Problems with Prusa XL since version 6.2.1
Since I updated my Prusa XL 5T printer in February, it hasn't stopped giving me problems because I added the four missing printheads and changed the software. It was a great printer, but now it's a piece of junk. It constantly fails to calibrate. When I calibrate it and start printing, the motors jump the belt and break it. I changed the belts thinking it would fix it, but it still doesn't... and these errors also occur:
extruder motor is not spinning on tool (17536)
Error Homing Z
Toolchanger error
And now with version 6.4.0, Prusa Connect isn't working for me, and it's giving me all the problems in one printout. Please don't release any more versions until you fix all these issues. A tool like this is worth a lot of money for it to fail so much. We're not beta testers, and I need the machine to work. It's causing me many more problems than it did when it arrived. I hope for a solution as soon as possible. If anyone else is experiencing the same problem, please let me know.
PS I'm testing which of the versions from February 2025 onwards gives the least problems to be able to work with it since the previous versions that didn't give problems are not there.
I've had two, perhaps three failed prints on the XL this year, all, I think, my fault - it's like my old MK3, a completely reliable workhorse.
Collect some videos/photo's of your issues and contact Prusa Support via chat; you will need your machine's serial number.
Cheerio,
RE: Problems with Prusa XL since version 6.2.1
6.4 alpha is broken. See https://github.com/prusa3d/Prusa-Firmware-Buddy/issues/4812
For me it crashes big time when trying to dock at the end of each and every print to the point that it has ripped the belt out.
No issues though with earlier versions. I have one of the first models and had some teething pains but it has been rock solid for a long time.
RE: Problems with Prusa XL since version 6.2.1
Since alpha is out, I haven't had a successful print yet. Tool changer crashes, in the middle of the print, all of a sudden a belt skips/jumps over and causes layer shifts (although belt tension is fine and homing tower looks good). z-axis callibration results in an error, then reboots itself and error pops up and nothing helps but rebooting again. Those crashes happen randomly. The only repeatable crash or error while z-callibration. During dock callibration the crash also happens, today during dock calli,and in the middle of the tool offset callibration.
nightmare
So report your issues with the alpha software - preferably on Github or at least on the announcement thread here on the forum - not in a separate thread like this one ... then roll back to stable software until the next pre-release software is posted for testing.
Cheerio,
RE: Problems with Prusa XL since version 6.2.1
It seems that version 6.4 of the software has a toolhead collision issue. After updating to 6.4, I also experienced frequent collision alarms during the toolhead docking process after prints were completed. Upon checking, I found that the issue occurs when the printer homes and purges the tool at the beginning — it makes an unusual noise and the homing position becomes misaligned. All of these problems disappeared after I downgraded the firmware to version 6.26. Try downgrading the firmware and see if the issue is resolved
RE: Problems with Prusa XL since version 6.2.1
After performing the hard-reset, downgrading FW to 6.2.5, no homing errors, no z-callibration errors. All calibrations performed flawlessly, even home tower doesn't have weird artifact on the front wall as it used to have with 6.4.0 alpha - purely due to firmware because on the back X there is no artifact, both Ys also don't have that artifact. With 6.2.5. that weirdo is gone.
So yes, downgrading the firmware and recalibrating helped a big deal - prints finish successfuly.
RE: Problems with Prusa XL since version 6.2.1
For those that have had issues what version did you settle on? I made the mistake of updating to 6.4.0 without noting what version I was on and now I'm trying to find a stable version, any suggestions? I believe I was at the point where the USB disconnect issues had been minimized but would still occasionally occur, but with the option to resume. That was close enough to stable.
RE: Problems with Prusa XL since version 6.2.1
I upgraded to the 6.4.0 "final" release and after recalibrating haven't had one issue. But I guess I must have been lucky because Prusa just pulled 6.4.0 and recommend downgrading.
No idea why I've been printing for weeks no problem. I have a close-to-day-one machine, maybe that has something to do with it.
Formerly known on this forum as @fuchsr -- https://foxrun3d.com/
I only upgraded a few weeks ago - for some time the link I usually follow was not itself updated so I didn't realise that 6.4.0 had been released for the XL but like most users I have had no issues and never have, it just works. Like @foxrun3d mine is another early XL, I have replaced two of the 0.6 nozzles with 0.4 but otherwise no changes. I don't see any point in rolling back unless issues occur.
I am a little surprised that Prusa have withdrawn the version as I strongly suspect that problems are related to poor initial assembly throwing off fine adjustments. These rare issues are insanely hard to debug - I remember a software issue about thirty years ago where a particular program on an early ARM computer suffered a rash of problems but only for a few weeks at a time on any one machine and only on a few computers at any one time; it wasn't until two users were persuaded to bring in their computers and we eventually noticed that both were using a free-download, comic, animated puppy-dog mouse pointer that we nailed the contention ... and I can't remember if we actually installed a fix or just specified "don't use that pointer" as it was going out of vogue in any case.
I guess that Prusa, despite having a bunch XL's in the print farm working 24/7 just couldn't reproduce the problem until, presumably, someone local returned a machine without disassembling it for transport.
Cheerio,