Prusa XL with Klipper  

RE: Prusa XL with Klipper

Is there a documented procedure to restore the XL to PRUSA firmware once Klipper is installed?

RE: Prusa XL with Klipper

ok all changes that have been made for fixes and other improvements and features can be found in the CHANGELOG.md now.. 

RE: Prusa XL with Klipper

i just added it to it 🙂

its in there now

RE: Prusa XL with Klipper

all changes are listed in the changelog.md and now there is 2 different flashing methods for doing klipper on the original way no bootloader flash and now also advance way of  doing it you can keep the stock prusa bootloader and then when you want to go back to prusa just add the files to thumb drive and reboot and let the prusa bootloader put everything back stock

should have all instruction in guide for doing either way and also recovery section with files needed to do a recovery from either way..

RE: Prusa XL with Klipper

That worked. The build ran successfully. Now on to the flashing of the board.

Thank you very much for all of the help. 

RE: Prusa XL with Klipper

and i just seen if your using my offsets in the printer.cfg section dont forget to comment out these [tool_offsets]#t0_z_offset: 0.0#t1_z_offset: 0.0#t2_z_offset: 0.0#t3_z_offset: 0.0#t4_z_offset: 0.0 just seen they are not commented out.. or leave them zero and run the calibration for them and it will overwrite mine and comment them out itself  but the [tool_offsets] does not get commented out just whats below it

RE: Prusa XL with Klipper

next i will be adding in the side leds to be used as strobes so you can see belt tension and see what it is set at like the Prusa Core one 

RE: Prusa XL with Klipper

Very cool. I am going to do everything I can to get 3D Printing Nerd to look at this and hopefully make a video. This deserves way more attention than it has been getting.

RE: Prusa XL with Klipper

Ok, now I am very confused. I purchased a 2nd buddy board to be able to keep one stock and flash the other with Klipper. I can't get either to go into DFU mode. I have installed 2 pin headers at the boot0 location and have a jumper installed. They both just boot normally.

RE: Prusa XL with Klipper

Did you try the alternate (and I would think safer) USB flashing method?

https://github.com/racoutlaw/KlipperXL/blob/master/docs/USB_FLASH_METHOD.md

RE: Prusa XL with Klipper

I had not as it requires cutting the appendix seal on the board. It is not that big a deal to do, just not a fan of permanent mods if I do not have to. 

RE: Prusa XL with Klipper

Sorry, I thought the DFU mode was more intrusive, live and learn!

RE: Prusa XL with Klipper

I bought a 2nd board to do this with. I am going to go ahead and cut the seal. It just cuts a trace on the board to bypass the firmware signature check.

RE: Prusa XL with Klipper

Ok, it looks like you need to perform an appendectomy to get it to load the firmware with either method. Once I cut the tab it flashed with DFU with o issues.

I think I am up and running.

RE: Prusa XL with Klipper

Must have been laparoscopy to have it off the table and running so quickly!

RE:

yes to flash anything other than prusa firmware you have to remove its appendix .. no way around that..

i have found some info and am i trying at the phase stepping again so time will tell or another 3 month rabbit hole..  we will see..

RE: Prusa XL with Klipper

Hello, I'm trying the thing and I'm feeling that I'm close to get some results. Thanks to you @RacOutlaw, I'm feeling very close to use PrusaXL with Klipper. You did a great work. Because of you, it has been a far easier task than what I expected at first to flash klipper firmware on PrusaXL and configure the tool environment.

But... despite all this I still haven't been able to print anything with Klipper. In two words, I'm stuck after "START_PRINT" phase with some errors that I'm looking to solve. And it's during my reseach that I found this topic. If you are so kind to give some advices, maybe the goal would be even closer!

