   #if ENABLED(SDSUPPORT)
     get_sdcard_commands();
   #endif
@@ -890,7 +869,7 @@ void advance_command_queue() {
     else {
       gcode.process_next_command();
       #if ENABLED(POWER_LOSS_RECOVERY)
-        if (card.cardOK && IS_SD_PRINTING()) save_job_recovery_info();
+        if (IS_SD_PRINTING()) recovery.save();
       #endif
     }
 

Marlin/src/inc/Conditionals_post.h

@@ -1629,7 +1629,7 @@
 // If platform requires early initialization of watchdog to properly boot
 #define EARLY_WATCHDOG (ENABLED(USE_WATCHDOG) && defined(ARDUINO_ARCH_SAM))
 
-#define USE_EXECUTE_COMMANDS_IMMEDIATE (ENABLED(G29_RETRY_AND_RECOVER) || ENABLED(GCODE_MACROS))
+#define USE_EXECUTE_COMMANDS_IMMEDIATE (ENABLED(G29_RETRY_AND_RECOVER) || ENABLED(GCODE_MACROS) || ENABLED(POWER_LOSS_RECOVERY))
 
 #if ENABLED(Z_TRIPLE_STEPPER_DRIVERS)
   #define Z_STEPPER_COUNT 3

Marlin/src/lcd/language/language_cz.h

@@ -253,7 +253,7 @@
 #define MSG_PAUSE_PRINT                     _UxGT("Pozastavit tisk")
 #define MSG_RESUME_PRINT                    _UxGT("Obnovit tisk")
 #define MSG_STOP_PRINT                      _UxGT("Zastavit tisk")
-#define MSG_POWER_LOSS_RECOVERY             _UxGT("Obnova vypadku")
+#define MSG_OUTAGE_RECOVERY                 _UxGT("Obnova vypadku")
 #define MSG_CARD_MENU                       _UxGT("Tisknout z SD")
 #define MSG_NO_CARD                         _UxGT("Žádná SD karta")
 #define MSG_DWELL                           _UxGT("Uspáno...")

Marlin/src/lcd/language/language_de.h

@@ -268,7 +268,7 @@
 #define MSG_PAUSE_PRINT                     _UxGT("SD-Druck pausieren")
 #define MSG_RESUME_PRINT                    _UxGT("SD-Druck fortsetzen")
 #define MSG_STOP_PRINT                      _UxGT("SD-Druck abbrechen")
-#define MSG_POWER_LOSS_RECOVERY             _UxGT("Wiederh. n. Stroma.")
+#define MSG_OUTAGE_RECOVERY                 _UxGT("Wiederh. n. Stroma.")
 #define MSG_CARD_MENU                       _UxGT("Druck v. SD-Karte")
 #define MSG_NO_CARD                         _UxGT("Keine SD-Karte")
 #define MSG_DWELL                           _UxGT("Warten...")

Marlin/src/lcd/language/language_en.h

@@ -728,8 +728,8 @@
 #ifndef MSG_STOP_PRINT
   #define MSG_STOP_PRINT                      _UxGT("Stop print")
 #endif
-#ifndef MSG_POWER_LOSS_RECOVERY
-  #define MSG_POWER_LOSS_RECOVERY             _UxGT("Power-Loss Recovery")
+#ifndef MSG_OUTAGE_RECOVERY
+  #define MSG_OUTAGE_RECOVERY                 _UxGT("Outage Recovery")
 #endif
 #ifndef MSG_CARD_MENU
   #define MSG_CARD_MENU                       _UxGT("Print from SD")

Marlin/src/lcd/language/language_it.h

@@ -266,7 +266,7 @@
 #define MSG_PAUSE_PRINT                     _UxGT("Pausa stampa")
 #define MSG_RESUME_PRINT                    _UxGT("Riprendi stampa")
 #define MSG_STOP_PRINT                      _UxGT("Arresta stampa")
-#define MSG_POWER_LOSS_RECOVERY             _UxGT("Ripresa da PowerLoss")
+#define MSG_OUTAGE_RECOVERY                 _UxGT("Ripresa da PowerLoss")
 #define MSG_CARD_MENU                       _UxGT("Stampa da SD")
 #define MSG_NO_CARD                         _UxGT("SD non presente")
 #define MSG_DWELL                           _UxGT("Sospensione...")

