very annoying half prints  

Re: very annoying half prints

I had a similar experience. Try checking the extruder pulley. Mine was gunked up with filament dust/residue. Try checking and cleaning this pulley.

Or, are you sure you have not had any filament tangle issues.

Re: very annoying half prints

Hi georg, i have do that i have cleaned the pulleysmy spiral springs are 14 mm long . yesterday i print with fresh opend prusa PET filament. an it stops again..the filament way is the original prusa one.

Re: very annoying half prints

Does the printer stop, or does it just keep going but is not extruding?

If it stopped, is there an error message on the front panel? A thermal runaway (bad thermistor or wiring) could cause this.

If it keeps going thinking it is printing but nothing is coming out, it sounds like a clog in the print head.

You need to be our eyes to help understand what is going on. Do you have OctoPrint by any chance?

Re: very annoying half prints

I do not know whether the printer stops or no more filament comes out of it. Is a very good question. The last print was the rambo1. My extruder is now at a height which looks as if he had finished but he did not. Oktoprint I do not use I print from the SD. But why comes after many hours print suddenly no more filament ..?

Re: very annoying half prints

Does the printer stop, or does it just keep going but is not extruding?

This is a good question i guess.
Could it be that Octoprint does something funny? Or that the gcode file is simply not complete?

Go back to basics, prints something from the Prusa SD card, not via Octoprint. Chose something with a bit of height, Adlinda maybe.

Re: very annoying half prints

Try printing directly from SD Card. This is highly probable that OctoPi is disconnecting from the printer and this is why printer stops.

I would start with checking USB cable/USB port on the printer or the device side. I have noticed on the pictures, that the printer tends to stop at the areas where are quite small movements of the printhead. Small movement means move vibrations and more wobble of the whole printer - bad contact at USB port or faulty cable.

When the printer stops next time, check if there is connection between octopi and the printer.

Re: very annoying half prints

]i print from SD Card i don´t use Oktoprint. but i think i have found my error. i have unload the filament and its looks see the foto ... 😯
whats wrong ? my spring on the screw have 14mm.. why it works for hours and then the filament look like this? the filament is Prusa PET.

[attachment=0]IMG_5463.JPG[/attachment

Re: very annoying half prints

Okay, we have determined that the printer keeps printing but has stopped extruding.

Your unload shows a clog in the extruder which prevents the filament from going in more.

Things to check:

1) What temperature are you printing at? Too hot can cause clogs like this as the filament gets soft too soon.
2) Is the cooling fan (the one on the side running at > 50C?
3) Does this do this with a different filament roll? I have one roll that is clearly out of tolerance in places and jams like this every few hours. I don't use it any more.
4) Is the extruder pulley thing (forget its name) that grabs the filament clean? If it has picked up debris dust, etc it will push that into the extruder causing occasional jams. Is it firmly attached to the stepper? If it slips the filament will not be pushed forward.
5) Is the filament free to unroll from the spool? If too much resistance (from the holder, or if the filament is crossed under itself) it will fight eat extruder, and sometimes win. Many people upgrade the spool holder to flow more easily.

Let us know what you find.

Re: very annoying half prints

yeah, check the cooling fan. might be that it's cable has a defect and when the x-axis reaches a certain hight, the cooling fan stops working -> which will cause a clogged extruder and can damage the whole extruder body (because the "coldend" gets hot and might melt the cover...).

Re: very annoying half prints

0) THX for your help:-)

1) What temperature are you printing at? Too hot can cause clogs like this as the filament gets soft too soon.
I use slice3d with the original set...PET230/80, PLA 210/55, PLA WOOD 210/55

2) Is the cooling fan (the one on the side running at > 50C?
Yes

3) Does this do this with a different filament roll? I have one roll that is clearly out of tolerance in places and jams like this every few hours. I don't use it any more.
yes with different rolls i use PrusaPETG, Colour fabbPETG, PLA from Filamentworld,

4) Is the extruder pulley thing (forget its name) that grabs the filament clean? If it has picked up debris dust, etc it will push that into the extruder causing occasional jams. Is it firmly attached to the stepper? If it slips the filament will not be pushed forward.
I have checked this since it is clean.da was only little dust

5) Is the filament free to unroll from the spool? If too much resistance (from the holder, or if the filament is crossed under itself) it will fight eat extruder, and sometimes win. Many people upgrade the spool holder to flow more easily.
My filament comes well to the extruder. My printer stand in a ikea lack like this https://www.thingiverse.com/thing:2012384 . I have a ventilation with termostat. Maybe the fan is after a few hours of print to small. At PET the hot plate is 80 degrees. My fan its a 15 cm fan ...
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Re: very annoying half prints

@ jeffjordan: Ok very good thought I will check:-)

Re: very annoying half prints

I would check wires. They have a good contact until at some height/angle the faulty spot disconnects and results with an error.

Had similar problem with nozzle heater wires. Everything looked OK outside. Most prints came out fine. Now and than some prints ended with thermal runaway error at different heights. All calibrations and self-test came back OK even when printer stopped printing on first layer. It took some hunting with multimeter but finally found the culprit. Noticed changing resistance on heater wires and when i gave it a wiggle one of them came out. Fixed it with solder. No problems since than.

Re: very annoying half prints

If I understand correctly, this all started with an enclosure?

Do you have a temperature measurement inside the enclosure? If it is getting too hot, the fan that cools the heat break may not be sufficient, and the heat break is getting too hot, causing the clog. Or an alternative fan there - there are massive threads about mods for that on this forum, under "Enhancements".

Try running with the enclosure door open. If this fixes the problem, then you need to thermally control the enclosure, (temp driven vent van) or allow some form of cooling to get to the extruder.

Re: very annoying half prints

i tested over night and print 12 hours PETG with open door. Its works well. So my enclosure is the problem.....

thank you guys for help i think the problem is found.