For the one interresed by my little adventure, you may like to know more about the setup and what has been done:

• Size modified prusaXL (doubled the height), I'm using only one Dwarf/toolhead (for the moment)
  • Changed the Z Axis steppers and bars (steps/mm has been divided by 2)
• Was able to make it print with Prusa firmware (had to change some parameters for height, compile and flash the modified fw). So far so good, but not Klipper yet.
• Now running with : KlipperXL(Klipper), Moonraker and Fluidd following the INSTALLATION_GUIDE.md from the doc folder of the repo "KlipperXL / docs"
• Compiled on the Pi itself from KlipperXL project by @RacOutlaw  ( https://tinkeratlas.com/projects/klipperxl - master branch) 
• Because I've only one Dwarf/Toolhead, I commented the toolheads T1-T4 in `printer.cfg`, macros and variables but still have some issues (e.g.: it's trying to park and change tools when asked) But this is not a real issue if I refrain from using thoses "missing" toolheads 😏
• Execution:
  • Tried first with a Pi3B+ but klipper is crashing when calibrating Z-axis
    • 32bits and 64bits Raspbian Trixie crashing all the same
  • Tried with a Pi400 and was able to go further and got stuck on print try 
    • 32bits and 64bits working fine, but needed Pi400 for other purposes so replaced by Pi5
  • Now using a Pi5 and still stuck on print phase
    • 64bits Raspbian Trixie. Setup is up to date and quite stable
• Most of the functions are working fine
  • XYZ calibration and homing
  • Bed calibrationand heating
  • Dwarf Toolhead Extruder heating, fan running as expected
  • Small issues when trying to use T1-T4 (park and change tool). It get stuck at "parking place" with wrong toolhead memorized. It was tricky to force T0 back.
  • Did not find how to test/calibrate the filament sensors
• Printing ...
  • Homing : OK
  • Extruder pre-Heating : OK
  • Bed heating : OK
  • Filament detection : WARNING
  • Start printing : ERROR see partial log bellow

I'm feeling I'm not so far from making it work, but I need some help to throw some light on the what and how. Tell me if you can help. I'll continue to investigate and post if anyone is interested.

Have a nice day and good printings!

22:16:10 // T0 reached 229C (target 230C)
22:16:15 // !! Filament runout detected on T0 (side sensor)! Pausing print.
22:16:15 // Unknown command:"_STATUS_PAUSED"
22:16:15 // Print already paused
22:16:21 !! Move out of range: 441.074 578.242 0.300 [40.000]
22:16:21 !! Move out of range: 441.074 578.242 0.300 [40.000]
22:16:21 // Unknown command:"_STATUS_PRINTING"
22:16:21 echo: Resuming print...
22:16:27 !! Move out of range: 180.000 696.000 10.000 [11.500]
22:16:27 !! Move out of range: 180.000 696.000 10.000 [11.500]
22:16:27 !! Move out of range: 180.000 696.000 10.000 [11.500]
22:16:27 // Unknown command:"_STATUS_ERROR"
22:16:27 echo: Print cancelled
22:16:27 // T0 hotend target: 0C
22:16:27 // Bed area cleared - all 16 bedlets at 85.0C
22:16:27 // Bed target: 0.0C (all 16 bedlets)
22:16:28 // T0 fan: 0/255 (0%)
22:16:28 // Dwarf 1 target temp set to 0.0C
22:16:38 // Parking T0 at dock X=25.0 Y=455.0
22:16:46 echo: Print paused - nozzle parked at front left
22:16:48 // Run Current: 0.94A Hold Current: 0.65A
22:16:48 // Run Current: 0.94A Hold Current: 0.65A
22:16:50 // Run Current: 0.65A Hold Current: 0.65A
22:16:50 // Run Current: 0.65A Hold Current: 0.65A
22:16:51 // T0 parked detected
22:16:52 // WARNING: Still reporting picked after depart!
22:16:52 // T0 parked successfully!
22:16:52 // All spool join remaps cleared

RE: Prusa XL with Klipper

Glad you're getting close! Three things are going on in your log, and they're independent — tackle them one at a time.

1. Move out of range (the showstopper)

Move out of range: 441.074 578.242 0.300 [40.000] Move out of range: 180.000 696.000 10.000 [11.500]

Those X/Y coordinates are past the edge of your bed. The Prusa XL print area is 360×360mm, so anything above ~360 on either axis exceeds what Klipper's position_max allows on stepper_x / stepper_y.

You mentioned you doubled the Z height, not X/Y — so your X/Y travel is stock. That means your slicer is trying to move the nozzle somewhere it physically can't go.

Check two things: - OrcaSlicer bed dimensions — make sure the printer profile shows 360×360mm (or whatever your actual print area is). If you accidentally scaled the bed with the Z modification, that'd explain the Y=696 value. - Model position in OrcaSlicer — confirm the print isn't placed partially or fully off the bed.

