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  1. Thanks for your help on this - much appreciated! Which chip is this on the board? Is it commonly available? I would like to replace it on the board I pulled out if possible.
  2. Thanks - I took some pics of the wire under a cheap USB microscope. Definitely a break in the insulation on one of the two wires. I checked with a meter for continuity to the terminals on the back of the print core and the wire with the break was connected to the 2nd connector on the back of the core (viewed from the back). I dind't check which pad this mapped to on the back - just the wire. I would be curious to know if that is a +24V line or ground.
  3. Just finished making two changes... - Added a bit of solder to the front of the connectors that hold the wires to the cap sensor board in the steel plate. There may have been a small crack in the solder, but I think it was just a shadow in my photos. - Replaced the PCBA in the extruder head It successfully passed the active level sensor test (no more low performance error), so I am now running the XY calibration print it has been unable to do since this issue started. After this print I am going to take another look at the wire on the print core I removed yesterday
  4. We have a "spare" print head PCB here from one that had a massive blob of material after a mechanical failure (head assembly replaced under warranty). If i get time soon I will try swapping that out.
  5. I will take a closer look next time i am in office. I wondered the same - it could be a hole in the insulation or at least a place where it frayed (since the heatshrink on the tab was in bad shape I think this is a good possibility. Here are a few more pics I took this afternoon along with a pic I think I posted before of the tab on that side of the sensor board. I put new heatshrink on that tab now.
  6. Update to my issues: I replaced the heatshrink on the RH tab that was deteriorated and reinstalled the bottom cover with no change in the leveling test. I then tried pushing the heater wires up to make sure they weren't in contact with the tab. No change. I then replaced the RH print core with a different one. There was a noticeable mark on one of the wires (see pic). Still no change. Removed both print cores and tried to do the leveling sensor diagnostic. Test wouldn't complete so I backed out. Factory reset printer. This DID ch
  7. Update: ONLY the LH core was swapped - not the right. So I guess that is something else I need to try next week! Thanks again
  8. We did try different print cores and that didn't help (I know they swapped the left core - i am waiting for confirmation that they also swapped the right). I will inspect those wires more closely next week. I will go back in next week (I am off work for a few days now) and inspect further to see if I can see if that was being rubbed/damaged by something in the head. I didn't probe them myself, but someone else confirmed no continuity between the metal bottom plate and the nozzle. I will double check this too while I am there. So the print bed moving toward the s
  9. I just got back from the office and read your response. Thanks for that! The two photos show 2 different printers. The one with the "clean" RH tab holding the PCB in place is from the working printer. The other photo shows the sensor board on the printer that keeps throwing the error, and has the RH holding tab showing what I previously described as corrosion (before having the opportunity to see it firsthand this morning). After seeing it this morning - I think it might just be that that "insulating" sleeve is deteriorated (almost looks like it is shredded). I am
  10. Yes fan disconnected at the back, and it still errors out. I just reinstalled the silicone boot and tried with the fan plugged in again - still errors out. Also checked continuity from the board terminals to the connector on the back of the extruder - those look fine. Tugged on the wires at the board, they seem solid. So basically stumped here.
  11. I am heading to the office tomorrow to investigate further. I don't think raising or lowering the bed will help here, since the bed only gets halfway up to the nozzle (from the bottom location) before the error comes up. At least this is how it was described to me - so I will confirm tomorrow. My assumption is that those bent tabs are an interference fit into the holes so there is electrical contact between the steel plate and the plating on the inside of the PCBA holes, and they are then bent over (and outward) to mechanically hold the plate in place. I think the plate needs to
  12. Also, why is there only an insulator placed on that right-hand hole?
  13. I know this is an older thread, but is it possible to elaborate on the way that this sensor works to help with troubleshooting? One of our 6 printers is doing exactly this, and we checked the fan cables and other cables - all look OK. There are no sources of interference nearby either. The capacitive board appears to be electrically connected to the steel bottom plate (the "shield"). Is the steel plate supposed to contact the brass extruder body? Or is there supposed to be a nominal gap there? When the nozzle touches the bed, I am assuming that the brass moves away from the st
  14. We have 6 of the Ultimaker S5 printers installed at work, and one of them has experienced the failure shown in the attached pic. The first time we were able to remove the large blob of material from the extruder and reassembled everything, but it happened again a few days later. We ran a short test print (or two) to confirm it was running correctly after the first reassembly. A similar incident occurred on another one of the machines shortly after we deployed them. That one had a massive blob on the extruder and we ended up getting that extruder replaced under warrant
  15. I may not have been clear in my last post. I actually WAS able to get the problematic printer connected. When the first printer was having issues, I tried a different printer and it connected with no problem. So I then went back to first printer, did the "Reset Digital Factory" option in the Network Menu, and attempted to connect it again, and was then successful. So I do have both of them connected. If we choose to go down this path, I will probably go ahead and do a Digital Factory Reset on the remaining 4 printers before attempting to connect them. I am not in the office today, but ma
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