RE: Core One crash/restart
I saw my first three crashes/restarts yesterday. I printed almost all weekend and then all of the sudden I got three crashes/restarts on the same print. Very strange. It's been really solid before this.
RE: Core One crash/restart
For anyone seeing this issue, check whether your nozzle is partially clogged/gummed up. It's an off the wall theory and I have no clue why it would occur, but I saw my nozzle temp drop slightly right before it happened once and did find the nozzle partially clogged. It hasn't happened since, and before that changing the nozzle seemed to fix the issue. I'm wondering if the reboot is being triggered by something in the nozzle when it's partially clogged, even if still printing okay. Especially seeing as it has a tendency to happen later in longer prints.
RE: Core One crash/restart
I worked on this issue with Prusa Support last night for over four hours. I’ve been unable to identify a root cause. The printer simply dies after sustained high speed diagonal movements. I have a model I’ve been trying to print that crashes the printer 100% of the time, on the first layer. 10 minutes from print start to hardware crash. Every. Time. I ran 10 tests last night and had 10 failures.
I’m actually “printing” without any filament installed as per Support’s suggestion for not wasting material. The filament was unloaded and the sensors were disabled. Still crashes. Every time.
This Core One is a MK4S conversion. It has worked flawlessly up until this point.
RE: Core One crash/restart
Can you please report it as GitHub issue for firmware developers with problematic gcode attached? Having sample that repeatedly crashes the printer would help them a lot to find the root cause of the issue and fix it.
RE: Core One crash/restart
I have a model I’ve been trying to print that crashes the printer 100% of the time, on the first layer. 10 minutes from print start to hardware crash. Every. Time. I ran 10 tests last night and had 10 failures.
As @biomech wrote, this is a major step forward in troubleshooting! Does it always crash at exactly the same point in the print? That would really point towards a firmware bug, rather than power supply issues, bad contacts, motor driver overheating or whatever.
RE: Core One crash/restart
Unfortunately I provided the same file to Support and it did not crash on their machine. So the issue seems to be machine-specific still. I can provide a link here to the bgcode if someone wants to try it on theirs.
RE: Core One crash/restart
Unfortunately I provided the same file to Support and it did not crash on their machine. So the issue seems to be machine-specific still. I can provide a link here to the bgcode if someone wants to try it on theirs.
Yes, please 🙂
Even if it doesn't crash our printers, it might be a good "stability test" to make sure ours are fine and won't become unstable at some point.
Sorry to hear about your continuous issues though :/
RE: Core One crash/restart
Here's a link to the bgcode, downloaded from PrusaConnect: https://drive.google.com/file/d/1lDnrUe323SxiLeBkq7pE4PC0c1EHNSpk/view?usp=sharing
I've also attached a .zip version of the same file to this post. If you're going to try this file I'd recommend doing the following:
1. Unload the filament. If it's going to the fail there's no point in wasting material.
2. Disable the filament sensor when the printer complains it doesn't detect any filament.
3. Ignore the filament type mismatch when it complains about that.
This model is a 10:1 Lego Cutlass, from printables: https://www.printables.com/model/149904-lego-inspired-cutless-2530
My printer crashes reliably within the first layer. I'd be interested to know if anyone else's does the same thing.
For those hoping it's power supply-related, I don't think that's the case. I say that because last night I spent a good long while swapping out the PSU in my Core One for the newer PSU in my MK4S. It didn't help. The Core One PSU was labeled as revision 1. The MK4S PSU was labeled as revision 3.
RE: Core One crash/restart
Hi there!
Any luck with the new power supply? I replaced the main Buddy board and power cables between the PSU and Buddy, along with the power panic and Buddy->Extender cables and still having the same issues (if not worse than before). Curious as to whether the PSU replacement worked for you.
RE: Core One crash/restart
Following up on my own post here. Here's a list of what I've tried so far:
I tried 3 different times using PLA filament. It crashed all three times. I'm printing from the spool, mounted in the side filament holder. I changed to a different spool of PLA filament. It crashed with that also.
I'm using the Prusa smooth PEI sheet from my MK4S as the print sheet. I tried another smooth PEI sheet from a different MK4S and it crashed with that also.
I tried enabling the log file in the Settings --> System menu. However, when the printer crashed there was no content in the log file. The file size was 0 bytes.
