Hi,
I am running Marlin 1.1.8 firmware on Velleman Vertex K8400 printer that I redesigned to work in CoreXY mode. Everything works fine, except that printer sometimes unexpectedly resets itself while printing. So far I observed resets only when printing one particular gcode file. Full print takes about 2 hours and I had about 60% successful completions of the same gcode. Close look at the last failure revealed that the nozzle was pushed into already printed layers all the way to the glass bed. Most likely this caused problem with movement along X, Y and lead to reset. I’ve seen few posts about random resets caused by unexpected movements along Z-axis, but they all were related to UBL. I don’t have UBL. Other resets related posts talk about wiring and power supply issues. I’ve checked these as well – all looks good. I read also that this can be caused by main board performance and lowered LCD update rate down to 1 per/sec. This did not made any difference. Resets happen when I print via Octoprint and also when I print directly from SD card. The shape of the object is similar to letter “G” and along Y-axis it occupies about 90% of print space. I am printing with PETG with 100% infill.

Here is Octoprint log fragment covering the time of the last failure:

Send: N15996 G1 X162.742 Y181.969 E2239.89878*86
Recv: ok
Send: N15997 G1 X162.587 Y182.249 E2239.91211*90
Recv: ok
Send: N15998 G1 X162.474 Y182.521 E2239.92437*80
Recv: ok
Send: N15999 G1 X162.394 Y182.804 E2239.93661*82
Recv: start
Printer sent 'start' while printing. External reset? Aborting job since printer lost state.
Changing monitoring state from 'Printing' to 'Operational'
Recv: echo:Marlin 1.1.8
Recv:
Recv: echo: Last Updated: 2017-12-25 12:00
Recv: echo:Compiled: Apr 11 2018
Recv: echo: Free Memory: 3992 PlannerBufferBytes: 1232
Recv: echo:Hardcoded Default Settings Loaded
Recv: echo: G21 ; Units in mm
Recv: echo: M149 C ; Units in Celsius
Recv:
Recv: echo:Filament settings: Disabled
Recv: echo: M200 D1.75
Recv: echo: M200 T1 D1.75
Recv: echo: M200 D0
Recv: echoteps per unit:
Recv: echo: M92 X160.00 Y160.00 Z4266.66 E150.00
Recv: echo:Maximum feedrates (units/s):
Recv: echo: M203 X120.00 Y120.00 Z3.00 E8000.00
Recv: echo:Maximum Acceleration (units/s2):
Recv: echo: M201 X3000 Y3000 Z100 E10000
Recv: echo:Acceleration (units/s2): P R T
Recv: echo: M204 P3000.00 R3000.00 T3000.00
Recv: echo:Advanced: S T B X Z E
Recv: echo: M205 S0.00 T0.00 B20000 X10.00 Y10.00 Z0.30 E5.00
Recv: echo:Home offset:
Recv: echo: M206 X0.00 Y0.00 Z0.00
Recv: echo:Hotend offsets:
Recv: echo: M218 T1 X0.00 Y0.00
Recv: echo:Material heatup parameters:
Recv: echo: M145 S0 H210 B55 F165
Recv: echo: M145 S1 H240 B80 F0
Recv: echoID settings:
Recv: echo: M301 P63.00 I2.25 D440.00
Recv: echoD init fail
Communication timeout while idle, trying to trigger response from printer. Configure long running commands or increase communication timeout if that happens regularly on specific commands or long moves.
Send: M117 Print Done
Recv: ok
Send: M84
Recv: ok
Send: M104 T0 S0

Config files and the image of failed print with the hole in it are attached.
Just wonder if anyone else has experienced similar failures and looking forward to hear your suggestions on how to troubleshoot this.

Thanks

Edited 1 time(s). Last edit at 04/22/2018 08:26PM by lmcbmai.

I think, I found the problem - while printing this particular part, my XY steppmotors overheat to the level that mainboard resets itself. I reduced driver current and the temperature went slightly down (I can at least touch the motors now), but they are still rather hot. I'm looking into options of attaching temperature sensors, heatsinks and fans to the motors. Then I will switch fans on and off from Raspberry Pi based on temperature readings.

Edited 1 time(s). Last edit at 05/01/2018 06:01PM by lmcbmai.

Quote
lmcbmai
I think, I found the problem - while printing this particular part, my XY steppmotors overheat to the level that mainboard resets itself. I reduced driver current and the temperature went slightly down (I can at least touch the motors now), but they are still rather hot. I'm looking into options of attaching temperature sensors, heatsinks and fans to the motors. Then I will switch fans on and off from Raspberry Pi based on temperature readings.

The steppers should not be run hot, stepper current might need to be a little lower. Or You might need a more powerful stepper for your application.
Could even be that something is binding causing undo stress on the steppers.


I had a similar problem, it was not caused by the steppers. Turns out that of the four controllers purchased only the one controller caused the problem.
It was one of the chips on the controller that was causing the problem. Haven't spent any more time after the Manufacture gave me a replacement.
I had all four controllers adjusted exactly the same at this time so it was not because of the setup / firmware including PCB controller fans.
I believe it was the LM2596 Simple Switcher Power Converter, and one day when I have a lot of free time I intend to prove my diagnostics correct.

Edited 2 time(s). Last edit at 05/01/2018 06:30PM by Roberts_Clif.