RE: Xl extruder stops
Just an Update in this topic - Prusa Service told me that the new dwarf connector they published on printables is fixing the problem to some extend. The Red Screens that keep occuring could come from already damaged cables (from the old connector). They have sent me new split cables. I will test and report back - if the problem is now finally solved.
RE: Xl extruder stops
Here is the 3mf file I used to create the five strain-reliefs.
It was a test case for me to see if this would work and it worked so well I have not had time to go back to refine it.
Here is what I did.
1) Removed all cables and sprayed both the male and female parts of the connectors with contact cleaner
2)Install the the cables and bend them down and through the V-Groove in the tool head case.
3)Start the install the strain relief part (It is a very tight fit so it may take a little bit of pressing)
4) Now I put pressure on the cable in the downward and outward directions. I want to create a pressure on the connector to keep it from doing any movement while the printer is in motion.
5) I also slide the cable covering sleeve up the cable a couple of inches so that when I press the strain-relief all the way down it is pressing on the cables not the sleeve.
6) Press the strain-relief all the way down for a tight fit againist the connector. The strain-relief will still up a little like in the pictures so that you can grab it later on if you have to remove it.
I have reached over 250 hrs of using all five heads with any red screens.
Good Luck.
RE: Xl extruder stops
Hi, thank you very much - I really appreciate it - I got new cables from Prusa.
I will use the new cables and your StrainRelief - I will report back to you, what my experience is with oyur solution.
Thanks for sharing- Cheers Peter
RE: Xl extruder stops
Printed and installed Prusa's solution. Ran fine for a month or so. Red screen of death today. I have lost faith in Prusa. six months of issues now. Unacceptable. Looking for a solutiom.
RE:
I know how you feel, I've been there. Month ago I installed fans for the dwarf boards to solve the problem because at that time I thought that heat would be the cause of the stopping extruders. The printer has been working since, but now I believe the issue was fixed by disconnecting and reconnecting the connectors on both the motherboard and the dwarf board. While this isn’t a perfect solution—since the connectors might disconnect again in the future—so far, it’s holding up (knock on wood).
Another possible fix was removing the motherboard’s back cover entirely, as I had been getting overheating error messages.
If you’re interested, you can find my earlier post in this discussion detailing the modifications I made. Even though I do not think that the fans solved the general problem, I now can have higher temperatures in my casing without trouble. So it was not completely for nothing.
I hope it might help.
RE:
Already running a cooling fan on the mother board if I want it (switched) don't notice a difference with or without it. I'm sorry but this one lands square in Prusa's lap. We've been trying their suggestions to fix things for coming up on seven months now. This is not a cheap hobby machine and I expect them to know what the source of a problem is and how to fix it! So far we've replaced the mother board , which was a problem. Both printer heads which solved nothing. Printed and installed their solution which worked for a bit. Do they even know what the issue is? Do they have a clue how to fix it? It's costing me money, time and reputation. Do they even care? I don't think so any more.....
We'll see what their latest solution is. But my patience is run out.
RE: Xl extruder stops
Hello.SailorEric.
I have been suffering from a malfunction for a long time.As the title of this thread says, the symptom is the extruder gear stopping.
There are two patterns: (1) immediate stop when the fan starts, and (2) in the latter half of a long print, the gear operation becomes unstable and the output volume drops significantly.
Over the past three months, the solutions presented by the help desk are as follows.
(1) Replacement of the dwarf board
(2) Replacement with the latest dwarf-cover-connector
(3) Replacement with the latest dwarf-cover-base
(4) Replacement of the cable (twice!!)
However, it was not a fundamental solution, and the problem did not occur for a certain period of time immediately after making some changes, but it would reoccur after about 0.5 to 15 hours of operation.
Since it seemed that the problem would not be solved even if I relied on the help desk, I decided to seriously think about a solution, and a hint I got was that the help desk was very concerned about the condition of the cable, including the connector cover.
