RE: Xl extruder stops
Well, my two head printer has been a brick for about a month now. It was pretty quirky from the get go with needing work arounds to get it to boot up. Then we developed he issue of just stopping extrusion on both heads. Then the initial boot up just completely crashed. No work arounds helped. They had to admit that the main board was dead and I'm getting to complete extruders and the main board. It has languished in customs for weeks as it's Christmas. Now they have released it and I should have it in a few days. I have to say live chat has been very problematic. Keep timing out and starting anew with the next person who wants to reinvent the wheel all over again. Email is slow, automatic four days every single time. They are way behind the curve on the XL I think. I lost track of the number of times I've reset and gone through all the steps. They seem to have a problem or set of problems they don't know how to address. It has cost us dearly in time, materials, labor and reputation. They don't seem to care. I hope that this fixes things because I've come to a point of washing my hands of Prusa if it doesn't.
RE: Xl extruder stops
However, yes, good point the extruder will re-enable itself on a re-dock.
Yesterday I tried swapping to T5, the one extruder that still works and that I've been using for support interfaces, and support interfaces on another tool. I added a small full height tower in the support material to ensure the tool was always changed. Despite this, the support tool stopped working after a few layers and never recovered. Fortunately it didn't ruin the print, but it does mean T1-4 are pretty much unusable.
RE:
However, yes, good point the extruder will re-enable itself on a re-dock.
Yesterday I tried swapping to T5, the one extruder that still works and that I've been using for support interfaces, and support interfaces on another tool. I added a small full height tower in the support material to ensure the tool was always changed. Despite this, the support tool stopped working after a few layers and never recovered. Fortunately it didn't ruin the print, but it does mean T1-4 are pretty much unusable.
A few questions:
1. Are you reassigning the filament before you print using the XL screen? Meaning, if PrusaSlicer was set to use T2 but you changed to T1 at the printer.
2. I pulled the cable from the tool when I had it picked (to the front) which faulted the printer. I then reseated the cable and made sure all pins were intact. I restarted the printer. The next day I ran a 7hr print just using T1 and it never messed up. Can you try the same sequence I did with the cable?
I couldn't get a print to last longer than an hour like 5 times in a row before the cable reseat. I'm curious.
RE: Xl extruder stops
A few questions:
1. Are you reassigning the filament before you print using the XL screen? Meaning, if PrusaSlicer was set to use T2 but you changed to T1 at the printer.
2. I pulled the cable from the tool when I had it picked (to the front) which faulted the printer. I then reseated the cable and made sure all pins were intact. I restarted the printer. The next day I ran a 7hr print just using T1 and it never messed up. Can you try the same sequence I did with the cable?
1. I generally leave it as the default in PrusaSlicer, then reassign to whichever tool I'm using
2. I won't be in the office with the printer until after the new year, but I can have a coworker try this tomorrow
RE: Xl extruder stops
We have this same issue and Prusa refused to provide any replacement parts, FW fixes, or refunds.
The T1 extruder motor stops spinning mid-print always and doesn't work (ignoring purge instruction and anything else that would move it) until it gets reset.
This printer was a horrible purchase based on the support experience.
RE: Xl extruder stops
I contacted support again today for an update and was told there is no current fix for this issue but would be expected in a future firmware update.
I've sent a polite email to Prusa conveying my disappointment.
I have also suggested that unless they can fix the XL to perform as advertised, then their responsibility to the customer is the offer of a replacement or a return/refund. It really isn't OK in my opinion that customers are expected to tolerate that their flagship printer, still under warranty, remains both broken and "unfixable" without providing the customer with an alternative solution.
RE: Xl extruder stops
Hi guys, little update from me.
I tried the live chat once and asked there about the extruder failure. The answer was that they are working hard on it.
The error has been classified as a top priority.
They gave me a test solution. I should remove the PETG Dwarf Cover Connector from the Cable Splitter - Dwarf. Only on the Nextruder side.
A print that has always failed due to its size has been running smoothly for hours. I don't want to promise anything but I'll stick with it.
