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Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

I got a new cable from Prusa, will install it with the Jerry's updated dwarf cover and do some tests with the new firmware. Worst case scenario, rollback firmware and wait for RC2.

 

Posted : 15/01/2025 11:54 pm
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

You know what would be crazy is to print that part in tpu. 🤔

Posted by: @jerry-lee

 

Posted by: @jim-nangano

I rolled back to 6.2 alpha 2

the part attached to the cable or the part attached to the dwarf board?

Posted by: @jerry-lee

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. 

Posted by: @jim-nangano

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.

 

Posted : 16/01/2025 3:30 pm
Jerry Lee
(@jerry-lee)
Eminent Member
RE: Extruder stops mid-print

ha... I was thinking of the exact same thing last night to print the part with some 95A TPU.  

Posted by: @jim-nangano

You know what would be crazy is to print that part in tpu. 🤔

Posted by: @jerry-lee

 

Posted by: @jim-nangano

I rolled back to 6.2 alpha 2

the part attached to the cable or the part attached to the dwarf board?

Posted by: @jerry-lee

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. 

Posted by: @jim-nangano

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.

 

 

Posted : 16/01/2025 3:37 pm
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

Well I can’t do any of this until Sunday, so if you do, let me know the results.

Posted by: @jerry-lee

ha... I was thinking of the exact same thing last night to print the part with some 95A TPU.  

Posted by: @jim-nangano

You know what would be crazy is to print that part in tpu. 🤔

Posted by: @jerry-lee

 

Posted by: @jim-nangano

I rolled back to 6.2 alpha 2

the part attached to the cable or the part attached to the dwarf board?

Posted by: @jerry-lee

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. 

Posted by: @jim-nangano

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.

 

 

 

Posted : 16/01/2025 3:40 pm
Theevilrocky
(@theevilrocky)
Eminent Member
Topic starter answered:
RE: Extruder stops mid-print

Wanted to leave a mark here that before installing the new dwarf board and cable (provided by warranty) i printed the possible fix: https://www.printables.com/model/1124941-secure-xl-nextruder-cable-connector-solution

I would also consider this as a working solution - 5 hours into print and everything is going smoothly.

Before another failure, won't change the dwarf board nor the cable.

Posted : 17/01/2025 2:13 pm
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

Friday night, more testing!

Test #1: firmware 6.1.3: With the secure cable connectors on. Five color print test successful.

Test #2: firmware 6.2.0-RC1: With the secure cable connectors on. Five color print test fail on extruder #4

Test #3: firmware 6.2.0-RC1: Removed all cable connector covers. Five color print test successful.

Test #4: firmware 6.2.0-RC1: Added TPU cable connector covers without screws. Five color print test successful.

Interesting, I'll add screws to the connectors and repeat the testing.

Posted : 18/01/2025 1:17 am
Brian
(@brian-12)
Honorable Member
RE: Extruder stops mid-print

 

Posted by: @jim-nangano

Friday night, more testing!

Test #1: firmware 6.1.3: With the secure cable connectors on. Five color print test successful.

Test #2: firmware 6.2.0-RC1: With the secure cable connectors on. Five color print test fail on extruder #4

Test #3: firmware 6.2.0-RC1: Removed all cable connector covers. Five color print test successful.

Test #4: firmware 6.2.0-RC1: Added TPU cable connector covers without screws. Five color print test successful.

Interesting, I'll add screws to the connectors and repeat the testing.

So what exactly did you do on test 4?  You reprinted the modified cable cover from TPU? 

Posted : 18/01/2025 1:54 am
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

Yes, I printed the standard cable cover in TPU.

Posted by: @brian-12

 

Posted by: @jim-nangano

Friday night, more testing!

Test #1: firmware 6.1.3: With the secure cable connectors on. Five color print test successful.

Test #2: firmware 6.2.0-RC1: With the secure cable connectors on. Five color print test fail on extruder #4

Test #3: firmware 6.2.0-RC1: Removed all cable connector covers. Five color print test successful.

Test #4: firmware 6.2.0-RC1: Added TPU cable connector covers without screws. Five color print test successful.

Interesting, I'll add screws to the connectors and repeat the testing.

So what exactly did you do on test 4?  You reprinted the modified cable cover from TPU? 

 

Posted : 18/01/2025 12:21 pm
CUKIO34
(@cukio34)
Active Member
RE: Extruder stops mid-print

I like others have been having this issue. Customer service sent me a new dwarf board/cable that didn't work. Customer service hasn't responded to my follow-up :(.

couple questions:

1. Can this replacement part be printed in PLA? Is there a preferred filament type?

2. How are you reverting the firmware back to previous versions. When I put a older firmware on the usb stick it wont detect on restart.

Thank you Jim and everyone else who have worked hard to fix this issue. I am so far behind in orders and I was starting to get really frustrated with this machine.

Posted : 18/01/2025 7:01 pm
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

When you power up the XL, when the boot screen  omes up, hold down the button for like three seconds. The printer will prompt if you want to flash with the file on the stick.