Marlin/src/lcd/language/language_ko_KR.h

@@ -259,7 +259,7 @@
 #define MSG_PAUSE_PRINT                     _UxGT("일시정지")
 #define MSG_RESUME_PRINT                    _UxGT("재시작")
 #define MSG_STOP_PRINT                      _UxGT("출력중지")
-#define MSG_POWER_LOSS_RECOVERY             _UxGT("Power-Loss Recovery")
+#define MSG_OUTAGE_RECOVERY                 _UxGT("Outage Recovery")
 #define MSG_CARD_MENU                       _UxGT("SD 카드출력")
 #define MSG_NO_CARD                         _UxGT("SD 카드없음")
 #define MSG_DWELL                           _UxGT("슬립모드...")

Marlin/src/lcd/language/language_pt-br.h

@@ -273,7 +273,7 @@
 #define MSG_PAUSE_PRINT                     _UxGT("Pausar impressão")
 #define MSG_RESUME_PRINT                    _UxGT("Resumir impressão")
 #define MSG_STOP_PRINT                      _UxGT("Parar impressão")
-#define MSG_POWER_LOSS_RECOVERY             _UxGT("Recuperar Impressão")
+#define MSG_OUTAGE_RECOVERY                 _UxGT("Recuperar Impressão")
 #define MSG_CARD_MENU                       _UxGT("Imprimir do SD")
 #define MSG_NO_CARD                         _UxGT("Sem cartão SD")
 #define MSG_DWELL                           _UxGT("Dormindo...")

Marlin/src/lcd/language/language_sk.h

@@ -278,7 +278,7 @@
 #define MSG_PAUSE_PRINT                     _UxGT("Pozastaviť tlač")
 #define MSG_RESUME_PRINT                    _UxGT("Obnoviť tlač")
 #define MSG_STOP_PRINT                      _UxGT("Zastaviť tlač")
-#define MSG_POWER_LOSS_RECOVERY             _UxGT("Obnova po výp. nap.")
+#define MSG_OUTAGE_RECOVERY                 _UxGT("Obnova po výp. nap.")
 #define MSG_CARD_MENU                       _UxGT("Tlačiť z SD")
 #define MSG_NO_CARD                         _UxGT("Žiadna SD karta")
 #define MSG_DWELL                           _UxGT("Spím...")

Marlin/src/lcd/menu/menu_configuration.cpp

@@ -36,6 +36,10 @@
   #include "../../feature/runout.h"
 #endif
 
+#if ENABLED(POWER_LOSS_RECOVERY)
+  #include "../../feature/power_loss_recovery.h"
+#endif
+
 #define HAS_DEBUG_MENU ENABLED(LCD_PROGRESS_BAR_TEST)
 
 void menu_advanced_settings();
@@ -350,6 +354,10 @@ void menu_configuration() {
     MENU_ITEM_EDIT_CALLBACK(bool, MSG_RUNOUT_SENSOR_ENABLE, &runout.enabled, runout.reset);
   #endif
 
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    MENU_ITEM_EDIT_CALLBACK(bool, MSG_OUTAGE_RECOVERY, &recovery.enabled, recovery.changed);
+  #endif
+
   #if DISABLED(SLIM_LCD_MENUS)
     // Preheat configurations
     MENU_ITEM(submenu, MSG_PREHEAT_1_SETTINGS, menu_preheat_material1_settings);

Marlin/src/lcd/menu/menu_job_recovery.cpp

@@ -34,58 +34,8 @@
 #include "../../feature/power_loss_recovery.h"
 