From my point of view, I didn't think that this cable was the cause, but I thought that there might be room for improvement in the connector contact.
So (and this is the main point) I tried cleaning the connector using a contact cleaner I had on hand.
The product in the photo is "DeoxIT GOLD G5".
I used this to clean both the connectors on the dwarf board side and the cable side, then reassembled and tried it.
The LED flickering, which had been bothering me until then, disappeared. This is a big change.
As a printout, I have been operating 5 parts for a total of about 40 hours so far, but the symptom has not occurred.
I am not sure whether this is a fundamental solution, but given the change in the LED, I feel that it would be beneficial to incorporate contact cleaning into regular maintenance items.
If this seems to help improve SailorEric's symptoms, please try it.
(Please note that the English may be strange because I am using Google Translate)
RE: Xl extruder stops
Interesting that my attempts are very similar from replacing the printheads, printing and installing the dwarf cable cover, etc. Last time I also used DeOxit professional. It semes to help, at least for a while. Now another new problem, I swear this printer can develop new issues as fast as you fix the previous ones. Currently getting a Blue screen of death on startup. They said a stepped sine wave UPS could cause it. I'm running a pure sine UPS that was fine for months. So plugged it strait in to wall power and it's still there. Also tried updating firmware. It's on the UPS but the printer doesn't see it. A very unhappy owner.
RE: Xl extruder stops
ThanksThanks for reply.
I see you've already tried the contact restorer.
I apologize for my assumption.
As you mentioned, if the improvement is only limited, I will have to take further measures.
I'm getting a bit tired of this cycle of hope and disappointment.
The cycle of hope and disappointment is starting to wear me out a little.
I hope the day will come when your machine operates normally.
RE: Xl extruder stops
First I run into the petg part deformation problems with the extruder (which was one reason for stopping extruding without error or warning). But thanks to Prusa support it could be fixed (after spending countless hours to figure out the problem).
Now it appears that I am also getting the red screen of death and have a hard time printing my multi color projects anymore as I get this error message now too. I wonder - why isn't there at least a power outage contuation possibility? That would at least ease this pain.
I will give the contact cleaning a try. Thanks for the tip! Sigh.
RE: Xl extruder stops
Now getting the endless blue screen of death on startup. This is pathetic for the money spent. Support is now taking a week or more to respond and not really getting any answers. I have managed ANOTHER work around and now just never power off the printer. I am suspicious that the mother board, #2, may have also failed.
RE: Xl extruder stops
OK, I'm going to take what I can. Was able to trick the printer into accepting new firmware with a USB and pushing the button rapidly during boot up. That has fixed blue screen of death. As far as the extruder stopping during printing I may have to take apart the cable mount (the latest design) every few months. Clean with DeOxit and reassemble and call it maintenance. After 7 months of problems I expect this is going to be as good as it gets. Am I happy? Not particularly. This mess has cost us dearly but will hope it all keeps working going forward.
RE: Xl extruder stops
Hello everyone,
The other day, I reported that applying contact restorer to the dwarf board connector had yielded positive results. However, the situation has changed, so I wanted to provide an update.
At the time of my previous report, although the output took about five hours, we were printing relatively thin objects (1 to 1.5 cm thick) and did not encounter any issues for around 20 hours.However, after we started printing objects with a thickness exceeding 3 cm, continuous warning screens began to appear.
The flickering of the LED on the extruder has indeed stopped after applying the contact restorer, so I did notice some improvement. However, it seems that the cause is something else..I will report this to the help desk again and wait for their feedback.
I apologize to everyone who had high expectations.
RE: Xl extruder stops
I now had my first rsod (red screen of death) midprint after several month of blissful printing without problems after the modifacations I made. So everything was for nothing. Has anyone solved the problem permanently?
RE: Paradas del extrusor Xl
I'm having the exact same problem. It started with one extruder and then moved on to the second.