This error solution is completely illogical but should help. Clamping the unshielded cables together could cause the extruder problem. That would be the only explanation for me why you should remove the PETG part.
I hope this helps until there is a final solution.
RE: Xl extruder stops
Hi guys, little update from me.
I tried the live chat once and asked there about the extruder failure. The answer was that they are working hard on it.
The error has been classified as a top priority.They gave me a test solution. I should remove the PETG Dwarf Cover Connector from the Cable Splitter - Dwarf. Only on the Nextruder side.
A print that has always failed due to its size has been running smoothly for hours. I don't want to promise anything but I'll stick with it.
This error solution is completely illogical but should help. Clamping the unshielded cables together could cause the extruder problem. That would be the only explanation for me why you should remove the PETG part.I hope this helps until there is a final solution.
This has been my theory all along. It's the cable/connector losing connection. When it goes to dock it's pulling hard to make connection, being docked resets the communication to Dwarf.
I mentioned earlier I found my connector not funny seated in the Dwarf and my next print was almost 7 hours non stop.
The crimp could be bad to pin, the pin could have some side to side play that's getting worse as we all gain hours and toolchanges with wear and tear.
T1 was my problem and it has 3x the filament and changes vs the rest.
I am hoping to do more testing in the next day or so.
RE: Xl extruder stops
Hello.
In response to my question to the help desk, I was also suggested to remove the PETG DWARF COVER CONNECTOR and test it.
I tried it right away, and the problem that the extruder gear stops (1) after the fan starts, or (2) during a long print of about 3 hours, stopped.
I have only been able to test it with small items like cookies, but I would like to try items that last 20 hours from now.
I hope this solution will be a BIG Christmas present!
After removing the connector cover, the cable is exposed, so I wrapped it with TESA fabric tape as a temporary measure.
RE: Xl extruder stops
Hi guys, little update from me.
I tried the live chat once and asked there about the extruder failure. The answer was that they are working hard on it.
The error has been classified as a top priority.They gave me a test solution. I should remove the PETG Dwarf Cover Connector from the Cable Splitter - Dwarf. Only on the Nextruder side.
A print that has always failed due to its size has been running smoothly for hours. I don't want to promise anything but I'll stick with it.
This error solution is completely illogical but should help. Clamping the unshielded cables together could cause the extruder problem. That would be the only explanation for me why you should remove the PETG part.I hope this helps until there is a final solution.
This has been my theory all along. It's the cable/connector losing connection. When it goes to dock it's pulling hard to make connection, being docked resets the communication to Dwarf.
I mentioned earlier I found my connector not funny seated in the Dwarf and my next print was almost 7 hours non stop.
The crimp could be bad to pin, the pin could have some side to side play that's getting worse as we all gain hours and toolchanges with wear and tear.
T1 was my problem and it has 3x the filament and changes vs the rest.
I am hoping to do more testing in the next day or so.
Hopefully I don't cause a problem now, I just replaced all of the parts of the Nextruder with PCCF, including that connector cover. I had to modify the parts in cad because they were too small. I suspect that they didn't account for the part shrinkage of the PCCF vs. PETG. I had to modify the Nextruder gear cover as well because the plastic bushing would not fit. I measured the PETG one and compared it to the PCCF one and then modified the STL to compensate for the additional shrinkage. After 2 tries it fit perfect.
Technically I didn't need to replace that with PCCF as it's not structural, I just wanted everything PCCF.
I guess we'll see if I cause a problem now as I have not had the extruder stop on me and I've been messing with the cables now.
RE: Xl extruder stops
It definitely seems to be a contact problem of some kind. The problem with stopping and flickering (almost completely) also disappeared for me after reconnecting the plug. I also left out the print part for the time being. I've had this before as the problem went away after a reconnect but it came back after a while, which leads me to the conclusion that the movement of the print head is somehow causing the contacts/connection to deteriorate.
RE: Xl extruder stops
I have to do mine as well. Did you just scale them up? If so, how much?
Hi guys, little update from me.
I tried the live chat once and asked there about the extruder failure. The answer was that they are working hard on it.
