CTotten

After some additional work, I think this was an issue with the print file, although not sure what would cause that. I switched over to printing the identical part in a different color, and that print is just fine. Odd. I printed 2 in red that came out as expected, had some issues with the machine that I had to fix, and also updated the print file to block support material in some areas that were not needed, then this started happening. The new prints in a different color are also using support blocking, but not issue. Oh, well. Chalk another one up to gremlins, I guess.

Have you checked to make sure your lift switch is calibrated correctly? If you #2 printcore is not lifting when it is not in use (thus dragging across layers, or colliding with things), that could explain a lot of what you are seeing. I had this happen a couple of times over the years, where the lift switch calibration suddenly was not correct.

I have seen this, and it is really annoying. It is using the Print Core Change button, the print head will move all the way to the front of the printer, and off to one side (say the right side if changing print core 2), and the print bed lifts all the way up. There is no way to open the door on the print head in that configuration. You can open it enough, and move the print core enough to break contact with the mating board (fool the printer into thinking it was replaced).

I recently started having some issues where large, flat layers are very "bumpy" and "fuzzy". I have A LOT of little balls of filament at the bottom of the printer, as well. The first picture is the top layer of the last 2 units I have printed. The second picture is the previous ones. Any ideas? The issues started after I had a bunch of issues all around the same time. Front fan stopped working, so I fixed that. Also replaced bowden tubes, cleaned the feeders (and checked tension), and replaced both print cores. And this is not limited to the top layer. I have seen this a lot of times over the years on the first layer, but it gets cleaner after every layer during the build, and never seen this on the top layers. I feel like this is over-extruding, but I haven't been able to get this to stop. I tried raising and lowering the extruder temp (+/- 5 degrees), tried reducing material flow (to 90%), and even tried slowing down the print speed (to 75%) all from the S5 touch screen during a print, with no noticable change. These are "lab fixtures", so they do not need to be pretty, but it is pretty annoying to have this sudden drop in quality of the finished surfaces.

I had been using the Vision Miner Nano Polymer adhesive for over 2 years with excellent results. I have printed over 100 full spools of CPE. But I am not very confident that this under the radar increase in bed temp is the cause of my issues. What frustrates me is that I use "profiles" that I set up. Apparently those profiles aren't as "secure" as I thought. I obviously only "locks" settings that I have changed from the default. And if the default value is changed in Cura, then it changes it in my profile with no notification...

I've had this happen several times, and it is frustrating that it is considered a "fatal" error. I also have recent had several instances of "Air Manager Fan Is Unable to Rotate at the Desired Speed".

I looked through my records: Sept 20, 2021: I updated CURA to version 4.11 Oct 16, 2021: I requested to order new S5 print bed glass panels through our purchasing system. This was after a few sheets got shreaded during printing. So my working assumption now is that when I updated to Cura 4.11, I got the update that changed the CPE print bed temp to 85C. This increased temperature is the cause of the bed delamination issues. I am not currently printing big jobs, but I will be overriding the print bed temp setting back down to the 75C range for S5 prints to confirm this was my issue. I also searched through the Cura update notes on the UM website, but couldn't find which version added the CPE temp change. But I know it was put into the code (through GitHub) around March 2021.

So I updated Cura to v4.11 around the end of September. Not sure if I was running 4.9 or 4.10 before that. But by mid-October, I was requesting to order new glass print beds, meaning I had starting having the glass delamination issue in late September to early October. I guess I didn't post anything on the forums until November, after it had happened multiple times. Can anyone confirm which Cura version added the change mentioned above?

That is very interesting. I started having my issues with the delaminating glass around November. I will have to dig through my records to see when I updated Cura versions. I don't update every time a change is made, so that may be when I finally got this update.

