Bed levelling failed
I just received my XL yesterday. Its the dual tool variant. After assembly the device walked me through all the calibrations it needed to do for the first time and it passed everything. Upon trying to print for the first time it would take a VERY long time to do the "nozzle cleaning" procedure which failed every time. Device would take upwards of 10 minutes painstakingly do what looked like bed levelling but only on the corner of bed where the steel sheet's pull tabs are (bottom right).
I upgraded the firmware to the 4.7.1 and ran every single calibration again and it passed all of them again. Trying to print I was met with the "nozzle cleaning failed" error again. Worst part is each attempt would take 10+ minutes just to give me an error at the end.
So I factory reset the device and ran the calibration wizard all over again and it passed every single test. Now when I want to print I am met with the "bed levelling failed" error. It does the bed levelling motion but somewhere in the middle of the bed the extruder starts vibrating and then homes the device and gives me an error.
Couldn't find any relevant info on this failure type on the internet probably because the device is too new.
Anybody have any idea on how to fix this?
RE: Bed levelling failed
Brand new machine, you should get on the chat with Prusa Support. That's one reason you paid the big bucks. And if it's a hardware issue, you'll immediately establish a record for warranty claims.
Formerly known on this forum as @fuchsr -- until all hell broke loose with the forum software...
RE: Bed levelling failed
No point in doing the chat, there support is rubbish now, I have my delivery of my prusa XL 2 tool head all pre assembled by prusa and it is faulty.
The filament senor on tool 2 does not function which means I can not finish the calibration.
The heat bed failed after 1 week and also the unit now fails to probe before printing and will which now means i can no longer print. Prusa sent me a replacement unit after days of chats with them telling them that this is extremely poor of a £2,500 unit that was pre built.
The new unit has arrived and this has dreadful banding all the way up the prints, prusa now no longer reply to my emails and are ignoring me, this whole thing has been a complete joke if you have pre ordered i can't advise you enough to just cancel your pre order and wait for a more professional company like bambu to release a printer like this, at least you will have more of a chance of it now being a 30KG £2,500 paper weight.
RE: Bed levelling failed
Is there any means to ensure both steppers on the Z are working? This smells like the sort of leveling problems one sees on bed flingers when one of the two Z steppers isn’t working for whatever reason.
RE: Bed levelling failed
words
My guy, I appreciate you're having a bad time but jumping into everyone else's thread to let them know how angry you are isn't really helping anyone else out. Probably not getting you any closer to solving your problems either.
RE: Bed levelling failed
Is there any means to ensure both steppers on the Z are working? This smells like the sort of leveling problems one sees on bed flingers when one of the two Z steppers isn’t working for whatever reason.
Here's the section in the assembly manual showing where the Z steppers hook into the controller board. I wonder if maybe one came loose in shipping?
RE: Bed levelling failed
HI not meaning to jump into other peoples threads, but when you are getting ignored and no where with a company that sells you a £2500 its hard not to vent.
I do not expect to have these kinds of issues especially on a printer that I paid £400 extra to have assembled and tested by the professionals.
If this was the only XL I had an issues with I would of been more tolerant but come on this is the 2nd one and it has still got issues, what testing has been done?, all they have done is print the tiny prusa logo and gone yep that works everything is good that is not testing, I would of thought they would of tested the replacement better since the 1st XL I received was plagued with faults.
RE: Bed levelling failed
I had the same problem. There's a temporary fix. It turns out there is a LARGE sag near the middle of the print bed. About 2.3mm sag near the middle. This causes several problems but there are temporary fixes for them.
The sag near the middle is large enough that the nozzle couldn't touch the bed without the sides of the bed bumping into the "Z-Axis Bearing Housing". So I simply removed both of the bearing housing. This allow the print bed to move high enough when probing so it actually touches the nozzle when probing the middle of the bed.
RE: Bed levelling failed
Also, once you got the printer working, YOU NEED TO PRESS DOWN ON THE PRINTBED FOR INITIAL PURGING!
Because the probing don't work well with such a large difference between the sides and the middle. So when it's purging, the nozzle actually starts BELOW the print bed and will smash the nozzle to the side of the bed. I didn't realize this until after a few prints. The nozzle already has cuts on it. Just waiting for PRUSA to tell me how to change the nozzle on a multi-tool XL now.
RE: Bed levelling failed
There's a couple of other problems the sagging printbed caused and possible temporary fixes. I can write it down if anybody else is interested.
RE:
Just waiting for PRUSA to tell me how to change the nozzle on a multi-tool XL now.
I can probably help on that one. You're going to want to follow this guide, but when you get to step 7 you might find (like I did) that there is no hole drilled through to access the set screw holding the nozzle in place. If that's the case, for steps 6 and 7 you want to have the head docked and you'll just pull the thing out of the dock to work on it instead of having it on the x-carriage.
See thread here for more on that issue.
RE: Bed levelling failed
Oh, there it is. Thx for the tip. I will play around with it tonight and test the other temporary fixes for the other issues caused by a sagging print bed.
RE: Bed levelling failed
This seems like what is happening. I will try your method and then see if I can get a print out of this thing. The middle of the bed is definitely sagging.
Would be nice to have a bed leveling setting...
I had the same problem. There's a temporary fix. It turns out there is a LARGE sag near the middle of the print bed. About 2.3mm sag near the middle. This causes several problems but there are temporary fixes for them.
The sag near the middle is large enough that the nozzle couldn't touch the bed without the sides of the bed bumping into the "Z-Axis Bearing Housing". So I simply removed both of the bearing housing. This allow the print bed to move high enough when probing so it actually touches the nozzle when probing the middle of the bed.