 static void lcd_power_loss_recovery_resume() {
-  char cmd[20];
-
-  // Return to status now
   ui.return_to_status();
-
-  // Turn leveling off and home
-  enqueue_and_echo_commands_P(PSTR("M420 S0\nG28 R0"
-    #if ENABLED(MARLIN_DEV_MODE)
-      " S"
-    #elif !IS_KINEMATIC
-      " X Y"
-    #endif
-  ));
-
-  #if HAS_HEATED_BED
-    const int16_t bt = job_recovery_info.target_temperature_bed;
-    if (bt) {
-      // Restore the bed temperature
-      sprintf_P(cmd, PSTR("M190 S%i"), bt);
-      enqueue_and_echo_command(cmd);
-    }
-  #endif
-
-  // Restore all hotend temperatures
-  HOTEND_LOOP() {
-    const int16_t et = job_recovery_info.target_temperature[e];
-    if (et) {
-      #if HOTENDS > 1
-        sprintf_P(cmd, PSTR("T%i"), e);
-        enqueue_and_echo_command(cmd);
-      #endif
-      sprintf_P(cmd, PSTR("M109 S%i"), et);
-      enqueue_and_echo_command(cmd);
-    }
-  }
-
-  #if HOTENDS > 1
-    sprintf_P(cmd, PSTR("T%i"), job_recovery_info.active_hotend);
-    enqueue_and_echo_command(cmd);
-  #endif
-
-  // Restore print cooling fan speeds
-  for (uint8_t i = 0; i < FAN_COUNT; i++) {
-    uint8_t f = job_recovery_info.fan_speed[i];
-    if (f) {
-      sprintf_P(cmd, PSTR("M106 P%i S%i"), i, f);
-      enqueue_and_echo_command(cmd);
-    }
-  }
-
-  // Start draining the job recovery command queue
-  job_recovery_phase = JOB_RECOVERY_YES;
+  enqueue_and_echo_commands_P(PSTR("M1000"));
 }
 
 static void lcd_power_loss_recovery_cancel() {
@@ -97,7 +47,7 @@ static void lcd_power_loss_recovery_cancel() {
 void menu_job_recovery() {
   ui.defer_status_screen(true);
   START_MENU();
-  STATIC_ITEM(MSG_POWER_LOSS_RECOVERY);
+  STATIC_ITEM(MSG_OUTAGE_RECOVERY);
   MENU_ITEM(function, MSG_RESUME_PRINT, lcd_power_loss_recovery_resume);
   MENU_ITEM(function, MSG_STOP_PRINT, lcd_power_loss_recovery_cancel);
   END_MENU();

Marlin/src/lcd/menu/menu_main.cpp

@@ -65,7 +65,7 @@
 
   #if ENABLED(MENU_ADDAUTOSTART)
 
-    void lcd_autostart_sd() { card.beginautostart(); }
+    inline void lcd_autostart_sd() { card.beginautostart(); }
 
   #endif
 

Marlin/src/lcd/ultralcd.cpp

@@ -659,13 +659,6 @@ void MarlinUI::update() {
 
   #endif // SDSUPPORT && SD_DETECT_PIN
 
-  #if ENABLED(POWER_LOSS_RECOVERY)
-    if (job_recovery_commands_count && job_recovery_phase == JOB_RECOVERY_IDLE) {
-      goto_screen(menu_job_recovery);
-      job_recovery_phase = JOB_RECOVERY_MAYBE; // Waiting for a response
-    }
-  #endif
-
   const millis_t ms = millis();
   if (ELAPSED(ms, next_lcd_update_ms)
     #if HAS_GRAPHICAL_LCD

Marlin/src/module/configuration_store.cpp

@@ -37,7 +37,7 @@
  */
 
 // Change EEPROM version if the structure changes
-#define EEPROM_VERSION "V62"
+#define EEPROM_VERSION "V63"
 #define EEPROM_OFFSET 100
 
 // Check the integrity of data offsets.
@@ -82,6 +82,11 @@
 #endif
 
 #include "../feature/fwretract.h"
+
+#if ENABLED(POWER_LOSS_RECOVERY)
+  #include "../feature/power_loss_recovery.h"
+#endif
+
 #include "../feature/pause.h"
 
 #if EXTRUDERS > 1
@@ -222,6 +227,11 @@ typedef struct SettingsDataStruct {
   int16_t lcd_contrast;                                 // M250 C
 
   //
+  // POWER_LOSS_RECOVERY
+  //
+  bool recovery_enabled;                                // M413 S
+
+  //
   // FWRETRACT
   //
   fwretract_settings_t fwretract_settings;              // M207 S F Z W, M208 S F W R
@@ -269,7 +279,7 @@ typedef struct SettingsDataStruct {
   // Tool-change settings
   //
   #if EXTRUDERS > 1
-    toolchange_settings_t toolchange_settings;                // M217 S P R
+    toolchange_settings_t toolchange_settings;          // M217 S P R
   #endif
 
