RE: Extruder stops mid-print
👍 👍 👍 Outstanding!
Mine has never failed since this revision. Thank you so much for all your efforts and for sharing this solution.
RE:
@jim-nangano awesome work on this fix. I have them on all 5 TH for my XL, but a couple of tool heads are still observing the flickering LED. Are you also seeing the same?
RE: Extruder stops mid-print
All my extruder LEDs flicker, I don't think that's an issue.
RE: Extruder stops mid-print
I see, glad to have you in the community.
RE: Extruder stops mid-print
Well.... I got bit over excited with this fix. Just had another mid-print stop extruding failure again on one of the 5 tool heads with this mod. Failure occurred around layer 5.
Going to retry printing the same model again on another tool head. Printing Jim's mod but skeletonized and using Prinline PCCF filament, which all my tool heads parts were upgraded with when I enclosed my XL. So, filament shouldn't be the issue (in theory).
I will make this skeletonized version (screenshot attached) available on Printables when I have it installed on my XL, stay tuned.
RE: Extruder stops mid-print
Well.... I got bit over excited with this fix. Just had another mid-print stop extruding failure again on one of the 5 tool heads with this mod. Failure occurred around layer 5.
Going to retry printing the same model again on another tool head. Printing Jim's mod but skeletonized and using Prinline PCCF filament, which all my tool heads parts were upgraded with when I enclosed my XL. So, filament shouldn't be the issue (in theory).
I will make this skeletonized version (screenshot attached) available on Printables when I have it installed on my XL, stay tuned.
So you had the set screws in the plug cover and the extruder stopped but it kept printing? Or did you have a different failure?
You need to make sure that the plug fits properly into the dwarf board. Make sure that the plug (not just the plug cover), is fully seated.
RE: Extruder stops mid-print
The connector base is seated all the way down and it's the M3 screws are securely fastened into the connector cover. All 5 tool heads were installed in same way. I've got another 30 minutes to go with my remix. Once this print is done (using tool head #1), I'll install this skeletonized version on #3 where I had the repeated failure and print another skeletonized cover as test. I'll keep everyone here posted my findings.
RE: Extruder stops mid-print
If you are still seeing issues, swap the extruder with another. If the problem moves withe the extruder, you may have a damaged dwarf board. If not, but still happens in that tool head position, it may be a bad cable.
The connector base is seated all the way down and it's the M3 screws are securely fastened into the connector cover. All 5 tool heads were installed in same way. I've got another 30 minutes to go with my remix. Once this print is done (using tool head #1), I'll install this skeletonized version on #3 where I had the repeated failure and print another skeletonized cover as test. I'll keep everyone here posted my findings.
RE: Extruder stops mid-print
Yup, that's the plan. if the issue follows to another toolhead, likely the board has gone bad from 6+ months of mid-print failures from poor connection with the factory connector and cover. Which reminds me, support still silent about this issue and still will not entertain the idea of sending me replacement dwarf PCBs.
RE: Extruder stops mid-print
Yup, that's the plan. if the issue follows to another toolhead, likely the board has gone bad from 6+ months of mid-print failures from poor connection with the factory connector and cover. Which reminds me, support still silent about this issue and still will not entertain the idea of sending me replacement dwarf PCBs.
I could see the connector being damaged from 6 months of not being properly connected and wiggling.