RE: Bed levelling failed
I had the EXACT same problem as the OP. Thanks to User64X for the solution! Took those bearing holders off and it calibrated and printed. I cut slots in the 3mm bolt holes and moved it up maybe 1mm. Just enough for the bearing to hold the jackscrew, and enough for it to clear. I didn't like the idea of leaving the jackscrew unsupported. Ideally, Prusa designs a bearing holder with 1mm more clearance......
n
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RE: Bed levelling failed
Wanna talk about a WTH , after several prints ( poor results i might add ) out of the no where the nozzle and Z just rammed the test part and couldn't figure why , at first i didn't notice what had happened . From what i can tell with every print the RH side Z rod motor wasn't properly moving the side of the bed and it had gone wonky . The bed was WAY crooked , the gantry frame and desk were all perfectly level. Talked with Prusa they had no idea how or why this would have happened. Worst part doing a Z Height calibration adjustment did not flatten the bed . It took 4 calibrations attempts and each time it would flatten more and more until it was finally flat again . They think for whatever reason it was a gradual adjustment error , so i went and checked all the screws on the bed and found the 2 on the bed at the zRod location loose and not even tightened . Dont know if that was the cause but im now keeping a strong eye on the bed position with each print ( still trying to get a good successful print out of this thing )
RE: Bed levelling failed
Many people have had this problem, including me…. I traced it down to gaps between the vertical and horizontal aluminum extrusions. They were made with an EXTREMELY tight fit…. You need to go back and forth between the two bolts until the plastic ridges on the vertical extrusions are compressed into the horizontal extrusion slots, and there is zero space between the extrusions… it takes alot of force - but use the torque wrench so you don’t snap the bolts.
If there is any space between these extrusions you will have all kinds of leveling and first layer problems. After I went back and fixed this, my first layer was PERFECT.
Prusa should place this warning in the assembly instructions.
I just received my XL yesterday. Its the dual tool variant. After assembly the device walked me through all the calibrations it needed to do for the first time and it passed everything. Upon trying to print for the first time it would take a VERY long time to do the "nozzle cleaning" procedure which failed every time. Device would take upwards of 10 minutes painstakingly do what looked like bed levelling but only on the corner of bed where the steel sheet's pull tabs are (bottom right).
I upgraded the firmware to the 4.7.1 and ran every single calibration again and it passed all of them again. Trying to print I was met with the "nozzle cleaning failed" error again. Worst part is each attempt would take 10+ minutes just to give me an error at the end.
So I factory reset the device and ran the calibration wizard all over again and it passed every single test. Now when I want to print I am met with the "bed levelling failed" error. It does the bed levelling motion but somewhere in the middle of the bed the extruder starts vibrating and then homes the device and gives me an error.
Couldn't find any relevant info on this failure type on the internet probably because the device is too new.
Anybody have any idea on how to fix this?
RE: Bed levelling failed
Hey guys,
just wanted to tell you that I had he problem and it seems I solved it by screwing off the upper right plastic part that holds the bearing for the lead screw. Than I put it back on but pressed the plastic part up while screwing in. I think it is now screwed in in a way that it rests maybe a tenth millimeter further up.
This seems to solve the problem for me, but I am well aware - this might not work for everyone.
RE: Bed levelling failed
Most of the fixes in this thread wouldn't work for me. The billet machined bed that is holding all the heating elements is MASSIVELY warped. I checked it with a straight edge. It had a 1.5mm gap in the middle!! Prusa should reconsider the way they machine that piece all together. The nozzle could not even come close to ever touching the bed in the middle sections. For a bed that is not adjustable that is a huge oversight.
Now for fixing this dumb design. It was a matter of raising the bed by that 1.5mm. The bed is still bowed and not even close to being straight but the leveling seems to compensate for it fine.
Someone tell the designers just because something is CNCd doesn't mean its straight. Either tighten up the quality control, come up with a better design, or add adjustability. This is simply unacceptable. Feels like an error that grad students would make.
Many people have had this problem, including me…. I traced it down to gaps between the vertical and horizontal aluminum extrusions. They were made with an EXTREMELY tight fit…. You need to go back and forth between the two bolts until the plastic ridges on the vertical extrusions are compressed into the horizontal extrusion slots, and there is zero space between the extrusions… it takes alot of force - but use the torque wrench so you don’t snap the bolts.
If there is any space between these extrusions you will have all kinds of leveling and first layer problems. After I went back and fixed this, my first layer was PERFECT.Prusa should place this warning in the assembly instructions.
I just received my XL yesterday. Its the dual tool variant. After assembly the device walked me through all the calibrations it needed to do for the first time and it passed everything. Upon trying to print for the first time it would take a VERY long time to do the "nozzle cleaning" procedure which failed every time. Device would take upwards of 10 minutes painstakingly do what looked like bed levelling but only on the corner of bed where the steel sheet's pull tabs are (bottom right).
I upgraded the firmware to the 4.7.1 and ran every single calibration again and it passed all of them again. Trying to print I was met with the "nozzle cleaning failed" error again. Worst part is each attempt would take 10+ minutes just to give me an error at the end.
So I factory reset the device and ran the calibration wizard all over again and it passed every single test. Now when I want to print I am met with the "bed levelling failed" error. It does the bed levelling motion but somewhere in the middle of the bed the extruder starts vibrating and then homes the device and gives me an error.
Couldn't find any relevant info on this failure type on the internet probably because the device is too new.
Anybody have any idea on how to fix this?
RE: Bed levelling failed
My latest email back from support had forwarded a link to updated Z Rod guides , I printed them out and installing them today while following a few other updates from them in the email as well . This was a factory assembled unit that seems to have had a lot of shortcuts on who ever did the assembly . I’ve attached the photos of the part that came off the machine labeled E4 and the updated part I printed in PETG labeled R2 
