XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Hey everyone, I have had the XL-5T for about 2 weeks. Everything was printing normally until last week. Specifically when I do a large format print such as the one pictured. This is the 7th fail of this specific model. I have had success with every other model I have attempted. I have printed other models in-between the fails without issue, some of the items are taller but not as wide/long, with no issues.
I have had 7 successful prints of this model, the first 5 prints were one after the other, no issues. Note: the error can happen at any point of the print. It has not been seen occurring in the same spot.
This issue seems to occur randomly. I have had prints fail on the second layer, halfway through the print and right before the top layer is being printed. Never on the first layer or anything the top layer before the color changes are started.
I am at a loss for what the issue may be and am looking to see if the community has encountered this before and if a solution has been found.
Here is what I have done to try and mitigate the issue:
1. Re-sliced the file: I have created 4 different versions of the gcode/bgcode. All of which have successfully delivered a print and then a series of fails before I re-slice and get a successful print and then fails follow again. Resliced with input shaper and without, with bgcode and regular gcode and the variables with the same outcome. 1 success out of every 5 attempted prints of this model.
2. I have rotated 90/180/270 degrees and still get the diagonal lines.
3. I have swapped out usb sticks out from the original PRUSA usb stick and still get the same fail at a random place in the print.
4. I have re calibrated and tested with a successful print/ different model and had success.
5. I have added a fan in front of the usb device (thinking overheating) and received a fail, the usb stick was room temp (70 degrees)
I am running the latest stable firmware: 6.0.0 but have not attempted a roll back yet.
Any help or guidance would be greatly appreciated.
Thanks everyone!
Best Answer by JoanTabb:
Total Guess. I don't have an XL. all of your errors seem to give diagonal lines in the same direction,
Core XY uses 2 motors at the same time to make 'X' axis moves, or 'Y' Axis Moves (On my Core XY printer, these motors are designated 'A' and 'B', If only one motor is operated the printer XY axis track at an angle of 45 degrees if the other motor is the only one to operate the printer XY axis tracks at 45 degrees in the opposite direction
When the printer is switched off, or at rest, can you manipulate the belts to emulate one motor running, and identify which motor actually gives you the diagonal motion that you are experiencing, then you will need to investigate the other motor for such issues as Loose connections excess friction causing jamming of the motion, possible motor controller overheating, etc.
since the printer seems to start printing well, then fail, I would probably be looking at thermal issues with the stepper motor driver or physical issues with the motion
regards Joan
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Re-sliced and ran again. Failed after 3 hours with the same result, in a different place.
Additional things I changed before starting this print:
1. Tested the fans, thinking the issue may be extruder #1. Extruder #1 failed the fan test 4 times. I removed the lower fan shroud and loosened the upper left bolt of that fan (The larger fan on the left side of the extruder). Ran the fan test again 4 times, all fans passed every time.
2. No errors or warnings on the printer when I went to check on it, extruder was once again rocking back and fourth extruding filament.
Next print is started, I have switched the starting extruder from # 1 to now #4. Attempting to now see if the issue is with the specific extruder. Note: This is the only print that this issue is occurring with. All other prints have had no issue with extruder #1.
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Update: 5-12-24
Spent the weekend attempting different things only to continue to get failures. These failures are still occuring at different times of the print. Sometimes 1 hour in. sometimes 5 hours in.
Things I have tried:
1. Connected with Prusa support and performed a hard factory reset and reflash to firmware 6.0.0 (No change)
2. Re designed the file from scratch.(No change)
3. Resliced the file in multiple varieties. Different infills, changed speeds, lowered/increased filament & bed temps
4. Unplugged my ups from the printer and plugged the printer directly into the outlet. (Thinking there may be power drops/surges causing the failure to kick in).
5. Scaled down the print to see if it was the large size causing the problem.(No change)
6. Switched extruders (No change)
Note: In-between these prints, I tested other small models (2mm H X 88.9mm L/W and was still able to get successful multi color prints.
Attached are all the failures and a sample of the successful print that happened prior to all theses issues starting.
Theory: Is one of the X/Y motors failing/timing out at random intervals?
Still on the hunt for a solution,
T
The bottom 5 logos in this photo printed first try, no issues, then I began getting failures on #6, then more failures before a success on #7 and now I have been unable to complete the print.
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Total Guess. I don't have an XL. all of your errors seem to give diagonal lines in the same direction,
Core XY uses 2 motors at the same time to make 'X' axis moves, or 'Y' Axis Moves (On my Core XY printer, these motors are designated 'A' and 'B', If only one motor is operated the printer XY axis track at an angle of 45 degrees if the other motor is the only one to operate the printer XY axis tracks at 45 degrees in the opposite direction
When the printer is switched off, or at rest, can you manipulate the belts to emulate one motor running, and identify which motor actually gives you the diagonal motion that you are experiencing, then you will need to investigate the other motor for such issues as Loose connections excess friction causing jamming of the motion, possible motor controller overheating, etc.
since the printer seems to start printing well, then fail, I would probably be looking at thermal issues with the stepper motor driver or physical issues with the motion
regards Joan
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Thanks Joan, I tried your and the motor does track at a 45 degree angle. I don't have a way to test for any heat issues. This is a good stepping off point though to continue trouble shooting.
I will check back in if replacing the stepper motor was the issue or it the problems persist.
Thank you
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Are the stepper motors interchangeable?
regards Joan
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
I think so, they are identical, they only have different bearings/pulleys at different heights. I think they are held on with a few grub screws.
I continued my ticket with Prusa and they think it is a driver issue the XL Buddy board. (Either heat or defect) they are sending me a new board to test.
When we tested the stepper motors for resistance/tension/sound everything checked out and not homing issues, the culprit seems to be the XL Buddy Board at this time.
Thank you for the support trouble shooting, it would have taken me much longer to get to the stepper motor 🙂
I will post an update once I install and run some more tests.
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Cheers Daniel.
At times it can be frustrating looking for answers because you almost need to know what the answer is, in order to ask the correct questions...
I am pleased that I could help you look in a valid direction...
regards Joan
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK
RE: XL 5 tool randomly stops printing the file and only extrudes in a zig zag pattern until a collision or a manual stop.
Update:
After working with Prusa it was determined that I had a bad Buddy Board for the stepper motors. Nothing can really be determined on why they were failing, but I suspect it was heat related. The performance issues happing intermittently is the only data point available. No errors on screen and short duration prints (5 hours or less) would print flawlessly.
Note: Installing the new board was very easy, just remove the UFL connector from the board and swap in the new board. Once you install the new board, a full calibration is required. Please allow yourself time to complete the process. Its not just a swap and start printing procedure.
Thanks to @JoanTabb and the Prusa team for helping me hunt down the issue and get a fix.
Hopefully my experience helps anyone else if they find themselves in this situation.
Happy printing.