Because a tight connector can cause issues, they say to remove the connector shell from the cable. So I printed the connectors in TPU and that seems to be working well. YMMV

 

Posted by: @cukio34

I like others have been having this issue. Customer service sent me a new dwarf board/cable that didn't work. Customer service hasn't responded to my follow-up :(.

couple questions:

1. Can this replacement part be printed in PLA? Is there a preferred filament type?

2. How are you reverting the firmware back to previous versions. When I put a older firmware on the usb stick it wont detect on restart.

Thank you Jim and everyone else who have worked hard to fix this issue. I am so far behind in orders and I was starting to get really frustrated with this machine.

 

Posted : 18/01/2025 7:14 pm
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

The TPU connection covers worked very well, 13 hour multicolor print finished without any issues.

Posted : 21/01/2025 11:50 pm
pcgeekesq and Brian liked
pcgeekesq
(@pcgeekesq)
Eminent Member
RE: Extruder stops mid-print

 

Posted by: @jim-nangano

The TPU connection covers worked very well, 13 hour multicolor print finished without any issues.

 

I'm glad it worked for you, but given that I have my XL in a Prusa Enclosure and sometimes run with the lid down and bellows up (for materials that need that) I'd be worried about the low heat deflection temperature of TPU (50C and up).  Any thoughts on that or it a non-issue?

Posted : 22/01/2025 3:53 am
Theevilrocky
(@theevilrocky)
Eminent Member
Topic starter answered:
RE: Extruder stops mid-print

Today i received also an official email for a fixfrom support.

The process is straightforward and should take no more than 10–15 minutes.You will need a few screws and printed parts. You can either print these parts yourself and follow these simple instructions, or contact our support team via this form, and we will send you the necessary components in the first half of February the latest.

Parts

https://www.printables.com/model/449554-xl-printable-parts

Instructions

https://help.prusa3d.com/guide/how-to-replace-the-main-cable-connector-cover-xl_831370

At the moment i'm satisfied with the previously printed parts so i cant confirm if Prusa provided fix works.

But it probably does, same principle.

 

 

Posted : 22/01/2025 5:28 pm
Brian liked
Jim Nangano
(@jim-nangano)
Trusted Member
RE:

I just checked printables, the cable cover and dwarf cover have some significant changes and was posted today! I will print them tonight and install them tomorrow.

Posted by: @theevilrocky

Today i received also an official email for a fixfrom support.

The process is straightforward and should take no more than 10–15 minutes.You will need a few screws and printed parts. You can either print these parts yourself and follow these simple instructions, or contact our support team via this form, and we will send you the necessary components in the first half of February the latest.

Parts

https://www.printables.com/model/449554-xl-printable-parts

Instructions

https://help.prusa3d.com/guide/how-to-replace-the-main-cable-connector-cover-xl_831370

At the moment i'm satisfied with the previously printed parts so i cant confirm if Prusa provided fix works.

But it probably does, same principle.

 

 

 

Posted : 22/01/2025 5:35 pm
KevChris
(@kevchris)
Active Member
RE: Extruder stops mid-print

FYI,  The step Files have not been modified, they are the older style.  Make sure to print the stl files

Posted : 22/01/2025 7:52 pm
Jerry Lee
(@jerry-lee)
Eminent Member
RE: Extruder stops mid-print

Here's the STEP file for the base. I do have a skeletonized version getting printed and will be up on Printables shortly if you'd rather wait for that. 

Posted by: @kevchris

FYI,  The step Files have not been modified, they are the older style.  Make sure to print the stl files

 

Posted : 22/01/2025 7:57 pm
Jerry Lee
(@jerry-lee)
Eminent Member
RE: Extruder stops mid-print

Attached is a preview of the skeletonized version of the new base cover. Still on the printer getting printed in PCCF, but already have the connector printed in Overture TPU.

Posted : 22/01/2025 8:00 pm
Jim Nangano
(@jim-nangano)
Trusted Member
RE: Extruder stops mid-print

did you convert the STL into a step file?

Posted by: @jerry-lee

Attached is a preview of the skeletonized version of the new base cover. Still on the printer getting printed in PCCF, but already have the connector printed in Overture TPU.

 

Posted : 22/01/2025 8:08 pm
Jerry Lee
(@jerry-lee)
Eminent Member
RE: Extruder stops mid-print

I did and cleaned it up a bit. The new release was missing all kinds of chamfered corners. 
I've just posted the skeletonized version on printables and also upload the new normal version step file. Hope this helps.

Posted by: @jim-nangano

did you convert the STL into a step file?

Posted by: @jerry-lee

Attached is a preview of the skeletonized version of the new base cover. Still on the printer getting printed in PCCF, but already have the connector printed in Overture TPU.

 

 

Posted : 22/01/2025 8:14 pm
KevChris liked
KevChris
(@kevchris)
Active Member
RE: Extruder stops mid-print

Thank you!  I haven't found a "convenient" way to convert STL to Step in fusion yet.  I appreciate your effort!!

Posted : 22/01/2025 8:19 pm
Jerry Lee liked
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