I have disabled the filament sensor and run without filament and the failure occurs within the same spot of the 3rd layer.
I hard reset the printer to factory defaults and reinstalled the firmware, 6.3.3, from a fresh download to the Prusa-supplied USB stick. The printer passed all calibrations on the first try. I configured WiFi. I linked the printer to PrusaConnect. All other settings left at default. The printer crashed on the next test.
I swapped the PSU with the PSU from a working MK4S. The Core One still crashed with the new power supply.
I removed and checked the power panic cable for damage. I found none. The Core One still crashed again when I reinstalled the cable and retested.
I rechecked the power supply connections on both the PSU side and the xBuddy board side. They are tight with no wiggle or play in the power connectors.
I checked the length of the xBuddy power supply cables for damage. I found none.
I checked all the connections on the xBuddy board for discolored connectors, melted cables, or other indications of damage. I found none. Pictures of the xBuddy box are available if needed.
I undid and rechecked the straps to the printhead/nextruder main cable to make sure there was enough slack. There was plenty and the printhead has full range of motion.
I tried a different power outlet on my powerstrip. I tried without the powerstrip connecting directly to the wall outlet. I moved the printer to another room and connected it to a pure sine-wave uninterruptible battery backup. I tried a different power cord. The printer crashed in all scenarios. The print failure statistics do not indicate any power-outage failures.
I have printed this file almost 15 times. It has crashed every time. Sometimes on layer 1, sometimes on layer 3. It has never finished layer 3 without crashing.
It has NEVER crashed on layer 2. Layer 2 does not have long diagonal movements. Layers 1 and 3 do and it always crashes on layer 1 or layer 3.
Ambient room temperature is 23 - 24C. Chamber temp is reported at 33C. Crashes have happened with chamber temps as low as 28C. Issue does not seem to be temperature related.
I tried a different USB stick. It did not help, it crashed on layer 3.
I tried a brand new hotend, never been used. It did not help, it crashed on layer 3.
I lowered the bed, loosened the trapezoidal nuts, raised the bed, lowered the bed, retightened the nuts (per Support). It crashed on layer 3.
I created a new model. Just a basic cube in the slicer. Short, narrow, and long. Oriented 45 degrees front left to rear right. It crashes on layer 3, just like the original Lego model that started this whole mess.
I printed the "Benchy_Rules_0.4n_0.2mm_PLA_COREONE_14m.bgcode" sample g-code file. It worked fine and the quality was outstanding.
RE: Core One crash/restart
Wow -- what a painful odyssey. Isn't it long overdue that Prusa sends you a new printer and you return your current one for analysis, exorcism or ceremonial burial?
RE: Core One crash/restart
Wow -- what a painful odyssey. Isn't it long overdue that Prusa sends you a new printer and you return your current one for analysis, exorcism or ceremonial burial?
The printer prints fine other than this particular type of motion so I'm not keen to get it replaced entirely. I'd like to discover the root cause of this issue so it can be fixed, for me any everyone else in this thread that's seen similar crashes.
RE: Core One crash/restart
Posted by: @jurgen-7
Wow -- what a painful odyssey. Isn't it long overdue that Prusa sends you a new printer and you return your current one for analysis, exorcism or ceremonial burial?
The printer prints fine other than this particular type of motion so I'm not keen to get it replaced entirely. I'd like to discover the root cause of this issue so it can be fixed, for me any everyone else in this thread that's seen similar crashes.
Your choice, of course. I appreciate the altruism, but am slightly concerned -- although not surprised -- about the "I'd rather keep this one, who knows how many things might be wrong with a replacement" attitude. Prusa should be concerned about that attitude as well, since it does not bode well for the quality perception of their products.
It seems very time-consuming to just take dozens of stabs in the dark, chainging various things around to see whether the crash goes away. A more systematic approach to narrow down the root cause would probably be more productive. Do you have measurement capabilities, e.g. an oscilloscope you could use to monitor supply voltages? Ideally one with storage capability, so you can capture the moment of the crash and just before. Or can Prusa support provide a custom firmware with extended logging capability?
RE: Core One crash/restart
Posted by: @jurgen-7
Wow -- what a painful odyssey. Isn't it long overdue that Prusa sends you a new printer and you return your current one for analysis, exorcism or ceremonial burial?
The printer prints fine other than this particular type of motion so I'm not keen to get it replaced entirely. I'd like to discover the root cause of this issue so it can be fixed, for me any everyone else in this thread that's seen similar crashes.
