Prusa XL stops mid print with no errors / warnings
I finished installing my Prusa XL and printed the included Batarang GCODE without issue. I sliced a print of one of my models and when I went to print it, it said that this included a new firmware update, and that my printer would update. It did. Since that, I have attempted (3) different prints. Each one gets about 3-5 hours into the job (each is 10-15 hours depending on the print), and then simply stops. The progress bar sits at 36% or 29% or similar, and simply waits forever. I have verified that the GCODE files are completely intact. I have opened them in GCODE viewer and verified them to be complete. I have also performed bytewise-comparisons to the sliced files on my laptop with those on the USB drive. So far, I am using the USB drive that was included with the printer.
Has anyone else experienced this and what is the solution? I cannot have accept an XL printer that is not capable of printing a job half the size that my M3 can handle with ease. WTAF?!?!
RE: Prusa XL stops mid print with no errors / warnings
Do you have the 5.1 Alpha-2 firmware installed? If you do, try to pause the print when it stops/freezes. Most likely it will say it lost contact with the USB stick. Unplug, replug and resume print. And, a snip of the blob created on the print before it bangs into it.
If you have the 4.7.2 I had the same thing happening to me, but I just cancelled the print. Maybe I should just have tried to pause or unplug and replug the USB stick, and then resume print, but I kind of got stressed out so I didn't really think it thru.
After upgrading to 5.1 Alpha-2 and then downgrading to 4.7.2 again (due to instability when I didn't have time for that,) I haven't experienced this.
Also, another thought; try to reformat your USB-stick. FAT32 is the way to go. It might help. Seems to me this problem has to do with the USB-connection getting stuck or lost.
Good luck.
RE: Prusa XL stops mid print with no errors / warnings
I've also had this problem with both the 5.1 alpha2 and 4.7.2 firmware, and multiple USB drives. The pause/re-plug USB/resume works in both firmwares, BUT you may lose a layer on your print.
And interesting note, I can print the model just fine as a single color print. But it fails every time, at random points, when I print it as a 5 color print.
RE: Prusa XL stops mid print with no errors / warnings
Interesting. I haven't had any problems after downgrading, but it sounds like I've just been lucky. Then again, the only long prints I've done are single colour prints.
Or maybe a freshly formatted USB-drive have, for the time being, helped me .
RE: Prusa XL stops mid print with no errors / warnings
I upgraded to firmware v5.1.0alpha and it made it through the night without issue. If the issue is resolved, I will not leave any more comments, and will presume that v4.7.2 was the problem.
RE: Prusa XL stops mid print with no errors / warnings
I had a false moment of hope. It made it through ONE 16 hour print with v5.1.0Alpha. Then it started flaking out again. Sometimes PAUSE/RESUME will work. Most times, I have to physically pull the USB stick out and re-insert it.
Once I babystep it through the rest of this print, I will try downgrading the firmware AND re-format the USB.
RE:
Just had the USB drive (Prusa one that came with machine) error on a 8h print. 5 objects, at least one is done for. I'm hoping it completes and the rest are ok. The longer I live with this printer the less I trust it. I cannot afford to run a development machine for Prusa. Contemplating returning it or selling.
EDIT: Thought I'd use the cancel objects to cancel the failed part. The options is greyed out even though I'm running the alpha fw and sliced on the 2.7 beta PS.
RE: Prusa XL stops mid print with no errors / warnings
FYI: I had this issue on multiple attempts for the same print. Each stopped at a different amount of progress. I tried a full power off (hard off at the switch, not a reset) and it did recover after power was restored but the print output was horrible. It was suggested to me by support to disable Prusa Link to address the problem. So far this has worked for me.
RE: Prusa XL stops mid print with no errors / warnings
This is the response I received from Prusa Support while troubleshooting the freezing-mid-print error running off USB:
"USB drives that are too large can cause issues, so try to use the ones below 32 Gb. Make sure to not have too many files in the USB. And format the USB to Fat32 (more about it here: https://help.prusa3d.com/article/sd-cards-and-usb-drives_112291 )"
RE: Prusa XL stops mid print with no errors / warnings
I've finally come across this error where the printer just pauses for seemingly no reason and the LCD controls are more or less frozen.
As a workaround I just manually force a power panic by pulling the XL's plug from the surge protector for a second then plugging it back in. The XL will rehome X and Y then get back to printing. Worked all four times I've tried so far.
XL-5T, MK3S MMU3 || GUIDE: How to print with multiple-nozzlesizes do read updated replies || PrusaSlicer Fork with multi-nozzlesize freedom || How Feasible is Printing PETG for PLA supports on XL very
RE: Prusa XL stops mid print with no errors / warnings
I have had this issue to and have tried various troubleshooting steps, nothing works:
Here is what I've done based on suggestions in this and other forums:
1. Reformated the thumbdrive
2. Replaced the thumb drive (twice) with better ones
3. Added a Tripplite UPS
4. Pulled the thumbdrive and attached an octoprint device
5. Updated to newest firmware (6.0)
Moving to octoprint reduced the failures, but not by much. I am convinced this isn't a USB issue.
The scary thing about this failure is that when it freezes-up, the hot-end stays heated at the fillament temperature until I reboot the printer. In some cases I don't realize that the printer has locked-up until hours later. So, now it is a safety issue.
I also believe that this behavior only happens on long multicolor prints. Again, no logs. It just freezes mid-print.
I'm updateing you, not for an answer, but to warn you to be careful.
Nothing from Prusa yet. Will update here if issue gets resolve
Any other suggestions are appreciated.
RE: Prusa XL stops mid print with no errors / warnings
I had this happen today at the 48% point of a 3 day print. The printer just stopped at what seemed to be the end of a layer before color change. I noticed the nozzle temp was dropping and Prusa Connect said it was cooling to 70C from 250C. I set it back to 250C and it seemed to heat back up, but no printing resumed. I pressed Pause on the printer and it just seemed to stick at "Pausing...". I couldn't resume form Prusa Connect. The display responded in sound to my clicking, dial moving, but nothing happened. I found your post, pulled the plug and plugged back in. The print job resumed! However, I now have a slight layer shift. 🙁 Pretty disappointing that this issue is not unique.
RE:
Just had the same happen to me. 4 hour print with 4 colors .
It just stopped at 33%, halfway a layer, with no errors/messages and started "blobbing".
The display/controls were still responding, so I "paused" the print, which did nothing for about 2 minutes and then it suddenly parked.
So I cut the blob away as best as I could and resumed, and it just started again.
Weird stuff this.
5 tools, firmware 6.0.0+14794 here.
XL (5T) / MK4 / MK3S+-MMU3 / MK3S / MK2.5S-MMU2S / Mini / SL1S
RE: Prusa XL stops mid print with no errors / warnings
I have registered this as an official bug at the Prusa github. Please go there and upvote so the devs know how many people this is affecting:
https://github.com/prusa3d/Prusa-Firmware-Buddy/issues/3983
RE: Prusa XL stops mid print with no errors / warnings
Hello everyone! First time posting on this forum. I had this happen to me yesterday. I had a look at the telemetry and saw that for some strange reason the second, non active nozzle was hot during the entire print. This was a single nozzle print. I ran the same g-code again (but with one of the objects cancel on start to save filament) and this time only the active nozzle was hot, leading me to believe that it was not a problem with the g-code.
Have anyone else checked the telemetry after a failed print and seen this?
