RE: Xl extruder stops
We replaced the wiring and so far is working well.
4 prints of 13 hrs each one and all good...
RE:
Hello folks!
I just wanted to tell you I have the same problem with my double toolhead XL. TL2 stops extruding after LH 0.6. X, Y, Z continues to move but the extruder motor stops working. With the selected toolhead, manual extrusion via the LCD display is also not possible. It looks like the motor or driver is crashing. After parking in the docking station, the motor can be controlled again and it extrudes the material as normal.
So NO clog or partial clog!!
For information, I'm currently printing simple PLA with 215 degree nozzle, 60 degree heat bed and 22 degree ambient temperature on FW 6.1.3 and PS 2.8.1
Does anyone already have a solution for this problem?
RE: Xl extruder stops
I talked too early.... T1 stop extruding on the 4th test of 13 hrs... same issue.
Frustrating....
RE:
I installed 6.2.0 alpha which does seem to fix the USB issue, but I encountered this issue once early on.
After installing Skeletton Dwarf Cover Base and Skeletton Dwarf Cover Back it hasn't happened since, so this could be the stepper driver or something shutting down due to heat.
Is anyone seeing this issue who doesn't have an enclosure or the printer in an unusually hot room?
RE: Xl extruder stops
I print in the basement and it's currently 18 degrees there. I don't have an enclosure either. I'm currently printing a slightly smaller object where I also have the same error. Just want to know if it also occurs at LH 0.6 or later.
This problem only appeared since I got a new Nextruder. Or since the new FW where the draft board was flashed.
The funny thing is, I printed a fire truck and the extruder stopped extruding after 1 hour. Print restarted and stopped at the same point. Re-sliced and then the print went through without errors. At this point the printer was in the apartment at a room temperature of 24 degrees.
completely frustrating..........
RE: Xl extruder stops
Im running without Enclosure and Room Temperature is around 23C
By suggestion of the Prusa Support Team I installed the 6.20 Alpha and run again the printing without any issue.
I need to keep running tests and see if this fix it. But definitively something is wrong, and i think what MalikDrako share would be interesting to try. Heat could be the problem.
I suggest Development at lest to sent an alarm if the extruder stop working on order to take actions...
RE: Xl extruder stops
Hi guys!
After a few tests and attempts, I haven't become much wiser.
BUT what I did: Unplugged and plugged in all cables from the Nextruder. Loosened the cover of the planetary gear and tightened it really lightly (with 2 fingers).
My guess here was too much friction and therefore overheating. The extruder motor cannot have a heat problem, otherwise it will lose steps and not fail completely. Another suspicion was the buddy board at the back of the printer. Because I could reset the extruder when I park the tool in the dock and picked it up again. But then the LCD display froze sometimes for a longer time or for a shorter time. I now have a fan mod on the back of the Buddy Board cover.
Here are a few temps. before and after installation. Ambient temp. 19°C
Before:
Heatbreak: 36°C
Temp. Board: 77°C
MCU Temp.: 63°C
Dwarf Board: 40°C
Dwarf MCU: 34°C
Bed MCU: 40°C
With Fan:
Heatbreak: 36°C
Temp. Board: 53 °C
MCU Temp.: 41°C
Dwarf Board: 40°C
Dwarf MCU: 34°C
Bed MCU: 40°C
Now i finished two 9h prints with no interruptions.
I will test this further.
I also reported the error to my Prusa support. Maybe he'll give you an idea too
RE: Xl extruder stops
The question is: Why we are having this issues and some other printers are just working well !
I have a friend running almost everyday with multi tool heads, no changes on the covers or extra fans and no problems at all, basically a Stock Machine !
I upgrade up to 6.2 Alpha and nos change, so is not a Firmware problem... I'm thinking in a bad control board.
Let see what support recommend !
RE: Xl extruder stops
If you suspect misalignment in the Nextruder they have instructions on how to align it. Maybe check into that. It involves possibly the alignment tool and at a minimum having the cover loose and running a calibration step on the printer before tightening the screws.
RE: Xl extruder stops
The question is: Why we are having this issues and some other printers are just working well !
I have a friend running almost everyday with multi tool heads, no changes on the covers or extra fans and no problems at all, basically a Stock Machine !
I upgrade up to 6.2 Alpha and nos change, so is not a Firmware problem... I'm thinking in a bad control board.
Let see what support recommend !
I have to tell you honestly, I have no idea.
The temperature problems on the Buddy Board and the MCU are no secret. With a FW update, Prusa has distributed/improved the handling of the temperatures but this still occurs. Who packs such components in a closed housing? Not even ventilation slots were made to exchange heat thermally.
But I'm completely with you. Improving or stabilizing a printer in this price range with mods is a bit disappointing.
If you suspect misalignment in the Nextruder they have instructions on how to align it. Maybe check into that. It involves possibly the alignment tool and at a minimum having the cover loose and running a calibration step on the printer before tightening the screws.
It was just a thought that perhaps the cover of the planetary gear was tightened too tightly and therefore there was higher friction resistance. This then leads to a higher load on the extruder motor and generates heat. That's my thought. I didn't immediately suspect a poorly assembled gearbox.
The idea of suspecting an error in this direction is interesting.
If the error occurs again and I don't have an answer from support yet, I will also look more closely in this direction. Maybe I'll find something.