RE: Extruder stops mid-print
Well... after moving the tool head #3 to #1 position, I first had a filament sensor at the tool head issue. the filament sensor at the tool head was reversed, so when filament is present, the sensor would indicate off and filament not present, the sensor would indicate on. not a big deal, I just reran filament sensor calibration. Then before I started the same print again, I manually undocked the tool head and shuffle it all around the area of the print area, docked it back and repeated that 5 times to simulate tool changes, and print. I started the same exact prin, and it failed at around 5th layer. Without making any changes, I manually undocked the tool head and shuffle it all around the area of the print area, docked it back and repeated that 5 times again. 90 minutes later, the print finished without any issues. I repeating the same process as above and will update the results again. Sadly, moving the tool head from #3 to #1 position is imo inconclusive at the moment. But after this print, I will follow same exact procedure as above for tool head #3 (which was originally #1)
RE: Extruder stops mid-print
Well... after moving the tool head #3 to #1 position, I first had a filament sensor at the tool head issue. the filament sensor at the tool head was reversed, so when filament is present, the sensor would indicate off and filament not present, the sensor would indicate on. not a big deal, I just reran filament sensor calibration. Then before I started the same print again, I manually undocked the tool head and shuffle it all around the area of the print area, docked it back and repeated that 5 times to simulate tool changes, and print. I started the same exact prin, and it failed at around 5th layer. Without making any changes, I manually undocked the tool head and shuffle it all around the area of the print area, docked it back and repeated that 5 times again. 90 minutes later, the print finished without any issues. I repeating the same process as above and will update the results again. Sadly, moving the tool head from #3 to #1 position is imo inconclusive at the moment. But after this print, I will follow same exact procedure as above for tool head #3 (which was originally #1)
Beware of dock crashes when moving heads around like this. I've completely disassembled the heads before and there is some variation in the head assembly. This is normally accounted for when calibrating dock position, so switching the heads around could possibly lead to a dock crash.
I'd just be on the lookout, and if you decide to leave the heads switched around permanently rerun the dock calibration.
RE: Extruder stops mid-print
Well... after moving the tool head #3 to #1 position, I first had a filament sensor at the tool head issue. the filament sensor at the tool head was reversed, so when filament is present, the sensor would indicate off and filament not present, the sensor would indicate on. not a big deal, I just reran filament sensor calibration. Then before I started the same print again, I manually undocked the tool head and shuffle it all around the area of the print area, docked it back and repeated that 5 times to simulate tool changes, and print. I started the same exact prin, and it failed at around 5th layer. Without making any changes, I manually undocked the tool head and shuffle it all around the area of the print area, docked it back and repeated that 5 times again. 90 minutes later, the print finished without any issues. I repeating the same process as above and will update the results again. Sadly, moving the tool head from #3 to #1 position is imo inconclusive at the moment. But after this print, I will follow same exact procedure as above for tool head #3 (which was originally #1)
Beware of dock crashes when moving heads around like this. I've completely disassembled the heads before and there is some variation in the head assembly. This is normally accounted for when calibrating dock position, so switching the heads around could possibly lead to a dock crash.
I'd just be on the lookout, and if you decide to leave the heads switched around permanently rerun the dock calibration.
for sure, that was actually my very first concern when I went to load filament sequence. But thanks for looking out for me. The tool heads will definitely go back to original position and I would redo dock calibration for both #1 and #3. Well, I actually do dock calibration anytime I remove the head for service just to ensure smooth pickup and docking.
RE: Extruder stops mid-print
Reporting back on my findings. Just a quick recap
All 5 tool heads were upgraded to secured cover and connector, and yes, I do consider @Fendbass22_1154698 a very good upgrade to Prusa's design.
Printing all kinds for different projects but going through tool heads 1-5. Tool heads 1 and 2 were able to successfully complete short (~1 hour) long and (12+ hour) prints. However, #3 failed to complete a print
Print failure - tool head stops extruding around 5 layer into a 194 layer print.
Swapped tool head #3 with #1, and now #1 (originally #3) also had same print failure at about the same layer, might be even earlier.
Retry same print again on #1 (originally #3), success
Retry same print again on #3 (originally #1), same failure around layer 5.
File I'm printing over and over again is here. The only difference between @Fendbass22_1154698 and mine post is mine is just skeletonized. Which I also originally had some level of concerned with lack of structural rigidity. However, @jim-nangano indicated he's also using skeletonized back and side covers.
Conclusion... I'm lost 🙂
Attached is what was printed successfully.
