RE: Xl extruder stops
Email is usually pretty slow. I've not had any issues with live chat, it works actually be good if this fixing your issue was passed on so that Prusa can help other customers that might be having the same issue.
RE: Xl extruder stops
With just the tape to secure the connector body, I have had another 36 hours of problem free printing. I also documented my issue with CS through the chat and has good luck. They offered tips, but no solution. However, I was clear that I was simply documenting the issue.
RE: Xl extruder stops
Short info to everyone.
Today a multi-material print was canceled due to the extruder failure on tool head 2. A few (over 40) printing hours have passed before this problem occurred again. I completely left out the dwarf cover connector on printheads 1 and 2. So all I can say is that the error returns here too.
It's just a temporary solution.
I have to keep waiting for a proper solution from Prusa. So that this fu**** printer finally works.
RE: Xl extruder stops
Short info to everyone.
Today a multi-material print was canceled due to the extruder failure on tool head 2. A few (over 40) printing hours have passed before this problem occurred again. I completely left out the dwarf cover connector on printheads 1 and 2. So all I can say is that the error returns here too.
It's just a temporary solution.
I have to keep waiting for a proper solution from Prusa. So that this fu**** printer finally works.
I honestly can't believe they are telling people to do this. With how much these loops get caught on each other you can't leave that tiny white connector to fend for itself. Its going to lose connection.
All I know is I couldn't get any print to run longer than 90 minutes on tool 1 and now I'm countless hours in with the cable connector secured. I need to do the rest of them.
RE: Xl extruder stops
Short info to everyone.
Today a multi-material print was canceled due to the extruder failure on tool head 2. A few (over 40) printing hours have passed before this problem occurred again. I completely left out the dwarf cover connector on printheads 1 and 2. So all I can say is that the error returns here too.
It's just a temporary solution.
I have to keep waiting for a proper solution from Prusa. So that this fu**** printer finally works.
I honestly can't believe they are telling people to do this. With how much these loops get caught on each other you can't leave that tiny white connector to fend for itself. Its going to lose connection.
All I know is I couldn't get any print to run longer than 90 minutes on tool 1 and now I'm countless hours in with the cable connector secured. I need to do the rest of them.
I agree. I am now on my fourth print with the dwarf cover “mod” and haven’t had a failure. I’ll keep you posted.
RE: Xl extruder stops
I think you guys nailed it. If this works for @sailoreric I think we can call this one solved as far as what the problem is. I really like the set screw fix, but we'll have to wait to see what Prusa comes up with. In the meantime I'd say print up the parts with the set screws and move on.
RE: Xl extruder stops
I've reconfirmed the problem a little, so I'll update you on the current situation.
[Premise]I usually make samples for car interior parts that require heat resistance, so I print with the fan completely stopped for both T1 and T2 at T1: ASA/T2: HiPS, 260℃/10℃ to prevent warping due to thermal contraction.
I bought the XL in June this year, and in early December I purchased and assembled the original enclosure (which was not completely enclosed).
[This month's events]
1. After setting up the enclosure, I was able to print without any problems for about two weeks, but in the middle of this month, I encountered for the first time a phenomenon in which the T1 gear stopped around the 10th layer.
2. When I contacted the help desk, they suggested that I remove the connector cover and test it, so I did, and the problem seemed to be resolved.
3. I thought it was inappropriate to leave the area around the connector unprotected, so I enlarged the original connector cover a little to make it less likely for minute misalignments to occur and try to prevent recurrence.
4. After this, I was able to print for about 90 hours without any problems.
5. I was interested in the relationship between heating inside the enclosure and the output quality of the ASA, so I installed a simple heater inside the machine, maintained it at about 45℃ to 50℃, and tried to output a file that would take 18 hours.
6. After about 10 hours, the operation of the T1 became unstable. Instead of the gears stopping completely as in the initial symptoms, they seemed to stop for a while in the middle, and it was in a spaghetti state.
7. When I printed again under the same conditions, the T2 began to move erratically as if it was not specified in the gcode file, so I thought that this might be a heat problem and stopped the heating test.8. I checked the area around the extruder again and found that the connector cover of the T1 seemed to have a little play, so I printed and attached a dwarf cover with screws and a connector cover made by @fendbass22.9. I printed for about 8 hours with ASA/HiPS in an unheated enclosure and it finished without any problems.
[Current Facts]
1. There are no problems with printing with ASA/HiPS with the fan completely stopped.
2. When printing a file with a fan in ASA, T1 stops at the layer where the fan starts. In some cases, it did not stop. (In both cases, the connector cover is firmly fixed.)
3. When printing with PLA (215℃/60℃, fan operates at high level from the second layer onwards), it strangely finished without any problems. The file was Bency and took about an hour, so I do not know about long-term printing.
[My own imagination based on limited information]
1. The condition of the connector contact is not the whole cause, but it is likely to be a cause in some way.
2 The symptoms seem to be more likely to occur at high temperatures, so it is possible that the performance of some component is reduced due to heat, causing the error.
3. It seems that the error is occurring during high loads when a lot of power is being used. Is the power supply design sufficient?
The plain looking MK3S was definitely a Toyota Corolla or Yaris. But this sleek and cool XL looks like something from Ferrari. Lol
RE: Xl extruder stops
So, I think I have a bit of news. I printed the dwarf connectors after installing the new buddy board and extruders. Printed them in PETG on my MK3S+ since the printer would boot up for a change but still wouldn't print even the simplest of files. They were a tight fit and I had to take a few strokes with a file to make them work. Still wouldn't print. Pulled them completely off and tried a print without any dwarf covers. A single extruder simple 15 minute print worked. First successful print in months. Now, the trick is to figure out what to do for a cover to make this piece of @*&% work.