@SandervG Can you confirm when you guys changed the default bed temperature on the CPE material? I remember it being 70C on my original UM3E profiles, and 75C on my UMS5 profiles. Now it is 85C on the S5 and UM3E. I have been using CPE almost exclusively over the last 3+ years. I have printed over 100 full spools of the material, and we love it. It is strong like ABS, but prints very easily without a lot of effort. Plus the chemical resistant allows us to use it in a lot of applications, including overmolding silicone over it. But over the last few months, I have been having issues that I think are related to a recent increase in the default bed temperature. We are routinely having bed delamination after big prints (never seen this before recently, but have replaced 6 glass beds since then across my 2 UMS5 machines), as well as the bottom layers on large (tall) prints are deformed, like the material on the bottom layers is staying too hot, and deforming from the weight of material above. Both are recent phenomenom (like since Nov/Dec time frame). I have not had a chance to test out my theory (eg reduce bed temp back to 75C), as I have not been printing as much lately.

Just an update. This is still happening. I have went through 6 total pieces of glass over the last 4 or 5 months. I also noticed that the first few layers of some of my prints appear to deforming, more than I ever noticed before. Not just the typical elephants foot on the bottom layer. I also noticed that UM increased the default bed temperature for CPE "recently". I just noticed that the bed temperature is now set a 85C for CPE prints. My memory was that it was 75C prior to this change. Does anyone know when this change occurred? My thinking is that the increased bed temperature (which I have never adjusted from the factory defaults) is possibly the culprit for the delaminating glass, as well as the deformation on the bottom few layers of the prints. They say the change was for "increased bed adhesion". But my delaminated glass says I have too much adhesion now, and the deformed bottom layers says the glass (and material) is staying too warm during the print, and deforming under the weight above on large prints.

Thanks. I was wondering about the humidity, as it has been pretty dry recently, even for a typical November here. I have switched to using the the UM supplied UHU stick, with a clean glass and a fresh coat of UHU prior to each print, and I have not had the issue over the last week. I did redo the manual bed leveling when this first started happening, thinking that a cooler temp (at night, since they cut the heat back) caused some contractions of the long Z axis components caused the first layer to print too close to the glass, but that didn't seem to change anything. And I run two different UM S5 Pro Bundles (one old version and one new version), and they both started doing this at the same time. So in my mind that eliminates the possibility of an issue with a single machine.

I have been using an S5 for about 2.5 years now (using two S5 Pro Bundles for the last year). Since I got the first S5, I have been using basically the same glass print bed for all our prints. Our original S5 has about 6000 operating hours on it, and our newer S5 has about 2000 hours on it, so they have been used quite a bit. Overall all of that time, I have had a couple of small glass delaminations occur, but we were basically still using the original glass beds. I started using Vision Miner's Nano-Polymer Adhesive about a year ago, because it held both the CPE that we print 95% of our jobs with, as well as BreakAway. I haven't had any issues with it, except that it holds the BreakAway really well, meaning I have some scraping to do between prints. In most cases, the CPE only prints just pop off after they cool down. Anyway, about a month ago, I came into work and found that both machines with finished prints, but when I removed them, significant portions of the glass delaminated with the print. I thought it was odd, but the glass was old and had a few chips in it, so I thought it just finally gave out. So I pulled out the brand new spares. The few days later, the same thing happened with brand new glass. - I reperformed the manual leveling on both machines, thinking maybe it was a thermal issue with colder weather causing the first layer to print too close. - I also switched over to using the UHU stic provided from UM on the CPE only prints. We got 4 new pieces of glass from our distributor, and got back to work. Today, I come into work and find both prints again caused significant delamination. One print is about 8" x 8" square with a solid bottom layer. The other is a 8" diameter circle, with about 50% of it being a solid bottom layer (with some openings). So they are both "large" prints with solid bases. But I have literally printed hundreds of items like this without an issue. I am running 6.5.1 on both units, and have not updated firmware in about 2 months. Any ideas on the causes of this? I have shreaded 5 sheets of glass (at about $45 each) over the last month, after not losing a single one over 2.5 years. I am printing the same things, with the same materials, using the same techniques that I have been using for a long period of time. But something seems to have changed.

So here I am again. After almost a full year of operation, the dreaded "ER80" popped up again, causing a 3 day print to fail (after about 48 hours). As before, the fan is running when I found it, so any loss of Air Manager had to have been momentary. I am still concerned that this is a "hard" fault, meaning there is no way to recover from this. Seems like if the system "losses" the Air Manager for a few seconds, it should be able to recognize that the Air Manager is found again, and resume the print... It would also be nice to have some recovery instructions on the ER80 page. You have to power off the machine (fairly obvious), but then you get in a state where material is loaded, but the machine does not give you a way to unload it. I tried to start a new print, using different colors in each nozzle, and while it did unload both old colors, it then went into ER998 before it started loading the new colors. After another reboot, it seems to be operating normally.

