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5S / „There is a problem with the active level sensor“


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Posted · 5S / „There is a problem with the active level sensor“

This is a more close up pictures for sure, -but cannot be sure that there is an open wiring.

 

At this close distance from the heater core, the heat will extend along the wire and sometimes you burn the insulation at some distance from the sleeve. But with this much wear and tear on the fastening tab, it's strange if there is no hole in the wires insulation..

 

Another thing, if there is no short here, this short/close distance -mean higher capacitance.

So could this increased capacitance be the reason for (out of specification sensed) this error?

For sure, there is some options.

 

We'll se tomorrow.

Thanks

Torgeir

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Posted · 5S / „There is a problem with the active level sensor“

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.

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    Posted · 5S / „There is a problem with the active level sensor“
    On 3/3/2021 at 7:44 PM, Torgeir said:

    This is a more close up pictures for sure, -but cannot be sure that there is an open wiring.

     

    At this close distance from the heater core, the heat will extend along the wire and sometimes you burn the insulation at some distance from the sleeve. But with this much wear and tear on the fastening tab, it's strange if there is no hole in the wires insulation..

     

    Another thing, if there is no short here, this short/close distance -mean higher capacitance.

    So could this increased capacitance be the reason for (out of specification sensed) this error?

    For sure, there is some options.

     

    We'll se tomorrow.

    Thanks

    Torgeir

    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 and try to get a better photo.

     

    since I changed two things at once I can’t be 100% sure the PCBA in the back of the head was bad, but I think it is likely.

     

    D231F0FD-1283-47AA-9A0D-4FC43A7EE3A7.jpeg

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    Posted · 5S / „There is a problem with the active level sensor“
    1 hour ago, Torgeir said:

    Hi Jeff,

     

    great to hear that this printer is up running again.

    Way to go.

     

    Torgeir

    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.

    IMG_0465.JPG

    IMG_0466.JPG

    IMG_0470.JPG

    IMG_0469.JPG

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    Posted · 5S / „There is a problem with the active level sensor“

    Hi Jeff,

     

    I've been looking into the wiring diagram for this circuit and since this heater element is driven by a NMOS p-ch transistor,

    both of this wires will be positive when no power is feed to the heat element. When the transistor is switched to on (for heating), the defined negative pin goes to ground. This will continue in a cycle pattern according to heat demand. I'll think ultimaker is using the "bang - bang" mode with a fixed frequency and timed on/off cycle (for reducing EMF noise).

     

    Anyway, it looks like your "capacitive electronic chip" is most likely fried by the 24 VDC.  Max input here is +3.3VDC!

     

    Way to go..  🙂

     

    Thanks

    Torgeir

     

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    Posted · 5S / „There is a problem with the active level sensor“
    1 hour ago, Torgeir said:

    Hi Jeff,

     

    I've been looking into the wiring diagram for this circuit and since this heater element is driven by a NMOS p-ch transistor,

    both of this wires will be positive when no power is feed to the heat element. When the transistor is switched to on (for heating), the defined negative pin goes to ground. This will continue in a cycle pattern according to heat demand. I'll think ultimaker is using the "bang - bang" mode with a fixed frequency and timed on/off cycle (for reducing EMF noise).

     

    Anyway, it looks like your "capacitive electronic chip" is most likely fried by the 24 VDC.  Max input here is +3.3VDC!

     

    Way to go..  🙂

     

    Thanks

    Torgeir

     

    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.

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    Posted · 5S / „There is a problem with the active level sensor“

    The chip for measuring the capacity is; U3 P/N: FDC1004DSCT.

    The chip U8 (protection diodes) also has to be changed and P/N is; PUSB3FR4.

     

    Thanks

    Torgeir

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