The error has been classified as a top priority.They gave me a test solution. I should remove the PETG Dwarf Cover Connector from the Cable Splitter - Dwarf. Only on the Nextruder side.
A print that has always failed due to its size has been running smoothly for hours. I don't want to promise anything but I'll stick with it.
This error solution is completely illogical but should help. Clamping the unshielded cables together could cause the extruder problem. That would be the only explanation for me why you should remove the PETG part.I hope this helps until there is a final solution.
This has been my theory all along. It's the cable/connector losing connection. When it goes to dock it's pulling hard to make connection, being docked resets the communication to Dwarf.
I mentioned earlier I found my connector not funny seated in the Dwarf and my next print was almost 7 hours non stop.
The crimp could be bad to pin, the pin could have some side to side play that's getting worse as we all gain hours and toolchanges with wear and tear.
T1 was my problem and it has 3x the filament and changes vs the rest.
I am hoping to do more testing in the next day or so.
Hopefully I don't cause a problem now, I just replaced all of the parts of the Nextruder with PCCF, including that connector cover. I had to modify the parts in cad because they were too small. I suspect that they didn't account for the part shrinkage of the PCCF vs. PETG. I had to modify the Nextruder gear cover as well because the plastic bushing would not fit. I measured the PETG one and compared it to the PCCF one and then modified the STL to compensate for the additional shrinkage. After 2 tries it fit perfect.
Technically I didn't need to replace that with PCCF as it's not structural, I just wanted everything PCCF.
I guess we'll see if I cause a problem now as I have not had the extruder stop on me and I've been messing with the cables now.
RE:
I have to do mine as well. Did you just scale them up? If so, how much?
Hopefully I don't cause a problem now, I just replaced all of the parts of the Nextruder with PCCF, including that connector cover. I had to modify the parts in cad because they were too small. I suspect that they didn't account for the part shrinkage of the PCCF vs. PETG. I had to modify the Nextruder gear cover as well because the plastic bushing would not fit. I measured the PETG one and compared it to the PCCF one and then modified the STL to compensate for the additional shrinkage. After 2 tries it fit perfect.
Technically I didn't need to replace that with PCCF as it's not structural, I just wanted everything PCCF.
I guess we'll see if I cause a problem now as I have not had the extruder stop on me and I've been messing with the cables now.
I did not scale the parts because the other surfaces lined up. I had to modify 2 parts.
The main cover over the gears on the Nextruder because the plastic bushing/spacer that goes inside the cover would not fit. I opened the STL in CAD and cut the opening slightly larger to fit. I'm not near my computer to see the exact amount, but I think I took .1mm off the inner ring and .2mm off the outer ring.
The other part was the plug opening on the dwarf board cover for the main plug. On that I did the same thing and opened it in CAD. I think I had to open that one .1 mm in all directions. Just where the plug fits in.
Note, the official modifications for the XL to put it in their enclosure does not change either of these parts to PCCF. I just did it to make everything PCCF. If you buy the Prusa enclosure they only change the idler door, door latch, part fan coming duct and the belt clamps. So what I did is not necessary. But I had an entire roll of PCCF so I did.
Also if your printer was made after June all of the parts are already PCCF. My printer was a mix of PCCF and PETG.
RE: Xl extruder stops
Thanks for the info. I did not make the June cut off unfortunately.
RE: Xl extruder stops
[It's been printing trouble-free for about 20 hours.」
At the suggestion of @gik and the support desk, I removed the DWARF COVER CONNECTOR, which stopped the phenomenon of the gear stopping during printing.However, it is obvious that without the COVER CONNECTOR, the connectors are overloaded and will cause future contact failures, so I tried a simple measures.
The aim is to reduce the gap between the DWARF COVER CONNECTOR and the opening in the Dwarf Cover Base (to make it almost snug).As a means of achieving this, the outer dimensions of the DWARF COVER CONNECTOR were slightly enlarged.The following file was downloaded and enlarged as shown in the attached image. https://www.printables.com/model/449554-xl-printable-parts/files#preview.file.OP5XL
After enlargement, the DWARF COVER CONNECTOR has almost no gap and is no longer shaky at all in both the X and Y directions.I have since tested the output, for a total of 20 hours and about 3 files, with no trouble.