I have the same issue. It is pretty frustrating that material station doesn't tell you that the material is loaded, but it doesn't recognize the material (just shows the Yellow Exclamation Point on the screen for the material you tried to load), unless I am missing something. Luckily, I have a ton of old spools laying around, so I just swap out the NFC tag.

Now if someone could just explain the mystery of the 3 seashells.... Sorry, I couldn't resist!

I have noticed that when the S5 is starting a print, and does it's active leveling routine, it starts with a Z-height measurement for Nozzle 2, then repeats this for Nozzle 1. What I am concerned with is that it does both of these at the exact same spot on the printbed. While I get they should be done very close to the same location, I have had some issues with prints and I think this may be the culprit. I have been having issues with UM Breakaway material not sticking to the glass very well. As I use a nano-polymer adhesive on the glass, it is not really an adhesion issue. Its as if the Breakaway material (in Nozzle 2) is not getting printed close enough to the glass. It looks stringy on the first layer, and successive lines are not touching. This results in several issues, including the support material moving around during the print, and sticking to the material printed above it. All of this, I have come to realize, is because the support material seems to be printer "higher" than the same build material layers (you can literally see it sticking up above the regular material. After many attempts to figure out what is going on, I noticed that some times during the active leveling process, the Breakaway material is slightly oozing from the nozzle when it does the Z-height measurement. Since the Nozzle 1 measure is repeated on the exact same spot, it is sensing that little glob left on the glass from Nozzle 2, and inserting an artificial off-set to Nozzle 2's Z-height. Thus my Nozzle 2 material is printed too high, even on the first layer. That is the only explanation I can come up with. My workaround has be to be standing by when it does this step of the process with my putty knife. I "wipe" Nozzle 2 just before it does its measurement. Then, while the machine is switching to Nozzle 1, I do a quick cleaning of the spot on the glass. When I do this, it prints just fine. The first layer of the Breakaway sticks to the glass nicely, with adjacent lines touching as they should. Can you update the Active Leveling Routine to have a slight offset in the locations that the two nozzles do their Z-height measurement? Even a couple of mm would prevent this from happening. And I have two S5 Pro-Bundles. Both do this intermittently. Sometimes it oozes, others times it doesn't. And this is all for the same print file, just duplicated from Cura Connect. I just happening to reprinting the same, large (3 day, 950g) print job over and over. It is a real pain to try to remove Breakaway that is bonded to the CPE material inside a cavity...

My older S5 (about 2 years old) just started making an odd noise at the very top and very bottom of the build plate travel. It seems to move normally, and no odd sounds except the last few mm either at the top or bottom. It sounds like a plastic squeaking noise, like when you try to run a screw through a tight piece of plastic. I cleaned the lead screw and re-lubricated it. I lubricated the two guide rods. And I visually inspected it to see if I could see anything stuck in the lead screw. Nothing, and it don't solve the issue. It sounds like a chunk of material got into the lead screw bushing, but I don't see an easy way to take that apart to clean and inspect that area. Any guides available for replacing the build plate or the lead screw? That would probably get me what I need.

I just unboxed our second S5 machine. It is way off in terms of the axis alignment, right out of the box. Our original S5 was also off. But I noticed that the instructions for aligning the axis is not found on the Ultimaker website. Is this procedure still available? Why was it removed?

Possible, but I generally have all CPE loaded in the machine. Well, CPE in bays 1-4 (sometimes 5), and Breakaway in 6. I have noticed the issue with it detecting an adjacent spool. It is a pain...

