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Everything posted by CTotten

  1. I was running 5.7.2 when this happened. I updated to 5.7.3 and it did not happen on the one print I have done since. This happened on two different prints, on different parts, different slices, etc. This was also the same printcore combination that I have been using for months, with the one exception of me using the CC 0.6 core one time, immediately prior this happening. I did not touch the X/Y calibration when I used the CC core because it was a single core print.
  2. Late last week, I had a print where the X position between printcores 1 and 2 was significantly off. This showed up as the prime tower looking like two interlocking rings instead of concentric rings. I re-did the X/Y calibration, and printed another job requiring support material (Breakaway), and the same thing happened. The only "change" before this happened is that I finally tried out the CC 0.6 printcore on a job using. I used it for one job, then went back to the AA 0.4 printcore that I had been using. Both of these instances occurred after that. What else could be causing this? In both cases, the "offset" distance was approximately the same.
  3. I saw there was a 5.7.3 firmware just released. In the release notes, it mentions a fix to an "end of filament" bug. Is that related to my issue?
  4. One more update. The last print did another end of spool change, which worked. But, at the end of the print, I got the wizard again saying the material is stuck in the printcore and unable to unload. The wizard worked, but.... I am still planning to roll back to the previous firmware version. Since updating to 5.7.2, I am about 50% on the material unloading from the printcore. This never happened before the firmware update. I understand the changes made in 5.7.2 were to reduce wasted filament and time during material changes; however, I have wasted 10X more material and time with the issues caused then from the previous firmware's excessive priming and de-priming cycle. And lets me honest, we are talking about several minutes of time and a few cents worth of material that were "wasted" in the previous version...
  5. I just went through another End of Spool material change, and it worked (PrintCore1 with CPE). So I guess I am 2 for 5, in terms of successful spool changes (no interaction from me) since updating to 5.7.2. But I was watching the temperature graphs. I was a bit surprised when I noticed that the S5 didn't start pulling the material until the PrintCore temp got down to like 75 or 80 C. I am not sure if this is "expected" behavior, but that seems to be doing a "cold pull". While I understand you are basically doing that at the end of a print to keep the tip of the material formed from the next job, I am wondering if this is required at the end of a spool of material? The machine can't use the remaining filament, so the shape of the tip is immaterial. And it sits idle for 2 to 3 minutes while it cools down to that temp. For the case of a mid-print material change (if you are concerned with how long it takes), why don't you pull the material from a warmer print core. This will speed up the process, put less stress on the machine (compared to a cold pull), and minimize any risk of the material getting stuck in the print core. The screen shot was taken a few seconds after the S5 began retracting the material for the material change.
  6. Thanks. One more update. The print finally finished, and the material in both PrintCores (#1 - UM CPE; #2 - UM BreakAway) successfully unloaded.
  7. I got lucky. I do not see a noticable layer shift. Finally something is going my way...
  8. The Wizard is new for firmware 5.7.2, so if you didn't update recently, you likely don't have it. For me, this issue only started happening after updating to firmware 5.7.2.
