Extruder suddenly reversing, restarting, reversing - so on. During print What could be the cause of my mendelmax 1,5+ (ultibots)? The extruder stepper motor can suddenly start going back and forth (maybe something like 1mm) continously for a minute or so. Then everything is ok again... until next minute. I have tried: Cleaning the extruder. Reconnecting ALL the wiring, checking for bad connections. Adjusting the pot on the stepper drivers (now set to 0,25V) Please ignore the bad bridging (/thickness) of the top layer... 7Jj16jFl.jpg mod_embed_images_loadimage('05829c0b71a9269866dfea63a2452181', '/forum/thumbcache/673/6ed/833/5fa/feb/ae4/721/8eb/499/8cc/85_800x400.png', 'http://i.imgur.com/7Jj16jFl.jpg', 'https://reprap.org/forum/addon.php?262,module=embed_images,check_scaling=1,url=http%3A%2F%2Fi.imgur.com%2F7Jj16jFl.jpg', '', 554462, 800, 400, 'Loading image ...', false); https://reprap.org/forum/read.php?262,554462,554462#msg-554462 Thu, 12 Mar 2026 09:29:20 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?262,554462,557614#msg-557614 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557614#msg-557614 But as Alex said, inspect the wires and if doubt replace the heater.]]> Downunder35m Printing Sun, 13 Sep 2015 05:24:45 -0400 https://reprap.org/forum/read.php?262,554462,557495#msg-557495 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557495#msg-557495 AlexY Printing Sat, 12 Sep 2015 21:39:48 -0400 https://reprap.org/forum/read.php?262,554462,557436#msg-557436 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557436#msg-557436 If the layer is too small, the extruder will pause.

Successful 6hrs print! :D

I also might have found the (or more than one?) errror. The extruder would not heat when I turned the heating on! - Just a tiny movement on the wire, and it started heating...


]]> Itek Printing Sat, 12 Sep 2015 15:27:55 -0400 https://reprap.org/forum/read.php?262,554462,557304#msg-557304 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557304#msg-557304 Simply check the speed setting after the next failure and increase the slowest speed a bit, or all if you dare.
I no longer go under 20mm/s for any movement and no problems ever since.]]> Downunder35m Printing Sat, 12 Sep 2015 07:18:52 -0400 https://reprap.org/forum/read.php?262,554462,557266#msg-557266 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557266#msg-557266
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Downunder35m
suddenly the snail-slow extruder started spinning so fast that it burnt through the filament

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Downunder35m
the nozzle moving all the way to the x-endstop and back.

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Downunder35m
I nailed it down to communication problems.

This has happened to me as well lately! - Didnt think this problem was connected to the extruder skipping steps/ back-forth movement though. As some of these problems were gone after I reconnected all the wiring in the 3D printer.

I will turn up the voltage to the extruder stepper motor now and turn on a 6hrs print. Will let you guys know how it went.

Will be continued...]]> Itek Printing Sat, 12 Sep 2015 04:57:49 -0400 https://reprap.org/forum/read.php?262,554462,557200#msg-557200 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557200#msg-557200 Was during a complicated print when suddenly the snail-slow extruder started spinning so fast that it burnt through the filament and partially melted it into the extruder (fun to clean and fix).
The next test caused the same thing to happen but combined with the nozzle moving all the way to the x-endstop and back.
Mind you I was using Simplify3D, which should not cause such problems (or so I thought).
I nailed it down to communication problems.
The stuff mainly happened shortly after I manually decreased the print speed to aid with details at this layer height.
But also with some extremely slow print moves, like when I tested the bridging speeds.
The software floods the printer board with commands until the buffer runs over.
Using hardware flow control helped a bit but only after INCREASING the crawling speeds the extruder accidents stopped.]]> Downunder35m Printing Fri, 11 Sep 2015 23:32:29 -0400 https://reprap.org/forum/read.php?262,554462,557156#msg-557156 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557156#msg-557156
I might go for 6inch later.]]> Itek Printing Fri, 11 Sep 2015 18:07:10 -0400 https://reprap.org/forum/read.php?262,554462,557127#msg-557127 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557127#msg-557127
Just curious, any reason why you didn't go for 6 inch props?]]> AlexY Printing Fri, 11 Sep 2015 16:42:00 -0400 https://reprap.org/forum/read.php?262,554462,557062#msg-557062 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,557062#msg-557062
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AlexY

If you're interested, I started a thread about my own 3D printed quad build, complete with a parts list: [forums.reprap.org]

I guess you should have a look at my build thread:

Pictures, and google translate is your friend:
[fpv.no]!]]> Itek Printing Fri, 11 Sep 2015 13:46:50 -0400 https://reprap.org/forum/read.php?262,554462,556685#msg-556685 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,556685#msg-556685
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Itek
I´ll just start printing as normal again (I have an upcoming project 3D printing a racing quad).