I think I am really regretting investing in the Material Station. It seems great in theory, but it has added many complications to the relatively reliable S5. If there is a problem, everything seems to take 10 times longer than if the S5 was by itself. For instance, today I am having all kinds of problems doing the XY calibration. Twice I have tried it. Both times the B filament didn't extrude. Both times the B filament also failed to unload. Both times, when it prompted me to enter the "Stuck Filament Wizard", it seemed like it started, but never told me what to do (I know what to do, having done it many times in the last 2 months), then acted like it was done, and said the print was completed. Filament still in both feeders. That took a while to correct, mostly due to the added complexity of the Material Station. Then, when I do finally get it corrected, I try again, but then I get an Active Leveling error. Then it takes a lot of time for the machine to unload both material again. Then it takes a lot of time to reload the material. On an UM3, an active level error costs you a minute. I have literally spent 3 hours today trying to do an XY calibration just to use a brand new, $120 printcore. And it is still not done!!! In reality, I purchased the Material Station almost exclusively to be able to do large prints, sometimes over the weekend, without having to babysit the machine. For the first few months that I had the Material Station, it seemed to do just that. But as it stands right now, I have a $3500 dehydrater box that adds to my daily/weekly workload of operating the printers.

Thanks. I did, but I will check it again more thoroughly. The weird part is that "most" of the time, the end of print depriming seems to work fine. Most of my issues have been in the material changing process mid print, where the CPE in core 1 "sticks" almost every time. I can recover most thru the stuck filament wizard, but a few have been lost, most recently because I am pretty sure the stuck filament caused an ER34 (comms error to printhead) trying to pull the filament out of the printcore. Failing a print after a whole spool of material is painful. So if this was a bowden tube problem, it should impact all depriming actions the same, not just the mid-print material change. All of the bowden tubes unique to the material station are the ones that came with the unit new. The bowden tubes on the S5 itself were replaced with parts from FBRC8, the US repair parts supplier. I hope they are the right length, but those changes were done months and months ago (December or January), and this issue just started in the last few months, right after I updated to 5.7.2 (which did tweak the material change process, from my understanding).

Sander: Unfortunately I cannot share the file. It is proprietary. The reason this is the file that is the bane of my existence is that it is a large print, requiring about 900g of one material (UM CPE) and another 150g of support material. So I have no way to avoid a material change during this print. But, this problem has occurred on other, smaller print jobs as well, when material changes occur. Those are less frequent in occurrence because I don't have to print those as much, and the material changes are just the normal course so that I used all the material on the spool. Just as a reference, before I updated to 5.7.2 (and then 5.7.3), I printed 10 of these without a single issue. Since the firmware updates, I have not completed a single one without the material being stuck. Several have been saved at the "Material Stuck Wizard" stage, but several have been lost by various errors that I am assuming are associated with whatever the main issue is (ER61, ER34, etc). And this morning, I was trying to run the XY calibration to account for a new AA 0.25 core that we were trying to use for the first time, and the Breakaway material failed to unload from core 2. This is a first. I got the wizard prompt, started it, then the machine basically left the wizard on its own, sat there for 20 minutes, then went to a "Ready to Print" state. I got no prompt to acknowledge the print was removed. Both materials are still loaded in the print cores. I am fed up. Can you provide directions on how to rollback the firmware? I have a copy of 5.5.12 stored on my network. I am pretty sure that is the version I was using before I upgraded to 5.7.2. I am losing too much production time trying to figure out these issues.

I thought I would play around a bit this morning. I ran a small, 7 minute print on the S5 using the same Light Gray CPE material. I was trying to confirm that the end of print routine was using the same 75C temp for the cold pull. That is confirmed. The material is cooled down to approximately 75C when the machine starts pulling the filament back on the unload cycle. But funny enough, I got into the wizard for the material being stuck in the printhead. I am pretty sure this is the first time that has happened at the end of a print. The reheating at the tail end of the graph was during the wizard process to correct the material stuck in the printhead (heats it up, has you manually pull out of top of printcore, then cut off the tip, before it unloads it).

Is this information that can be posted? I would be interested to see what the temperatures are supposed to be, atleast for the UM materials. And I understand it is not a set 15C above glass transition, but my concern is that the CPE temp my S5 is trying to use is BELOW the glass transition temp. Unfortunately, for me to do more testing on this requires a lot of time to set up and a lot of material to waste, to force this into the end of spool behavior.