Dear VASP developers,
As you are well aware, users have been getting errors when using ALGO=Conjugate, getting the message "internal error in: rot.F at line: 822; EDWAV: internal error, the gradient is not orthogonal". Here I am providing my experiences with this issue, as well as an example where I have encountered this, since as far as I understood from the other topics in this forum it is still an unclear issue.
Generally speaking, I work with slabs and molecules (on/near the surface or in the gas phase) in the same calculation, which typically do not exhibit this error when using Conjugate. However, I encountered this issue really a lot when performing calculations on small bulk systems. I am not sure if there is even a specific pattern in those calculations when it fails. I also don't believe ISEARCH has an influence on this, other than that the "randomness" of when it exactly fails changes.
I have included several examples (Li, Na, V computed with M06L) with complete inputs and outputs (except of course the POTCAR), as well as some of the scripts and job files to run the calculations. These sets of calculations have been used to compute lattice constants for fcc and bcc solids through EOS fitting of single points, after first roughly determining the equilibrium constant through cell optimization (ISIF=3). In some cases, the issues became so severe that I had to drop the prior equilibration entirely and simply do only the single points for the EOS fit while hoping enough single points would run fine, because convergence is impossible for ALGO=Normal and Conjugate exhibits the aforementioned issue. I have used VASP 6.5.1. Note that the setup of these calculations might not be perfect (e.g., ISIF=4 for cubic systems) or sometimes even down right dirty, but they have done the trick for a large amount of calculations regardless.
PS. I know that M06L is a terrible DF to use for these kind of calculations (see the included examples). But that is exactly the point of running those specific calculations. Nevertheless, I have this problem with all kinds of functionals and their flavours (GGA, mGGA, with(out) D3, with(out) vdW-DF correlation).
PS2. I also managed to get the "internal error in: us.F at line: 1367; internal ERROR SETYLM_AUG" often enough. The way I can "reliably" reproduce this error is to perform a geometry optimization on a molecule present in S22 with a numerically hard to converge DF (like M06L, which might be one of the worst) and ALGO=Normal, with standard mixing parameters. In those cases, you typically cannot converge the SCF at all (like many orders of magnitude difference in energy going from one SCF cycle to another), causing the geometry optimization to work with terrible forces and therefore probably also at some point generating bad geometries that cause this specific error. One could argue it is a user/input error (the calculation doesn't converge at all, so what do you expect?), but in the error message it clearly states "If you are not a developer, you should not encounter this problem.; Please submit a bug report.". Therefore, I have also included an example for this case as well.

