michaelpalin

I was having the same out of filament issue with the secondary feeder on my S5. A close examination of the flow sensor that is in the filament drive mechanism revealed that one corner of the flow sensor circuit board rub against the housing, thus interfering with movement of the flow sensor. The metal roller of the flow sensor is magnetic, the little IC chip on the circuit board detects the change in magnetic flux of the roller as it rotates. The magnetic roller is held against the filament by a spring. The magnetic roller and circuit board are meant to pivot so that the roller can stay in contact with the filament, but because the circuit board lightly rubs against the housing it prevents the roller from staying in contact with the filament. Thus allowing the filament to slip by the magnetic roller without making it rotate triggering a out of filament message. I sanded a little bit of the corner off of the circuit board to give it more clearance and have not had any more trouble with out of filament messages. Even though I wasn't having any problems with the primary drive flow sensor I disassembled it to take a look at its flow sensor, and apparently the dimensions are slightly different because its flow sensor circuit board had a little more clearance. However just to be on the safe side I sanded a little bit off of the of its circuit board for good measure. I hope this information will help others that are having the same issue.