 } SettingsData;
@@ -747,6 +757,22 @@ void MarlinSettings::postprocess() {
     }
 
     //
+    // Power-Loss Recovery
+    //
+    {
+      _FIELD_TEST(recovery_enabled);
+
+      const bool recovery_enabled =
+        #if ENABLED(POWER_LOSS_RECOVERY)
+          recovery.enabled
+        #else
+          true
+        #endif
+      ;
+      EEPROM_WRITE(recovery_enabled);
+    }
+
+    //
     // Firmware Retraction
     //
     {
@@ -1388,6 +1414,20 @@ void MarlinSettings::postprocess() {
       }
 
       //
+      // Power-Loss Recovery
+      //
+      {
+        _FIELD_TEST(recovery_enabled);
+
+        #if ENABLED(POWER_LOSS_RECOVERY)
+          EEPROM_READ(recovery.enabled);
+        #else
+          bool recovery_enabled;
+          EEPROM_READ(recovery_enabled);
+        #endif
+      }
+
+      //
       // Firmware Retraction
       //
       {
@@ -2075,6 +2115,10 @@ void MarlinSettings::reset(PORTARG_SOLO) {
     ui.set_contrast(DEFAULT_LCD_CONTRAST);
   #endif
 
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    recovery.enable(true);
+  #endif
+
   #if ENABLED(FWRETRACT)
     fwretract.reset();
   #endif
@@ -2643,6 +2687,15 @@ void MarlinSettings::reset(PORTARG_SOLO) {
       SERIAL_ECHOLNPAIR_P(port, "  M250 C", ui.contrast);
     #endif
 
+    #if ENABLED(POWER_LOSS_RECOVERY)
+      if (!forReplay) {
+        CONFIG_ECHO_START;
+        SERIAL_ECHOLNPGM_P(port, "Power-Loss Recovery:");
+      }
+      CONFIG_ECHO_START;
+      SERIAL_ECHOLNPAIR_P(port, "  M413 S", int(recovery.enabled));
+    #endif
+
     #if ENABLED(FWRETRACT)
 
       if (!forReplay) {
@@ -2683,7 +2736,7 @@ void MarlinSettings::reset(PORTARG_SOLO) {
     #if HAS_BED_PROBE
       if (!forReplay) {
         CONFIG_ECHO_START;
-        SERIAL_ECHOPGM_P(port, "Z-Probe Offset (mm):");
+        SERIAL_ECHOPGM_P(port, "Z-Probe Offset");
         SAY_UNITS_P(port, true);
       }
       CONFIG_ECHO_START;

Marlin/src/sd/cardreader.cpp

@@ -478,7 +478,7 @@ void CardReader::openFile(char * const path, const bool read, const bool subcall
 void CardReader::removeFile(const char * const name) {
   if (!cardOK) return;
 
-  stopSDPrint();
+  //stopSDPrint();
 
   SdFile *curDir;
   const char * const fname = diveToFile(curDir, name, false);
@@ -549,7 +549,7 @@ void CardReader::checkautostart() {
 
   if (cardOK
     #if ENABLED(POWER_LOSS_RECOVERY)
-      && !jobRecoverFileExists() // Don't run auto#.g when a resume file exists
+      && !recovery.valid() // Don't run auto#.g when a resume file exists
     #endif
   ) {
     char autoname[8];
@@ -577,6 +577,7 @@ void CardReader::closefile(const bool store_location) {
   file.sync();
   file.close();
   saving = logging = false;
+  sdpos = 0;
   #if ENABLED(EMERGENCY_PARSER)
     emergency_parser.enable();
   #endif
@@ -622,8 +623,12 @@ uint16_t CardReader::getnrfilenames() {
 }
 