As an additional measure, try adjusting the tightness of the cable between the DWARF COVER CONNECTOR.As shown in the attached photo, in the preliminary step of wrapping the cable cover, wrap the appropriate tape around the cable to increase its diameter, then put the cable cover over it, clamp it between the DWARF COVER CONNECTOR and tighten the screws.Doing it this way will also reduce the play between the DWARF COVER CONNECTOR and the cable harness, which should reduce the vibration transmitted to the connector even more. (I applied this too)
RE: Xl extruder stops
Well, I am at the point of giving up. New Buddy board and new extruders. At least the printer boots up. But still have random issues. Wheel in extruder stops at second layer. Switched extruders around, I have a two head, now it keeps trying to do a filament change on a single head print. After 6 months of never working correctly and endless tries at the customer support merry go round I may just heave this thing. I'm over the Prusa mystique. I have two uber dependable Mk3S+ machines but this has driven me over the edge. I just spent another pointless day of trying to make it work. Any great ideas?
RE: Xl extruder stops
Well, I am at the point of giving up. New Buddy board and new extruders. At least the printer boots up. But still have random issues. Wheel in extruder stops at second layer. Switched extruders around, I have a two head, now it keeps trying to do a filament change on a single head print. After 6 months of never working correctly and endless tries at the customer support merry go round I may just heave this thing. I'm over the Prusa mystique. I have two uber dependable Mk3S+ machines but this has driven me over the edge. I just spent another pointless day of trying to make it work. Any great ideas?
I'm at a loss, if you've replaced everything I'm finding it hard to believe it's hardware related. I'm skeptical of the firmware being an issue because if it was the problem should be more wide spread. There are plenty of us without issue and I'm sure people here on the forums makes up less than .1% of machines out there.
Did they replace the wire harness?
It also makes no sense that it starts on the 2nd layer. We've got to be missing some key element here.
Hopefully Prusa can figure it out.
RE: Xl extruder stops
Hopefully Prusa can figure it out.
I'm out of patience after 6 months. I'm ready to start pursuing a refund. this has cost us dearly and we should at least recoup some of the money.....
RE: Xl extruder stops
[It's been printing trouble-free for about 20 hours.」
At the suggestion of @gik and the support desk, I removed the DWARF COVER CONNECTOR, which stopped the phenomenon of the gear stopping during printing.However, it is obvious that without the COVER CONNECTOR, the connectors are overloaded and will cause future contact failures, so I tried a simple measures.
The aim is to reduce the gap between the DWARF COVER CONNECTOR and the opening in the Dwarf Cover Base (to make it almost snug).As a means of achieving this, the outer dimensions of the DWARF COVER CONNECTOR were slightly enlarged.The following file was downloaded and enlarged as shown in the attached image. https://www.printables.com/model/449554-xl-printable-parts/files#preview.file.OP5XL
After enlargement, the DWARF COVER CONNECTOR has almost no gap and is no longer shaky at all in both the X and Y directions.I have since tested the output, for a total of 20 hours and about 3 files, with no trouble.
As an additional measure, try adjusting the tightness of the cable between the DWARF COVER CONNECTOR.As shown in the attached photo, in the preliminary step of wrapping the cable cover, wrap the appropriate tape around the cable to increase its diameter, then put the cable cover over it, clamp it between the DWARF COVER CONNECTOR and tighten the screws.Doing it this way will also reduce the play between the DWARF COVER CONNECTOR and the cable harness, which should reduce the vibration transmitted to the connector even more. (I applied this too)
Your problem didn't get better because you left the cover off, but because you put the plug back on. The problem will come back, you'll see. It's just a matter of time. I've been through the whole game 4 times, what you're experiencing now. Believe me.
RE: Xl extruder stops
Hopefully Prusa can figure it out.
I'm out of patience after 6 months. I'm ready to start pursuing a refund. this has cost us dearly and we should at least recoup some of the money.....
I fully agree with them. My next step will be to ask for a complete exchange of the printer. I'm getting, well, fed up.