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Printing issues ...
Dizybear - did you confirm the bed is set for 24V. If its set for 12V you will be drawing about 15amps. If the driver survives you will have maxed out your PSU.
Chances are the driver is limiting the current but the hot end can be doing the same.
Aschie - whats the latest on your issue? Yours seems to be a software issue - The error message "thermal runaway" is being triggered when the temperatur
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MCcarman
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Printing
What layer height have you set? This looks like the layers are not being forced together. Check your layer height is no more than 80% of the nozzle diameter. So for a 0.4mm nozzle set the layer height less than 0.33mm.
Or could be under extrusion so check the layer height first.
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MCcarman
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General
Since the Z height doesn't change and the hot end is actually moving to the correct positions it can only be an extrusion issue.
I don't expect this is due to Gcode (check if you want) so its about flow rate through the hot end.
With modern tensioned idlers on the extruder you can overcome grinding situations since the filament is pressed against the hobbed bolt regardless of the filament size. S
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MCcarman
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Printing
Since this was extruding OK at lower temperatures you shouldn't assume just changing the extruder so you can increase the idler load will solve the issue.
I would be looking at the temperature effects. Sounds like the higher temperature is causing the hot end jam. So we need to confirm there is no strange installation issues such as a short heat break tube, insufficient insertion of the heat brea
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MCcarman
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Printing
Lets see if we can get some interest in this one.
It does seem an odd issue and you have done some good checks.
As you say it doesn't seem to be mechanical.
Have you looked at the Gcode to check that is correct?
Since the issue seems to be related to corners, which is actually motor speed changes then any acceleration control parameters may have an effect. Might be worth stating these.
Might be g
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MCcarman
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Printing
Wondering if its moisture absorption.
May be a coincidence but a lot of these surface issues seem to crop up with black material.
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MCcarman
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Printing
This some how seems familiar.
Looks like the new nozzle is "taller". Can't tell if the across flats is smaller but it looks it.
If the tip is further from the heater and/or the across flats is smaller then it will run cooler at the outlet. Try bumping the temperature up a bit?
Is your infill speed higher than your perimeter speed? If so this may contribute to why the infill is having an affect.
I
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MCcarman
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Printing
Some thoughts:-
Presumably your new hot end has a different nozzle.
Might be worth a close look at the flat area. Do you have a fixed width for your print width and is it more than 20% larger than the nozzle.
You could be trying to print widths wider than the flat area of the nozzle which will cause it to print a V groove that the next layer bounces over. I am thinking this is probably more prono
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MCcarman
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Printing
Here is a few considerations.
Have you considered making the frame wider in Y? It will be more stable, big enough to make into an enclosure?.
Your current design looks like the centre of the bed will be over the lower frame in max and min Y position. If its any further you could lose stability. Triangulation gives the greatest rigidity so strong beams may not be as useful as triangulated corners
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MCcarman
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General
I don't use autoleveling or Marlin but just check you have the offsets set correctly.
The sensor to nozzle z offset is particular for the auto levelling but not related to the 1st layer height.
However the Z offset in slicer is the distance between the nozzle and the bed at 0 height. Slicer compensates for this in calculating the Z height it will request in the Gcode. If Marlin has an equivalent
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MCcarman
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Printing
What are "normal values"?
If you disconnect the thermistor and get 0degrees that's not normal. You should get an error message.
Have you got an additional resistor in parallel to the thermistor. (Short on the controller board). That would create a temperature reading (that may be 0). Then when you add the thermocouple it will pull the resistance down and can trigger the max temp error.
A change
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MCcarman
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General
220-230 seems high for PLA. I am no expert as I mainly use ABS. I have read on here that too high a temperature can cause the pla to melt and flow back up the hot end where it cools-solidifies and jams the hot end. I have seen on here temperatures for PLA quoted at around 185 - 190.
Another possibility is that the idler pressure on the extruder gear is too high. Normally I would have expected gri
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MCcarman
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Prusa i3 and variants
Not my field but looks like an electrical issue. The error code seems to indicate you have sensor fault and the motors should not be activated.
Recheck all wiring, pins and jumper settings. Check for short circuits. Power up without the motors, then reconnect each motor in turn to see what causes an issue.
If your board allows you could try turning the 12v OFF and running the controller off the U
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MCcarman
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Prusa i3 and variants
You are sure its PLA filament?
Use the values you know are correct or sensible. Measure the filament diameter if possible. leave the feed rate at 100%. bottom layers at a sensible number ( 4), layer height 0.2, infill 40%. Retraction setting 4mm (long Bowden), slow speed 40mm/s, turn support off. Then show us the results or tell us what's wrong.
