Hotend selftest failure after Revo 6 swap
3+ year old MK3 that was upgraded to MK3S and swapped for the Bondtech extruder running 3.9.1.
Got my Revo a few weeks ago and installed it, but I can't do anything the easy way. Because I hate dealing with the tail and control box, I spliced JST-XH connectors into the fans and PINDA (IR sensor is easy to unplug and the Bondtech extruder motor already uses a JST connector on the motor itself).
My initial pass at it worked and the self test passed completely, but there wasn't enough play in the cables to route them appropriate to avoid issues at the extreme X (right side) and Z (top) ranges. So I pulled out the soldering iron and built some new cables that had plenty of extra to them, but this time when I turned the printer on the LCD kept flickering like something was loose or there was interference. So I ordered replacement fans and a new PINDA to scrap the only easy disconnect idea.
This morning I finally installed the new parts and put it back together, but the self test fails with "Selftest error! Please check: Heater/Thermoresistor Not connected". So I opened it back up and double checked (all was as it should be). When I powered it back on I used Settings -> Temperature to set it to 170 and it reached the temp fine and clearly stopped trying to heat it further. I also ran a PID tune for 210 degrees and that completed successfully. When I ran the selftest again, however, it still failed with the same error.
I have been seeing reports emerging of people having problems with the Revo heater and E3D needing to replace it, but all of those reports that I've seen appear to be that they got as far as actually printing some before it starts having issues (e.g. mintemp and thermal runaway). Is this likely an issue with the heater block or is there maybe something else I can check?
Best Answer by gnat:
So in doing e3d's tests it turns out that it is working fine except with the extruder in the home position. In that position the thermoresistor is working fine, but the heater is not doing it's job. If I fiddled with the connection to the extension cable, the heater would turn on and off and the heater side of the connection was slightly warm to the touch compared to anything else in the area (e.g. not absorbed heat from another source).
So e3d is having me send it back for replacement, but replacements are back ordered and they don't have an ETA yet...
RE: Hotend selftest failure after Revo 6 swap
I updated the firmware to 3.10.1 last night and now in addition to the self test failing, it no longer heats up via the PID tune or Settings -> Temperature methods. The nozzle stays cold too the touch, so it's not like it's heating and the thermo isn't registering.
e3d has sent me a few troubleshooting steps test their heater/thermo, so I'll see what that shows when I get to it later today.
RE: Hotend selftest failure after Revo 6 swap
So in doing e3d's tests it turns out that it is working fine except with the extruder in the home position. In that position the thermoresistor is working fine, but the heater is not doing it's job. If I fiddled with the connection to the extension cable, the heater would turn on and off and the heater side of the connection was slightly warm to the touch compared to anything else in the area (e.g. not absorbed heat from another source).
So e3d is having me send it back for replacement, but replacements are back ordered and they don't have an ETA yet...
RE: Hotend selftest failure after Revo 6 swap
I just ran into a "Thermal Runaway" issue myself. For me:
- The Revo 6 was installed a few days ago. Self Test passed just fine.
- I've only done three test prints
- Just now, the "Thermal Runaway" error caused a print failure ~3 hours into a print using the 0.8mm nozzle. I noticed that the heater did seem to have trouble keeping the hotend at the desired temperature (set to 240, but was actually averaging closer to 235 or less).
I have not yet done any troubleshooting nor reached out to E3D, but I am bummed.
RE: Hotend selftest failure after Revo 6 swap
It's happening to me too. I do not know what to do.
I just ran into a "Thermal Runaway" issue myself. For me:
- The Revo 6 was installed a few days ago. Self Test passed just fine.
- I've only done three test prints
- Just now, the "Thermal Runaway" error caused a print failure ~3 hours into a print using the 0.8mm nozzle. I noticed that the heater did seem to have trouble keeping the hotend at the desired temperature (set to 240, but was actually averaging closer to 235 or less).
I have not yet done any troubleshooting nor reached out to E3D, but I am bummed.
RE: Hotend selftest failure after Revo 6 swap
I'm sorry I never responded to @mitch-3-2, I missed the post notification 😔
@mcv, don't hesitate, reach out to E3D. Unfortunately I've had to talk to them twice, but both times they were quick to respond and got me a replacement quickly.
Check the cable insulation where it meets the end of the cable support on the extruder. My replacement failed after around 300 hours with thermal runaways. I couldn't see it until I removed the core after they shipped me a new one, but the edge of the support had cut into one of the thermo cables. I have also read a few other similar cases.
What I think is happening is that the insulation on the wires is much thinner than on the stock wiring. This prevents the zip ties from holding the cables firm and also movement to rub. On this new core I added some heat shrink tubing around the cables in that are to bulk them up and offer some abrasion resistance. Unfortunately some other issues have kept me from printing since then so I don't have any idea if that is successful or not.
It's happening to me too. I do not know what to do.
I just ran into a "Thermal Runaway" issue myself. For me:
- The Revo 6 was installed a few days ago. Self Test passed just fine.
- I've only done three test prints
- Just now, the "Thermal Runaway" error caused a print failure ~3 hours into a print using the 0.8mm nozzle. I noticed that the heater did seem to have trouble keeping the hotend at the desired temperature (set to 240, but was actually averaging closer to 235 or less).
I have not yet done any troubleshooting nor reached out to E3D, but I am bummed.
RE: Hotend selftest failure after Revo 6 swap
It’s good to hear your experience @gnat.
If you have pictures of the heatshrink tubing job, I’d appreciate the inspiration.