  9. On the third attempt, after swapping PrintCores, both extruder 1 and 2 went through the normal material change (end of spool) process without any interaction from me. However, when extruder 1 went through the end of spool process a second time, I got the wizard again. This time I followed the directions precisely (including leaving 5mm of material out of the Bowden tube when I cut it off), and it seems to have saved the print. The material unloaded, the next spool loaded, and the print resumed. The first time through the wizard, I do not think I cut off the end of the filament that came out of the PrintCore, plausibly being the reason it stuck in the feeder. The second time through the wizard I don't remember what I did, but it didn't work. So I am still left with this: In 18 months with the S5 (4 months with the Pro Bundle), I have NEVER had material stick in the PrintCore during unloading (end of spool, end of print, or changing material). Since installing firmware 5.7.2, this have happened 3 out of 5 times on CPE material in PrintCore 1 (3 out of 4 times on end of spool, and 0 out of 1 on an end of print - X/Y calibration); 0 out of 2 times on BreakAway material on PrintCore 2. I understand that 5.7.2 did make some changes to the material priming/depriming process. Can you please look into this? Is it not heating the PrintCore as much? Is it not pulling as hard as it used to? If the Pro Bundle can no longer reliably change over spools when it runs out, then it lost it's "value added" to me and my company. We purchased the Pro Bundle to maximize printer up-time. If I have to baby-sit material change overs, including pulling the Bowden tube out of the PrintHead, then I might as well just remove the Material Station from the system. Also, I am "eager" to see if the process of freeing the stuck material has caused a layer (X/Y axis) shift in the print. Since the PrintHead does not re-home after this process, there is a high likelihood that the actions the Wizard had me take to free the material inadvertently moved the PrintHead, inserting a bias in the coordinate system. This would potentially cause another failed print, since it will not meet the customer's quality inspection. I am holding my breath on this one....
  10. I may have it working now. Very frustrating, but I removed both print cores to check them, swapped their positions, and re-did the X/Y calibration. Both sides loaded and unloaded properly. I re-started the previous print job that the failures occurred on, and started with about 2 feet of filament left inside the material station after loading, to force early material changes. Material 1 just went through its material change just fine. Material 2 will be changing over fairly soon, so I will update after that. While I had not touched the PrintCores in months, I did have failure last week where the BreakAway did not bond to the printbed well, and a big chunk of it came loose during the print and caused all kinds of problems (including several large axis shifts during the print, presumably from collisions between the Print Head and the loose BreakAway section). I am now wonder if that jarred the PrintCore enough that was not positioned correctly in the PrintHead, and that a misalignment was the cause of the material sticking in the PrintCore (but not enough to cause loading problems)? I guess we will see. And I seem to have bad timing (or luck) with Firmware changes. This is the second time I have had "new" issues right after installing new firmware, but the firmware was not really the cause...
  11. One thing that I did notice after the fact. The machine should have been doing a material change. There was absolutely NO filament pieces on the bottom of the printer, meaning it did
  12. UPDATE: I have now tried 2 prints since I updated to 5.7.2, and both have failed in the same way. At the end of a spool, the material is "stuck" in printcore, so it cannot change spools. The wizard does appear, but even after freeing the stuck material from the printcore, it does not fully unload, causing an ER61 error, and a lost print. I installed 5.7.2 because I thought "Great, I will save a few cents per print since it doesn't prime as much material, especially when printing with the same color material over and over". Well, at this point, I have lost about $125 worth of material in the two failed prints!!! This is a job that I have printed dozens of times over the last few months with no issues. In the two weeks prior to this, I have had atleast 5 material changeovers in the Material Station with no issues. At this point, I want to roll the firmware back to the previous version because I don't trust this machine now, and I have work to finish. ____ I installed the latest firmware (5.7.2) yesterday. I started a print, and all seemed well. When I get to work this morning, the print was paused saying the current spool did not unload due to being stuck in the printhead. It took me into the Wizard, and walked me through a couple of steps to free the material. The procedure says to release the bowden tube at the top of the printcore, and then cut the material. As I was trying to free pull the end of the bowden tube, the material pulled free from the printcore, so I didn't cut it. With the material now released, I continued but it stopped unloading when the free end got the feeder, and gave me an ER61 error. So the Wizard worked (sort of), but didn't save the print. Also, on the ER61 page, it seems to give you two options if the material did not fully unload. One is if the material is visible outside of the Material Station, and the other is if it isn't visible. In the case of it being outside the Material Station, it seems to imply I should be pulling the material out through the small tube before the Decoupler. In my case, there was about 15 inches of material past the Decoupler. It seemed to work fine to pull the material "forward" through the Decoupler (I removed the input line to the Feeder). Perhaps you should update that troubleshooting page to indicate options that include the material being stuck in the Feeder.
