Filament Jamming, extruder gears clicking on MK3S+ with Brand New Prusament PETG
First let me say I already found the thread labeled: "Extruder clicking and PLA filament jammed" in the "Assembly and First Print Troubleshooting" section.
I made this new post for two reasons. First, I have been printing without issue for a year and a half and almost exclusively with Prusament PETG. As I am not using PLA and this is not a new printer or first print I made this thread.
I have a Prusa MK3S+ with no MMU.
I have easily put a dozen 1KG spools through the printer in the time I have owned it without any major issues. The printer has been flawless since early days of ownership.
I have not printed for about 2 months and am now working on a project that requires 22 sets of 10 hour prints to complete. I ordered 4 new spools but while I was refining the model I was using an older spool of Prusament PETG Signal white I had on hand while awaiting delivery of the new ones. I printed several versions of the model without issue before settling on the final and only had enough left for a couple of prints with 4 of the models on the plate.
I don't recall having issues on the older spool printing 4 at a time but at some point I started getting the "hovering" no output prints that made me cancel those runs. The first time I did nothing and all seemed well the next go. The second time I heard the clicking I paused the print, retracted, cut the filament and reloaded and was able to continue through octopi without issue to completion?! A few prints later it happened again. I cancelled, cleaned out the print head and tried again. I have successfully printed about 1/3rd of what I am trying to but have had at least 6 occurrences of jamming which are becoming more frequent now. Yesterday I replaced the entire hot-end. Heatsink, heat-break, heat block and the heater itself. Only the thermistor remains and that is getting changed out tonight. I started a new print and failed after an 8 hours. I read in the PLA thread about using the E3D heat break. I had ordered replacements from E3D and had no idea that the E3D was different than the PRUSA one so I am already using the E3D heat break as of yesterday with no change.
I am on spool 3 of the new roles I ordered and this continues to happen. I know what moist filament sounds like with the small popping sounds, that is not happening at all. The extrusion is smooth and flawless for 60+ minutes. Last night failed after 8 hours, the time this occurs has varied. First it was under 10% then 50% now 71% complete. When I see this I stop the print and have tried various things. I would retract the filament and found that the extruder has ground a spot on the filament where it was in contact turning but without movement. Later I would try to advance the filament through the control knob and it would not come out. All I have to do is retract, cut off the end and the print will continue.
I am at a loss, I know this is a long post but I wanted to include everything I had already tried and/or found in the PLA thread so no one would link to it or suggest things I have done.
Please help, thanks.
RE:
I should have added than in the hot end replacement the nozzle was replaced as well. I have been using a .06 nozzle, first Nozzle X and now Brass.
I am using the lack table enclosure but I have a temp sensor rig and the enclosure temp is ~32-33C
RE: Filament Jamming, extruder gears clicking on MK3S+ with Brand New Prusament PETG
I stepped away from the printer for a couple of days and started looking in to it this weekend after my post. I replaced the thermistor as I said I would and I rechecked every connection. For me this is quite difficult because it is in the lack enclosure and I mounted the PSU underneath. I have connections to undo etc... because wires route through the floor to the underside for the PSU and Octoprint.
At any rate after all the examination and replacing the thermistor I hooked it up and it stopped extruding about 15 mins into the print. I was so upset I just turned it off and walked away. The next morning I walked in to the room with the intent to figure this out. In a few short minutes after walking around the enclosure I figured out what the problem was this time....... After all that long post above the problem was the new spool I had loaded, a couple of rows had come off the edge of the spool, wrapped around the bar holding up the spool and it basically got stuck there.
In the end it appears the hot-end replacement did solve my problem I just had it occur one more time due to the spool dropping a couple of loops off the side.
Now.. I am having layer shifting intermittently! ?! New post to come.