Ultimaker 2+ Pauses at roughly 99% complete then crashes!?

[lukeogden 0]

Wondering whether anyone can help me with my Ultimaker 2+, it has started getting to between 20-60 seconds before finishing print, pausing itself and then when you click resume it moves the Z-Axis and crashes straight back into the print with usually disastrous consequences. 

 

Literally printed for 12 hours yesterday and in the last few minutes it paused, waited until the user clicked resume before moving and crashing, ruining the whole print by pushing a hot end straight through the top.  

 

I've replaced the motherboard, the control board and the LCD display and all the leads between them.

 

Updated the firmware using CURA

 

Any other suggestions?

 

Thanks in advance 

 

Luke

[CarloK 203]

This is weird, the printer can only start a pause action from two actions:

1) The user selecting the pause option in the menu

2) A pause command in gcode

 

You are sure not to have pressed the menu pause function. Which leaves option 2.

Which slicer program are you using?

Did you perhaps activate a plugin like 'pause at height" in Cura

 

When still withou clue, can you post the last 50 lines of your gcode file here?

[lukeogden 0]

Hi, 

 

Yes it is very weird. Its although the printer thinks it has finished. I'll try and video it on a print tonight. 

 

So to try and repeat the issue I've printed the calibration cube 5 times it printed 1/5 okay the other 4 it messed up in the last few seconds of the print. 

 

Here is the gcode, there appears to be a comment added by CURA about aborting if on 2.6 firmware (Ultimaker 2+ on V3.3) this is added by CURA on several other 3D prints: (but this should be fixed by being on firmware 3.3)

 

G0 F7200 X120.329 Y119.521
G1 F1350 X119.52 Y120.329 E5799.68843
G0 F7200 X120.086 Y120.329
G1 F1350 X120.329 Y120.087 E5799.70215
G0 F7200 X110.115 Y118.986
G1 F1350 X108.772 Y120.329 E5799.77812
G0 F7200 X108.207 Y120.329
G1 F1350 X109.549 Y118.986 E5799.85406
G0 F7200 X108.984 Y118.986
G1 F1350 X107.641 Y120.329 E5799.93003
G0 F7200 X107.075 Y120.329
G1 F1350 X108.418 Y118.986 E5800.00601
G0 F7200 X107.852 Y118.986
G1 F1350 X106.51 Y120.329 E5800.08195
G0 F7200 X105.944 Y120.329
G1 F1350 X107.287 Y118.986 E5800.15792
G0 F7200 X106.735 Y118.972
G1 F1350 X105.378 Y120.329 E5800.23468
G0 F7200 X104.813 Y120.329
G1 F1350 X106.735 Y118.407 E5800.34341
G0 F7200 X106.735 Y117.841
G1 F1350 X104.247 Y120.329 E5800.48415
G0 F7200 X103.681 Y120.329
G1 F1350 X106.735 Y117.275 E5800.65691
G0 F7200 X106.735 Y116.71
G1 F1350 X103.115 Y120.329 E5800.86166
G0 F7200 X102.669 Y120.21
G1 F1350 X106.735 Y116.144 E5801.09167
G0 F7200 X106.735 Y115.578
G1 F1350 X102.669 Y119.644 E5801.32168
G1 X102.599 Y119.714
;TIME_ELAPSED:4397.165090
G10
M107
;Version _2.6 of the firmware can abort the print too early if the file ends
;too soon. However if the file hasn't ended yet because there are comments at
;the end of the file, it won't abort yet. Therefore we have to put at least 512
;bytes at the end of the g-code so that the file is not yet finished by the
;time that the motion planner gets flushed. With firmware version _3.3 this
;should be fixed, so this comment wouldn't be necessary any more. Now we have
;to pad this text to make precisely 512 bytes.
M82 ;absolute extrusion mode
;End of Gcode
;SETTING_3 {"global_quality": "[general]\\nversion = 4\\nname = Fine #2\\ndefini
;SETTING_3 tion = ultimaker2\\n\\n[metadata]\\nsetting_version = 16\\nquality_ty
;SETTING_3 pe = normal\\ntype = quality_changes\\n\\n[values]\\n\\n", "extruder_
;SETTING_3 quality": ["[general]\\nversion = 4\\nname = Fine #2\\ndefinition = u
;SETTING_3 ltimaker2_extended_olsson\\n\\n[metadata]\\nsetting_version = 16\\npo
;SETTING_3 sition = 0\\nquality_type = normal\\ntype = quality_changes\\n\\n[val
;SETTING_3 ues]\\ncool_fan_speed = 5\\ninfill_sparse_density = 60\\nspeed_print 
;SETTING_3 = 45\\n\\n"]}

Edited December 7, 2020 by lukeogden

[CarloK 203]

It's been more than 2 years since I worked on that bug fix. We intended to have this new firmware integrated with the Cura 3.3 release, but it might have been delayed till the 3.4 release. This shouldn't matter since everyone is now on Cura 4.8, right?

 

The extra text at the end of the gcode is there for any printers running older firmware from before Cura v3.3, so even the older firmware versions will work correct.

 

I don't see anything weird in the posted gcode. Also the fact that the print did succeed once is an indication the problem is not in the gcode file.

 

Which Cura version are you using? 
You said you updated the firmware using Cura. Which Cura version was that?

Are you printing from SD card? Could this be a newer type that the printer can't handle?

 

Can you describe your system setup? Like, is there a usb cable between the printer and a computer? Or are you using an external host like octoprint? 

[lukeogden 0]

Yes I am on the lastest CURA 4.8.0 and updated it from this version on my laptop. 

 

Yes printing from an SD card (SD card is at least 2/3 years old but can try a different SD card), I think I had the same issue from a wired connection but can run a check print to see. 

 

Ultimaker is setup in corner of my lounge and I just print using the SD card, no external hosts involved. 

 

I have already paid to change the motherboard, the control board and the LCD display as I assumed it was a motherboard issue. 

 

Thanks Luke

 

[lukeogden 0]

So here is the video eventually managed to get it, it is paused 1 second before finish. 

 

Several clicks of the resume button and it finishes. Sometimes it collides with the part, I haven't been able to film this at all. 

 

Thanks Luke

IMG_1506.zip

Edited December 16, 2020 by lukeogden

[CarloK 203]

Thanks for posting the video.
Like I said, it's a weird bug. Weird, because I checked and the pause command is only activated from 2 situations: 
1) The user activating the menu option
or
2) An M0 or M1 gcode command.

Neither of those situations are present...

Is it always the same file that's failing?

[lukeogden 0]

No I have tried printing several different components, all with the same and varying impacts. Sometimes it finishes fine, other times it pauses and just leaves a peak on the part. 

It is very strange is there anything that Ultimaker are able to do?

 

Luke

[CarloK 203]

I'm one of the software engineers that worked on the UM2 so we should be able to figure this out. It's very weird and the only thing I can think of is that it is similar to the bug we fixed in firmware v3.3.0

 
I know you updated the firmware using Cura, but let's double check. Can you go to the maintenance menu and verify the firmware version? It should report as:

Mar 15 2018 13:03:13

Vers:_3.3.0

[CarloK 203]

How were the results when you tried with another SD card?
A long shot, but what type is the SD card you use? We only support standard SD and SDHC cards, the newer card types SDXC and SDUC are not supported. i.e. most cards up to 32Gb are fine, anything larger than 32Gb will fail.