  13. I re-did the X/Y calibration, and the settings shown on the display were pretty close. I maybe had to change them by 0.5 of 1.0. So that doesn't appear to be it. I did notice that in the last few days, my Cura was displaying some configuration errors. So I deleted the installation, re-installed the same Cura, re-imported the file, re-sliced it, and just started the print again. It will be about 30 minutes or so before I can see if the Breakaway is printing over the base material...
  14. I don't think that is possible. They are both set up in Cura, so you cannot slice on a 3E and then print to a S5 through Cura (atleast as far as I know). Firmware has not been updated in months. Printcores have not been changed (or even removed) in months. Cura has not been updated in months. Its just odd that this comes out of the blue...
  15. On Friday, I printed a file with 2 materials, and it worked great. Then I tried to print a different file using 2 materials, and suddenly there is a LARGE offset in the X axis between the two print heads, meaning the Breakaway (core 2) is printing on top of the CPE material (core 1). The "shift" is close to 0.25 inches in one direction. I didn't touch the printer settings, in terms of the offsets or calibrations. I didn't touch the print cores. The only thing that I did between prints was change from Red CPE to Light Gray CPE. I aborted the print after I noticed this (about 2 hours in). I also re-sliced the file, and tried to reprint it, but it was doing the same thing. Has anyone seen this before? I have had this machine for about 15 months, and an 3E for about 2.5 years, and I have never seen something like this. I am pretty frustrated by this. I guess I need to re-do the calibration.
  16. So far, I just had this error the one time, about 4 weeks ago (had been using the Pro Bundle for about 2 months). Since then the S5 has basically been running non-stop, without happening again. I did not create a help ticket for this since it occurred just the one time, but I will if it occurs again.
  17. After working through the North American support, I had to replace the main board on the Material Station. That seemed to stop the machine from trying to unload material in Bay D. I still have not re-installed the Material Station into the system; I have only powered it up by itself.
  18. Not sure if @maht or @SandervG have checked up on the GitHub issue, but to summarize: The gyriod infill pattern is "high-resolution" and the S5 Linux board is not keeping up, causing the printer to basically buffer during the print, causing unexpected slow downs. So my workaround is to stop using the gyroid infill pattern; but it seems like some finger pointing saying the S5 hardware is not fast enough to keep up...
  19. Thanks. Here are the two simple plots I made of the progress. Whenever I could check on the machines, I tried to log the completion time estimate throughout the print. I even backed out the time for any pauses (material changes) to keep it as consistent as possible. The print job has a large cavity in the middle, that goes up to over half the height. On the gyroid plot, the cavity (support area) was just about complete when I made the series of entries toward the end of the second day. It seems like the "growth" in time got worse around that same point. My assumption was that after the support area was done, the percentage of the print area getting the gyroid infill went up, causing the increase in the slope or the line. And it is hard to see, but after the first 45 minutes of the gyroid print (before it started the infill pattern layers), the completion time estimate was constant. Unfortunately it was late in the afternoon, so I didn't get a lot of data points during that part of the print.
  20. That is my working theory right now. I read somewhere (can't remember where) that the jerk setting on the gyroid pattern was reduced at one point (from 20 to 8), so that could possibly explain a delta in the calculated time, if the time estimation still uses the old value. But when I open up those settings in Cura, the default value doesn't seem to match up (shows 25 mm/s for infill jerk). Is this an issue for Ultimaker to look into, or should this go to GitHub? I like using the gyroid infill pattern because it seems to run very smoothly compared to other infills. But if I can't rely on the time estimate, then I have to stop using it because I rely on the time estimate in estimate work (cost, workflow, etc.).
  21. As of this morning, I am about 90% through the second print (tri-hex infill), and the estimated finish time is tracking very well. In fact, the estimated finish time says it will end 13 minutes earlier than originally predicted.
  22. I am 12 hours into the 64.75 hour (Cura estimate) print of the same part, this time using Tri-Hex infill at 25%, and the estimated completion time is holding (in fact, it is now scheduled to end 5 minutes earlier).
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