Your choice, of course. I appreciate the altruism, but am slightly concerned -- although not surprised -- about the "I'd rather keep this one, who knows how many things might be wrong with a replacement" attitude. Prusa should be concerned about that attitude as well, since it does not bode well for the quality perception of their products.
It seems very time-consuming to just take dozens of stabs in the dark, chainging various things around to see whether the crash goes away. A more systematic approach to narrow down the root cause would probably be more productive. Do you have measurement capabilities, e.g. an oscilloscope you could use to monitor supply voltages? Ideally one with storage capability, so you can capture the moment of the crash and just before. Or can Prusa support provide a custom firmware with extended logging capability?
I never said I was worried about other things being wrong with the replacement. I'm more concerned about it being destroyed in shipping than something new being wrong with it.
Support is sending a new Nextruder main cable for me to install, so I'll be swapping that in once it arrives. In the meantime I've got a few more things I'm going to investigate to see if I can find the issue, or, at the very least, cross a few more potential things off the list.
I do not have a scope at my disposal. Even if I did, I'm not familiar enough with debugging electronics at that level to be even remotely capable of using it effectively.
RE: Core One crash/restart
I have no the same problem with my converted Core one.
A few days everything was good, but now a large PETG print crashes nearly every layer 🙁
RE: Core One crash/restart
I got a similar problem and I got it on video while filming the back of the printer with the board and the PSU visible.
It beeps 10 times. The PWR LED stays on all the time. On both the board and the PSU. The crash happens pretty randomly. For now it happend with PETG prints which take all around 4.5h. Sometimes it only happens once and sometimes it happens up to 7 times. When I used the printer for the first time it didn't happen and it seems to get worse over time but I didn't collect enough evidence to be sure about that. It seems that it happens less in silent mode.
Here the video: https://www.youtube.com/shorts/KIW79EtBXsY
The Video shows the crash at around 55s and The print automatically continues after a few seconds.
RE: Core One crash/restart
I got a similar problem and I got it on video while filming the back of the printer with the board and the PSU visible.
It beeps 10 times. The PWR LED stays on all the time. On both the board and the PSU. The crash happens pretty randomly. For now it happend with PETG prints which take all around 4.5h. Sometimes it only happens once and sometimes it happens up to 7 times. When I used the printer for the first time it didn't happen and it seems to get worse over time but I didn't collect enough evidence to be sure about that. It seems that it happens less in silent mode.
Here the video: https://www.youtube.com/shorts/KIW79EtBXsY
The Video shows the crash at around 55s and The print automatically continues after a few seconds.
This is the exact same behavior as my unit. I was able to get console debug output from the usb-c port and the printer has indicated it's activating the power panic. But there's no loss or break in power here. I'm running out of ideas.
RE:
So what are the possibilities?
- voltage drop caused by high speed motor movement, and out of spec power supply - could be tested even with a good multimeter.
- firmware error - false detection
- faulty xBuddy/extension board
Unlikely common reasons, but possible for some people:
- loose connectors
- using a poorly grounded socket
RE: Core One crash/restart
Maybe the quality of the PSU is not very good. Currently I'm trying the printer using a different socket behind a net filter. It crashed once already though. The question is now if it crashes less. Why am I doing this? Whenever my fridge turn on or off I have a huge power spike and before putting my AVR behind a net filter I always had a verd noise out of my speakers. So maybe the PSU is very sensitive to such kind of behaviour in the power net? Of course this is all nothing but speculation.
RE: Core One crash/restart
I've been working with support every night so far this week. We've narrowed down the (suspected) problem to the x-axis motor. The issue only seems to happen during long front left to rear right movements (45 degrees). In those scenarios the x-axis motor is doing most (all?) of the work moving the print head. After ~10 minutes of this sort of movement a power panic is triggered.
We tested this by swapping the x-axis and y-axis motor connectors on the xBuddy board. This essentially inverted the printbed from the printer's perspective. Instead of homing in the front right, it homed in the rear right corner. What this did was move the load from the x-axis to the y-axis motor while keeping the connector on the xBuddy board the same. The problem did not happen with the y-axis handling the movements.
It's entirely possible the x-axis motor isn't the problem, but it certainly looks related at the moment. A new x-axis motor is being sent to me.