Printer = XL semi assembled, firmware = 6.1.3+7898, filament = Priline PCCF, layer = 0.2mm, nozzle=0.4mm ObXidian
RE: Extruder stops mid-print
Update
I loaded up the new RC1 firmware and did a five color test print, this one: https://www.printables.com/model/538505-mmu2smmu3-5-color-wheel
I wasn't testing the functionality of the nextruders, but I need to see if the color combination looked good. Well, first print had an error with nextruder #4 motor not turning. I'm like what the hell? So I tried printing it again, same error, same extruder, same layer start. I go check the github and see this possible remedy for the error.
The printer shows the message "Extruder motor is not spinning on tool #". In place of #, the number of the Dwarf board is shown.
"This problem occurs due to increased resistance between the Dwarf connector and the cable connector, which is caused by the cable and connector being held too firmly in position. Remove the dwarf-cover-connector, as it might hold the cable and its connector too firmly. Fully loosen the bolt that holds the part, and remove the bolt. The dwarf-cover-connector can then be spaced out more, and removed from the Nextruder assembly. "
So, that didn't make any sense. BUT!
I figured what did I have to lose, so I loosen the screw holding the connection halves together maybe three turns and tried the print again.
Son of a *****, the print completed without any issues.
So, if any of you are still having issues, loosen the connection screw a bit on the problem nextruder.
RE: Extruder stops mid-print
Further testing with the new firmware, I had more errors with "Nextruder motor not turning", even on a nextruder that I was having no issues with.
So, I rolled back the firmware to the previous version and everything was printed perfectly.
Come on Prusa, fix this damn issue!
RE: Extruder stops mid-print
Jim, which version did you rolled forward and rolled back to? So, I had this crazy idea, since Prusa support also asked me to test with the connector base completely removed. I'm thinking why not just print without any covers to the dwarf PCB. It's a bit ugly, sure, but better than a $5000 paper weight imo.
I just finished a few back to back 10 hour prints with no covers to the dwarf PCB. No issues on the known working tool heads. Going to test out the known non-working tool heads next. Will keep everyone here posted.
Further testing with the new firmware, I had more errors with "Nextruder motor not turning", even on a nextruder that I was having no issues with.
So, I rolled back the firmware to the previous version and everything was printed perfectly.
Come on Prusa, fix this damn issue!
RE:
I rolled back to 6.2 alpha 2
the part attached to the cable or the part attached to the dwarf board?
Jim, which version did you rolled forward and rolled back to? So, I had this crazy idea, since Prusa support also asked me to test with the connector base completely removed. I'm thinking why not just print without any covers to the dwarf PCB. It's a bit ugly, sure, but better than a $5000 paper weight imo.
I just finished a few back to back 10 hour prints with no covers to the dwarf PCB. No issues on the known working tool heads. Going to test out the known non-working tool heads next. Will keep everyone here posted.
Further testing with the new firmware, I had more errors with "Nextruder motor not turning", even on a nextruder that I was having no issues with.
So, I rolled back the firmware to the previous version and everything was printed perfectly.
Come on Prusa, fix this damn issue!
RE: Extruder stops mid-print
I rolled back to 6.2 alpha 2
the part attached to the cable or the part attached to the dwarf board?
Jim, which version did you rolled forward and rolled back to? So, I had this crazy idea, since Prusa support also asked me to test with the connector base completely removed. I'm thinking why not just print without any covers to the dwarf PCB. It's a bit ugly, sure, but better than a $5000 paper weight imo.
I just finished a few back to back 10 hour prints with no covers to the dwarf PCB. No issues on the known working tool heads. Going to test out the known non-working tool heads next. Will keep everyone here posted.
Further testing with the new firmware, I had more errors with "Nextruder motor not turning", even on a nextruder that I was having no issues with.
So, I rolled back the firmware to the previous version and everything was printed perfectly.
Come on Prusa, fix this damn issue!
The part that attached to the cable. Prusa's official name of the printable part is the dwarf connector.
RE: Extruder stops mid-print
I think long term without some sort of strain relief on the connector, flexing will break it off the board. There needs to be some sort of strain relief. Some had luck with just loosening the screw in the connector that squeezes it together. Apparently in some cases it squeezes the plug and wires too tight.