If you're interested, I started a thread about my own 3D printed quad build, complete with a parts list: [forums.reprap.org]]]> AlexY Printing Thu, 10 Sep 2015 16:13:11 -0400 https://reprap.org/forum/read.php?262,554462,556560#msg-556560 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,556560#msg-556560
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imqqmi
I found this in another thread, this is when just extruding and is always happening, would this also illustrate your intermittent problem?
[www.youtube.com]

Wow! Yes, It looks exactly like that!

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AlexY
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Itek
No, I didnt try pushing manually.Yes. I agree the stepper motor doesn´t seem powerful enough. Does anyone know if I turn the pot on the stepper driver to higher Vres voltage, the stepper will be more powerful?

Yes, turning the pot clockwise will increase the stepper motor torque but make it run hotter. If you increase it too much the driver will overheat and restart, causing skipping as well. Try turning it a little to see if it helps.

Aha! I did turn the pot counterclockwise. If I understand correctly, this will deacrease the motor power. I think my stepper motor controllers are cold, they have their own heatsink, with thermal paste and a fan constantly blowing on them.

I´ll just start printing as normal again (I have an upcoming project 3D printing a racing quad).

Will come back to this thread if I have succeeded! (or not) (:


Thanks!]]> Itek Printing Thu, 10 Sep 2015 12:00:39 -0400 https://reprap.org/forum/read.php?262,554462,556251#msg-556251 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,556251#msg-556251
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Itek
No, I didnt try pushing manually.Yes. I agree the stepper motor doesn´t seem powerful enough. Does anyone know if I turn the pot on the stepper driver to higher Vres voltage, the stepper will be more powerful?

Yes, turning the pot clockwise will increase the stepper motor torque but make it run hotter. If you increase it too much the driver will overheat and restart, causing skipping as well. Try turning it a little to see if it helps.]]> AlexY Printing Wed, 09 Sep 2015 16:35:31 -0400 https://reprap.org/forum/read.php?262,554462,556233#msg-556233 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,556233#msg-556233 [www.youtube.com]

Just thought of something. Since it's not happening always and only after a long time unattended, could it be the filament being in a knot, the extruder motor is stalling? You could try blocking the filament and see if this replicates the symptoms. Just a thought.]]> imqqmi Printing Wed, 09 Sep 2015 15:58:40 -0400 https://reprap.org/forum/read.php?262,554462,556218#msg-556218 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,556218#msg-556218
If you can't record video, maybe you can record the audio, maybe you can identify the problem by the sound alone. Skipping steps or fast back and forth motion can tell a lot what is happening.

Another idea is to hook up another thermistor onto the board and attach it to the stepstick chip or cooler. Repetier host will record the temperatures, maybe it is overheating after 4 hours and get some unexpected behavior. A fan could help in that case if you didn't use one already.

Maybe you can artificially push the printer to give this error sooner by turning the speed way up, maybe also increase acceleration. If it can show the error within minutes instead of hours would make it much easier.]]> imqqmi Printing Wed, 09 Sep 2015 15:30:47 -0400 https://reprap.org/forum/read.php?262,554462,556205#msg-556205 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,556205#msg-556205
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imqqmi
The reversing thing isn't repeatable, you can't reproduce it at will? Those are the harder things to troubleshoot. I just fixed some network printers hanging the spooler service in windows only around the afternoon. It took nearly a week before I could find a reproducable workflow of the problem.

It could be usb/serial related. If you own a sd card and the printer has a reader, long prints may be more reliable to print.

No, I cant reproduce it at will :(
Yes It makes it harder. I always print from my SD card reader.

Thats why Im asking you guys. :) Im glad you found out of your problem.


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AlexY
Did you get a chance to try manually pushing filament through? It still seems to me that the problem is with the stepper motor not being powerful enough. It usually happens when heat creeps up the hotend due to inadequate cooling and causes a jam, which would be fixed with better cooling.

Edit: Also, do you have a video of the problem?

No, I didnt try pushing manually.Yes. I agree the stepper motor doesn´t seem powerful enough. Does anyone know if I turn the pot on the stepper driver to higher Vres voltage, the stepper will be more powerful?