I think you guys nailed it. If this works for @sailoreric I think we can call this one solved as far as what the problem is. I really like the set screw fix, but we'll have to wait to see what Prusa comes up with. In the meantime I'd say print up the parts with the set screws and move on.
RE: Xl extruder stops
So, I think I have a bit of news. I printed the dwarf connectors after installing the new buddy board and extruders. Printed them in PETG on my MK3S+ since the printer would boot up for a change but still wouldn't print even the simplest of files. They were a tight fit and I had to take a few strokes with a file to make them work. Still wouldn't print. Pulled them completely off and tried a print without any dwarf covers. A single extruder simple 15 minute print worked. First successful print in months. Now, the trick is to figure out what to do for a cover to make this piece of @*&% work.
I think you guys nailed it. If this works for @sailoreric I think we can call this one solved as far as what the problem is. I really like the set screw fix, but we'll have to wait to see what Prusa comes up with. In the meantime I'd say print up the parts with the set screws and move on.
Print up these from @ray123
https://www.printables.com/model/1124941-secure-xl-nextruder-cable-connector-solution/files
RE: Xl extruder stops
Hi all,
TL/DR : @fendbass22 - your solution works - thankyou.
Just adding my experience to his. I own a 5XL, no enclosure, have been running it for about 18 months. I have had the extruder issue as you've described on Toolhead 4 consistently - to the point of predictability now for a couple of months and it ocassionally occurs on Toolhead 5. Not sure if co-incidence with some others here on the forum - but for me, Toolhead 4 is the one where the wiring loom tends to snag on Toolhead 5 due to the way tilts over, so it probably experiences more stress on the dwarf connector than the other toolheads.
To test this, I ran a print with 5 simple cubes, each assigned to a toolhead, using the standard Generic PLA profile, wipe tower on, no other changes. This print predictably failed on Toolhead 4 after the first 2 layers on several print attempts.
I then printed and installed this modified dwarf connector cover and have repeated this print SUCCESSFULLY 7 times in a row.
Feels like this has fixed it for me - such a relief - can't tell you how many failed prints and machine reboots I've been fumbling through in the lead-up to this.
@fendbass22 if this DOES turn out to be a reliable fix, Prusa owe you BIG TIME mate.
RE:
Hello everyone.
Unfortunately, it may be unstable after all.
As I reported recently, I have been repeating tests with the following specifications, but the T1 gear has stopped even under conditions that did not cause any problems before.
Machine:XL2T
With enclosureScrew-on dwarf cover and connector installed
Conditions:
ASA/HiPS250/102℃
Temperature inside enclosure approx. 36℃
Fan completely stopped
gcode file size 9.6MB
printsize 26cm x 26cm
Print time: 18 hours 20 minutes
It had failed several times in the past, and after installing the improved dwarf cover and connector, it succeeded several times, but it started to fail repeatedly.
Examples of failures are as follows.
(1) After about 17 hours, the amount of T1 discharge became unstable (probably temporarily decreased) for some reason, the adhesion became weak, and then it became spaghetti. This happened twice in a row.
(2) The T1 gear stopped at about the third layer. However, unlike before, the amount of filament discharged in the second layer gradually decreased, and eventually the gears stopped. After stopping the print, I tried purging, but the gears on both T1 and T2 did not move.
Previously, I thought that the T1 gear either rotated normally or stopped completely, but it may be in a state where it rotates unstably.
With the same settings as above, it was successful with a relatively small file of 10cm x 10cm, so I think the size of the load may also be a factor.
Either way, I'm a bit tired. I'll keep an eye on everyone's progress and try to recover my strength.GoodLuck!
RE: Xl extruder stops
Hello everyone.
Unfortunately, it may be unstable after all.
As I reported recently, I have been repeating tests with the following specifications, but the T1 gear has stopped even under conditions that did not cause any problems before.
Machine:XL2T
With enclosureScrew-on dwarf cover and connector installed
Conditions:
ASA/HiPS250/102℃
Temperature inside enclosure approx. 36℃
Fan completely stopped
gcode file size 9.6MB
printsize 26cm x 26cm
Print time: 18 hours 20 minutes
It had failed several times in the past, and after installing the improved dwarf cover and connector, it succeeded several times, but it started to fail repeatedly.
Examples of failures are as follows.
(1) After about 17 hours, the amount of T1 discharge became unstable (probably temporarily decreased) for some reason, the adhesion became weak, and then it became spaghetti. This happened twice in a row.
(2) The T1 gear stopped at about the third layer. However, unlike before, the amount of filament discharged in the second layer gradually decreased, and eventually the gears stopped. After stopping the print, I tried purging, but the gears on both T1 and T2 did not move.
Previously, I thought that the T1 gear either rotated normally or stopped completely, but it may be in a state where it rotates unstably.
With the same settings as above, it was successful with a relatively small file of 10cm x 10cm, so I think the size of the load may also be a factor.
Either way, I'm a bit tired. I'll keep an eye on everyone's progress and try to recover my strength.GoodLuck!
Do you have the PCCF idler door and latch?
RE: Xl extruder stops
Hi @BraianThank you for your question.
I have already replaced the idler, swivel and nut with the PCCF parts that were included in the enclosure kit.
So I am very confused.
RE: Xl extruder stops
I've been thinking and I think I'm going to revamp the set screw design and use 2 shcs screws from the top of the plug so that your essentially screwing the plug in. Similar to how old computerplugs connected that had the screws on both sides of the plug. That would eliminate all chances of wiggle.
It would look something like what I drew in red below on both sides of the plug with a m3 screw holding it on.