RE: Xl extruder stops
The screws on the cover should be able to be tight. They are on mine.
RE: Xl extruder stops
There's finally news!
I received an answer from Prusa Support today. The error with the extruder failure is known and they are still collecting data. The fact is, the error is FW related! A part has already been fixed in FW 6.2.0 alpha but it still doesn't work for everyone.
The error should be fixed in FW 6.2.0. this FW is nearing completion.
So any suspicions I expressed are irrelevant. The fan mod only gives me cooler temperatures on the board and the MCU but doesn't fix the error either.
We have to wait for FW 6.2.0.
RE: Xl extruder stops
Great news Gik!
Hope this happens soon.
RE: Xl extruder stops
I have read what everyone is saying on this forum and have been dealing with this issue since I received my XL in April '24.
Problem: Extrusion gear stops, filament is not pushed through and thus printer continues to print (as if it is still extruding) but it is not. My printer is in a clean temperature-controlled environment. I have had hundreds of successful prints throughout these four months but after a string of good prints the same issue will always come back, no extrusion. I then usually check the extruder unplug and replug some chords and sometimes that will fix the issue for a while but ultimately the same issue will come back.
Troubleshooting (all to no avail):
- taken parts off of the extruder and reassembled hoping maybe it was a connection issue. worked for maybe a few prints at a time then ultimately same issue.
- Prusa sent me a new dwarf board and a new gear motor both did not resolve the issue (not hardware).
- Then they said to turn off Prusa Connect (print via USB) and turn off phase stepping. Did both individually and in tandem.
- They then sent me an Alpha version of the new firmware mentioned (6.2.0), also did not work.
Asked Prusa support if I could just get a new one and send mine back but they pushed back saying that since mine is the semi assembled (the one people suggested we get to understand how it is all put together) there is too much liability due to incorrect assembly... have been working with support (which have been responsive and kind) but I feel that they are running out of troubleshooting options.
for me, I dont think the issue is solely heat induced. I have printed it in cold ambient temperatures and hot (I print ASA so I prefer 95F). I personally think this is an electronic issue. Will report back on any more troubleshooting successes/failures.
RE: Xl extruder stops
I agree with you…. Definitively is an electronic issue.
Last Thursday I ran a new test.
1) star a 40 min print, after 5 min the extruder stop.
2) I pause the printing and wait 20 min to cold down
3) Restar the printing and the extruded still not workin, so is not a heating problem.
4) With the machine running I shout down the machine and turn it on again immediately, the recovery printing asked if I want to continue, I agreed and the extruded start working.
So, basically the restart helps to restart the extruder… then after some minutes stop again.
something on the main board is not working well.
They will send me dwarf board and motor, but i think will not fix the problem.
RE: Xl extruder stops
Hello folks!
A small update. I have now had many successful prints with PLA, TPU, PETG and failed again in 2 days due to extruder failure. It all started after the tenth start of a TPU print. Same bgcode, successful ten times and then suddenly the extruder failed earlier and earlier. I can't make it past layer 2 anymore. TPU and PLA, PLA Silk. What do I have or what has changed in general? Nothing. I'm still on FW. 6.1.3 and Prusa Slicer is also the latest version. I now also have these failures on the TH1 extruder.
Strangely enough, so far I can print PETG or PCTG without any failures from the extruder.
Nothing changes the problem no matter what I try to change or change in the slicer.
It's hair-tearing
Does anyone have any positive news about the problem?
RE: Xl extruder stops
Hello Gik,
I just received and installed a new Dwarf board and new motor. I already ran two small prints without problems. Tomorrow will try a long print and see what happens.
Will keep you posted,
Saludos
RE: Xl extruder stops
I'm having the same issues. This printer has not run consistently since we got it a few months back. One issue after another. This is not a hobby for us but a vital part of what we do and we are now way behind. I'm under the distinct impression that customer lack of support is blind guessing. I guess I can try 6.2.0 nothing to lose. the extruder will no longer even run to load filament.
RE: Xl extruder stops
RE: Xl extruder stops
Same here SailorEric, we are running a business, and now we need to deal with this, and i´m really frustrated....
We are running with 6.2.0 Alpha 2. Support sent me a motor and Dwarf board, and we have been running well since yesterday. I need to run several more tests in order to confirm and put it back on production again.
We use ESD filaments and are not cheap,
RE: Xl extruder stops
Anyone figure this out?
I am seeing the exact same problem on T1. I assumed it was related to heat with the PETG stock idler arm assembly. I purchased some PCCF and printed new a new idler arm assembly using T2. I installed the pccf idler arm assembly on T1. Then was printing the assembly for the other extuders using t1. The extruder stopped extruding again. So I paused the print and did a filament change. The gear would not turn to extract the filament. So I pull the idler arm down to see what was going on. The gear doesn't turn at all. I got the filament out by pulling it out with the idler arm down. Then the change filament process continued. So inserted the filament in and it wouldn't load. So I pulled the idler arm down again and watched as I went through the load process. The gear wasn't turning at all. So I gave up and turn off the printer. I restarted it and did a purge filament on t1 and it purged. The gears are turning fine. It appears that there is some sort of software issue here not mechanical. So the question is why does the extruder gears stop turning after a 10 to 15 layers?
I spent too much time wasted chasing the heat issue with the idler arms.
Any help / advice would be greatly appreciated.
Carmine