No video. Not sure If I got a camera that can shoot continously good quality video for 4 hrs or more....]]> Itek Printing Wed, 09 Sep 2015 15:03:03 -0400 https://reprap.org/forum/read.php?262,554462,555817#msg-555817 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555817#msg-555817
Edit: Also, do you have a video of the problem?]]> AlexY Printing Tue, 08 Sep 2015 23:04:26 -0400 https://reprap.org/forum/read.php?262,554462,555799#msg-555799 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555799#msg-555799
It could be usb/serial related. If you own a sd card and the printer has a reader, long prints may be more reliable to print.]]> imqqmi Printing Tue, 08 Sep 2015 18:51:53 -0400 https://reprap.org/forum/read.php?262,554462,555642#msg-555642 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555642#msg-555642
I was lucky to wintness it in that 6hrs print above. It only happened 2 times, and it was 4hrs into the print.

I have been printing recently, with success.]]> Itek Printing Tue, 08 Sep 2015 12:04:45 -0400 https://reprap.org/forum/read.php?262,554462,555361#msg-555361 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555361#msg-555361 imqqmi Printing Tue, 08 Sep 2015 02:22:09 -0400 https://reprap.org/forum/read.php?262,554462,555337#msg-555337 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555337#msg-555337
- Tim]]> tadawson Printing Tue, 08 Sep 2015 00:26:26 -0400 https://reprap.org/forum/read.php?262,554462,555213#msg-555213 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555213#msg-555213
Yes, a digital volt meter. Run the gcode and whenever it reverses, see if the voltage changes. From dir pin to ground.]]> imqqmi Printing Mon, 07 Sep 2015 15:21:34 -0400 https://reprap.org/forum/read.php?262,554462,555108#msg-555108 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555108#msg-555108
When you say "You could try putting a dvm on the dir pin of the extruder". Do you mean a digital volt meter? Also, between what pins? DIR and ___ ? Ground?

I expect the extruder need to be warm when I do this, but does the printer have to be runnning?

Thanks for your reply! (:]]> Itek Printing Mon, 07 Sep 2015 11:56:38 -0400 https://reprap.org/forum/read.php?262,554462,555058#msg-555058 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,555058#msg-555058
Also note that the generated gcode uses absolute positioning, when extruder is at say 100mm and then G1 E95 will retract. There are regular g92 e commands to reset it to zero.]]> imqqmi Printing Mon, 07 Sep 2015 09:58:36 -0400 https://reprap.org/forum/read.php?262,554462,554870#msg-554870 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,554870#msg-554870
I do agree that the extrusion is a bit too high, Ill turn down the extrusion multiplier a bit. Thanks.

What if I turned the knob on the stepper driver board (ramps) too low? What would happen?]]> Itek Printing Mon, 07 Sep 2015 01:46:26 -0400 https://reprap.org/forum/read.php?262,554462,554706#msg-554706 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,554706#msg-554706
You might also need to calibrate your extrusion. If your printer thinks it's extruding 100mm when it's actually pushing out 150mm then it would be likely to jam the extruder/hotend.]]> AlexY Printing Sun, 06 Sep 2015 12:29:42 -0400 https://reprap.org/forum/read.php?262,554462,554546#msg-554546 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,554546#msg-554546
I went into the gcode, edited it, so it started at the layer of problems.

Printed that layer:



So.. Its not the gcode. I do not see why it should retract at this stage.

Other ideas?
]]> Itek Printing Sun, 06 Sep 2015 04:51:44 -0400 https://reprap.org/forum/read.php?262,554462,554512#msg-554512 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,554512#msg-554512 imqqmi Printing Sun, 06 Sep 2015 02:21:49 -0400 https://reprap.org/forum/read.php?262,554462,554488#msg-554488 Re: Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,554488#msg-554488 Start there and let us know.]]> cat.farmer Printing Sat, 05 Sep 2015 21:56:36 -0400 https://reprap.org/forum/read.php?262,554462,554462#msg-554462 Extruder suddenly reversing, restarting, reversing - so on. During print https://reprap.org/forum/read.php?262,554462,554462#msg-554462
The extruder stepper motor can suddenly start going back and forth (maybe something like 1mm) continously for a minute or so. Then everything is ok again... until next minute.

I have tried:
Cleaning the extruder.
Reconnecting ALL the wiring, checking for bad connections.
Adjusting the pot on the stepper drivers (now set to 0,25V)

Please ignore the bad bridging (/thickness) of the top layer...

]]> Itek Printing Sat, 05 Sep 2015 18:44:29 -0400