Check your settings - we can some times miss the ob
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MCcarman
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Printing
Flow : 150 % - Ok for a first layer but not for a generic setting.
Have you calibrated your extruder?
Looks like under extrusion with some oozing blobs.
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MCcarman
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Printing
Whats the filament like?
Could be one side of the filament role is poor for some reason.
Is the extruder idler wheel/bearing damaged/sticking/has a lump of filament stuck to it.
What is the route the filament takes to the extruder. I have my filament drum under my printer and feeding up the back. I had to make a guide to keep it away from the bed to avoid the bed bending the filament - bent filam
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MCcarman
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Prusa i3 and variants
Thanks Paul.
Quite Fascinating.
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MCcarman
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Printing
It does seem to be printing these. They are consistently at about 40degrees.
These actually look repeatable if you compare the different parts.
Have you tried a preview of the code to check this isn't a problem in the model or the slicing.
With complex (curved) surfaces you can get model errors that are hard to identify.
If you looked at a single layer at just the printing you may miss it as it w
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MCcarman
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Printing
Can anyone clarify how the IR sensor works and its sensitivity.
I assume its triggering based on the amplitude of the IR frequency it is filtered for. So I would assume that a heated bed will affect the response based on its temperature - it radiating a broad spectrum of frequencies.
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MCcarman
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General
If I understand this right your problem is that there is a position error that's incremental on every Y movement. Such that a single movement of 100mm gives a different travel to 10 movements of 10mm.
That implies it is related to either starting a move or finishing a move. As the control factor is motor steps it must be related to the number of step signals for a given move.
So the size of the m
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MCcarman
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General
Is the X belt aligned with the drive gear and idler?
Do you have flanges on the drive gear or idler?
Are the shafts perpendicular to the X axis (Motor is mounted square)
Flanges and some misalignment may cause the belt to ride up on the flange increasing the effective diameter and there fore the travel.
I would expect the carriage side of the belts to be the issue as the other side goes right acr
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MCcarman
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Prusa i3 and variants
I think there are more issues than 1st layer sticking.
What size nozzle do you have? Set the layer height no more than 80% of the nozzle size. So for a 0.4nozle max layer height 0.32mm.
You can over extrude the 1st layer to get a good base so set it to 150%.
Your layers are all over the place so are the belts tight (and the bearing fixings).
Looks like under extrusion as well so calibrate the ext
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MCcarman
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Printing
The other possibility Is that the boards are different. All components have a tolerance so there will be subtle differences.
Usually some one has asked about temperatures by now. It does look like one could be hotter than the other. That's not the setting temperature but the reported temperature being the issue.
If you are actually running the hot end at a lower temperature you could have the flo
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MCcarman
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General
check the start up code.
check the z offset in your slicer settings should be something like negative 0.15 = -0.15
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MCcarman
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Printing
Building on Fas point.
Is there anything stressing the hot end such as cables, Bowden or filament path? Is the hot end loose. I am wondering if you are twisting the hot end at certain points in the X travel. It looks like something is pushing the hot end in the Y direction then at a certain X travel it releases.
Assuming you have a Pruisa style machine.
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MCcarman
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Printing
Before this goes to far of the original topic:-
Yes its speed related not the steps. the area of a 0.2mm nozzle is 0.44 of that of a 0.3mm so reduce all your print speeds. Take the current speed and multiply it by 0.44
This will only get you to the same situation as with the 0.3mm nozzle. If there was an issue with 0.3mm you will have the same issue with 0.2mm
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MCcarman
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Prusa i3 and variants
It depends on the control board how you switch this off. On a Meltzi there is a jumper you move.
The boards are designed so you can power the controller from USB so you can sort the software out. The USB will only provide limited current - different computers have different limits and the more devises in USB ports the less current you can have. This current is insufficient to do anything mechanic
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MCcarman
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Prusa i3 and variants
So is this the face that was on the bed?
Could be under extrusion but did you specify solid top and bottom layers?
by
MCcarman
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Printing
Check the temperature file.
As a practical test. Set the bed temp to 100C so it forces the heater on at 100% up to 100C.
Look at the temperature profile in repetier. The temperature should rise smoothly. You will see where an error in the table causes the reported temperature to change the slope of the curve.
This is repeatable because its a reporting error at these specific thermistor values.
I
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MCcarman
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General
I have no experience of ramps but hope I can clarify some of the issues.
The circuit in the sensor requires a permanent power circuit so Brown is connected to a + source (seems OK here). Blue is connected to an earth source. The - pin on the RAMPS sensor pins seems OK. The Black signal goes to the S pin on the RAMPS sensor pins (I assume this is right but I don't know RAMPS). This sensor its Norm
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MCcarman
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General