The motor stalls as if it's running out of power. All the PETG parts were replaced when assembling the cover. It ran for hundreds of hours before the failure started, but after that, I haven't been able to print properly again.
I've also done the same tests you describe, and it's exactly the same.
If I loosen the pressure screws almost to the maximum (almost no pressure on the material and the Nextruder), the filament loads, but it causes problems unloading and doesn't print correctly. It has intermittent extrusion errors.If I adjust the pressure screws as indicated in the manual (the same position that worked before and as I have it on other Nextruders running at 100%), the filament doesn't even load.
I've been chatting with PRUSA for over 60 hours (we've had the problem for 30 days now), and now they're asking me to return both complete heads, but I really doubt that's part of the solution. The underlying problem is the lack of power from the motor, which doesn't have enough torque to pull the filament.
Hello,
After over 300 hours of printing without any issues, I’m encountering a serious problem with my Prusa XL.
Firmware 6.1.3
VIDEO 1 : https://drive.google.com/file/d/1QJHpvAfExyEbboPiqk1p0-9A5YVP6PWa/view?usp=sharing
VIDEO 2 : https://drive.google.com/file/d/1D5FIj3R__p3ETSZupOnn_zWTxflZ7sQ2/view?usp=sharing
The extruder motor is locking up, causing extrusion to stop. Initially, I thought it was a clogged nozzle, but even after replacing it, the problem persists.
I confirmed the blockage by running the XL without the Nextruder cover. I invite you to watch the two videos where the problem occurs as soon as the filament loading procedure begins.
I’ve performed the following tests :
• Full reset
• Replaced the idler parts
• Adjusted the spring tension (both + and -)
• Tried different filaments
• Installed new nozzles
• Checked temperature with an external probe: OK
• Disassembled / degreased / reassembled / lubricated the Nextruder (using the PG-assembly-adapter)
• Extrusion by manually pushing filament with the idler open: OK
• Disconnected all Nextruder connectors, cleaned the connections
You’ll notice that as soon as the “pressure” on the filament is released, either by opening the idler and holding it by hand or by pressing the springs, the motor starts again.
Do you think is the same issue as this topic ? I open a ticket on prusa support, i'm waiting for the return.
Any idea ?
Charles.
RE: Xl extruder stops
I used the solution provided by Prusa and it's been working great for the last 4 prints that are 6-7 hours long. Here's the link again for those who don't want to search the whole thread again.
https://help.prusa3d.com/guide/how-to-replace-the-main-cable-connector-cover-xl_831370
Before you begin, you have to download and print 2 parts per extruder (plus 1 jig that only needs to be printed once). And you need to buy (per extruder):
- 2 M3 DIN 562 square nuts
- 2 M3x10 bolts
You must salvage the existing 2 M3 DIN 562 square nuts and 2 M3x6 bolts, and another single nut from the parts you remove.
I didn't have the extra metal nuts and bolts on hand so I cannibalized another extruder I hardly use. So for my first try to fix it I used 2 M3x6 bolts in place of the 2 M3x10 bolts and they were a little too short, I had to carve out enough space on the part so the bolt would go deep enough to secure the assembly. I ordered the needed nuts and bolts and will fix my 5 extruders properly once I get them.
Anyway I really appreciate all the contributors to this thread and those who brought this to the attention of Prusa, and all your patience and frustration through the process. I'll keep this thread updated if anything changes for me.
RE: Xl extruder stops
For anyone who hasn't seen yet, Prusa released a RC firmware version that should fix extruder errors for parked tools https://github.com/prusa3d/Prusa-Firmware-Buddy/releases
I also installed Prusa's connector solution yesterday. I've only done a few 1-3h single extruder prints so far but no stops, and I did notice the LED flickering is gone.
RE: Xl extruder stops
Hi there. We're having this issue with our printer at the company I work for and I have a couple of questions.
1) Has anyone tried replacing the motor with something that has higher torque?
2) Has anyone tried to improve/increase the voltage supply to the extruder motor?