The [40.000] and [11.500] at the end are extrusion amounts — that first one is the prime line, the second looks like a bed heating wipe. Both are controlled by your start g-code coordinates passed to START_PRINT.

2. Unknown command: _STATUS_PAUSED / _STATUS_PRINTING / _STATUS_ERROR

Those macros live in led_effects.cfg, which drives your XL's side LED strips. Your printer absolutely has them from the factory — you just need to wire up the plugin.

Install the klipper-led_effect plugin (from Section 8.1 of the install guide):

cd ~ git clone https://github.com/julianschill/klipper-led_effect.git ln -s ~/klipper-led_effect/src/led_effect.py ~/klipper/klippy/extras/led_effect.py

Deploy the LED effects config:

cp ~/KlipperXL/config/led_effects.cfg ~/printer_data/config/led_effects.cfg

Make sure printer.cfg includes it:

[include led_effects.cfg]

A couple of XL-specific notes that trip people up: - Color order is RGB with chain_count: 2 — each side strip is actually two daisy-chained WS2812 drivers: - Index 1 = RGB color channel - Index 2 = White LED on the RED channel (driver 2) - Mux select pin PE9 is held HIGH via [static_digital_output led_mux_select] in printer.cfg — don't remove this or the strips won't light up.

After that, restart Klipper. The _STATUS_PAUSED/PRINTING/ERROR macros will resolve, your side lights will work, and you'll get breathing/status indicators during prints.

3. False filament runout on T0

Filament runout detected on T0 (side sensor)! Pausing print.

Either your side filament sensor isn't wired, is permanently reading "empty," or the logic is inverted. If you don't have the sensor hooked up, comment out the relevant [filament_switch_sensor] / [filament_motion_sensor] block in printer.cfg until you get a first print working. You can re-enable it later.

About T1-T4

The parking glitches when things reference T1-T4 are expected since you only have one Dwarf — the macros and puppy_bootloader.py still have logic that assumes all 5 toolheads. Your workaround (just use T0) is the right call for now. A proper single-tool mode is something I can look into adding later.

Work through 1, 2, 3 in that order. Issue 1 is the one keeping the print from running — the other two are noise but will still interfere. Post the log after the next attempt and I'll take another look.

RE:

I tested it. Had some initial problems with loadcell, then increased the value.

Picking a tool takes more time then stock fw (printer pauses after each move)...

I also submitted some issues to the tracker : https://github.com/racoutlaw/KlipperXL/issues and some of them were resolved by @racoutlaw. Enclosure fan is not controlable (I haven't found the right PIN or method).

Here is a video showing that extruder buttons work on KlipperXL:

RE: Prusa XL with Klipper

Hi, I'm the guy behind TinkerAtlas. Fair point, when it's not one of the established repo sites I get the suspicion.

TinkerAtlas isn't first and foremost a repo site though. It's a social platform for makers, with additional tools like project hosting (KlipperXL being one example), printer maintenance tracking, and soon giveaway tools for maker streamers, among other things. I'm trying to build a good home for our community. Nothing sketchy about it, there's no spam, and digest emails can be adjusted to whatever frequency you want or unsubscribed from entirely.

As for needing an account to download, that's because TinkerAtlas is a community platform, not just a file host. It's the same reason you need an account on GitHub or Printables to interact with projects there.

I've been working on it every single day since I started in July 2025, no days off. We're still in beta because I keep finding features I want to build.

On YouTube you asked if I was the author of this project. I'm not, I said as much. RacOutlaw is a friend of mine and I wanted to help him get the word out about KlipperXL. You also asked whether the TinkerAtlas link was more of a promotion rather than pointing to the original GitHub location. I said it was hosted on TinkerAtlas because as far as I knew, that was the original location. The GitHub repo was supposed to be a private backup, not the public-facing home for the project.

Posted by: @jsawyer

With the recent supply chain attacks, etc. any repository that is not one of the established ones is looked at with some suspicion.

TinkerAtlas also feels kind of pushy. You can't download without joining and when you do join there is a fair amount of spam that comes with it.

It didn't help that when I posted a reply to the video asking if they were or were associated with the creator, the response was that they were in the process of rebranding and did not say anything about you or an association to you.