 /**
- * Dive to the given file path, with optional echo.
- * On exit set curDir and return the name part of the path.
+ * Dive to the given DOS 8.3 file path, with optional echo of the dive paths.
+ *
+ * On exit, curDir contains an SdFile reference to the file's directory.
+ *
+ * Returns a pointer to the last segment (filename) of the given DOS 8.3 path.
+ *
  * A NULL result indicates an unrecoverable error.
  */
 const char* CardReader::diveToFile(SdFile*& curDir, const char * const path, const bool echo) {
@@ -993,12 +998,18 @@ void CardReader::printingHasFinished() {
 
 #if ENABLED(POWER_LOSS_RECOVERY)
 
-  char job_recovery_file_name[4] = "bin";
+  constexpr char job_recovery_file_name[4] = "BIN";
+
+  bool CardReader::jobRecoverFileExists() {
+    const bool exists = recovery.file.open(&root, job_recovery_file_name, O_READ);
+    if (exists) recovery.file.close();
+    return exists;
+  }
 
   void CardReader::openJobRecoveryFile(const bool read) {
     if (!cardOK) return;
-    if (jobRecoveryFile.isOpen()) return;
-    if (!jobRecoveryFile.open(&root, job_recovery_file_name, read ? O_READ : O_CREAT | O_WRITE | O_TRUNC | O_SYNC)) {
+    if (recovery.file.isOpen()) return;
+    if (!recovery.file.open(&root, job_recovery_file_name, read ? O_READ : O_CREAT | O_WRITE | O_TRUNC | O_SYNC)) {
       SERIAL_PROTOCOLPAIR(MSG_SD_OPEN_FILE_FAIL, job_recovery_file_name);
       SERIAL_PROTOCOLCHAR('.');
       SERIAL_EOL();
@@ -1007,31 +1018,12 @@ void CardReader::printingHasFinished() {
       SERIAL_PROTOCOLLNPAIR(MSG_SD_WRITE_TO_FILE, job_recovery_file_name);
   }
 
-  void CardReader::closeJobRecoveryFile() { jobRecoveryFile.close(); }
-
-  bool CardReader::jobRecoverFileExists() {
-    const bool exists = jobRecoveryFile.open(&root, job_recovery_file_name, O_READ);
-    if (exists) jobRecoveryFile.close();
-    return exists;
-  }
-
-  int16_t CardReader::saveJobRecoveryInfo() {
-    jobRecoveryFile.seekSet(0);
-    const int16_t ret = jobRecoveryFile.write(&job_recovery_info, sizeof(job_recovery_info));
-    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-      if (ret == -1) SERIAL_PROTOCOLLNPGM("Power-loss file write failed.");
-    #endif
-    return ret;
-  }
-
-  int16_t CardReader::loadJobRecoveryInfo() {
-    return jobRecoveryFile.read(&job_recovery_info, sizeof(job_recovery_info));
-  }
-
+  // Removing the job recovery file currently requires closing
+  // the file being printed, so during SD printing the file should
+  // be zeroed and written instead of deleted.
   void CardReader::removeJobRecoveryFile() {
-    job_recovery_info.valid_head = job_recovery_info.valid_foot = job_recovery_commands_count = 0;
     if (jobRecoverFileExists()) {
-      closefile();
+      //closefile();
       removeFile(job_recovery_file_name);
       #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
         SERIAL_PROTOCOLPGM("Power-loss file delete");

Marlin/src/sd/cardreader.h

@@ -106,11 +106,8 @@ public:
   #endif
 
   #if ENABLED(POWER_LOSS_RECOVERY)
-    void openJobRecoveryFile(const bool read);
-    void closeJobRecoveryFile();
     bool jobRecoverFileExists();
-    int16_t saveJobRecoveryInfo();
-    int16_t loadJobRecoveryInfo();
+    void openJobRecoveryFile(const bool read);
     void removeJobRecoveryFile();
   #endif
 
@@ -217,10 +214,6 @@ private:
   SdVolume volume;
   SdFile file;
 
-  #if ENABLED(POWER_LOSS_RECOVERY)
-    SdFile jobRecoveryFile;
-  #endif
-
   #define SD_PROCEDURE_DEPTH 1
   #define MAXPATHNAMELENGTH (FILENAME_LENGTH*MAX_DIR_DEPTH + MAX_DIR_DEPTH + 1)
   uint8_t file_subcall_ctr;