Active Levelling Failure - Ongoing Issues

[DesignLightCo 0]

Hello All 

 

Our company has purchased a UMS5 and using happily for a few months, unfortunately, issues are becoming more frequent. Usually, simple to fix, thanks to these forums. However, this, I have not found a solution, I hope someone can help. 

 

What happened? 

On a 17hr print using Tough PLA & PVA, Core 1 pulled out the bowden tube from the back coupler whilst printing. This did not stop the print and the filament continued to be rolled out. This went unnoticed for many hours. When it was noticed, there was an abundance of coiled, hard, filament inside the printer, tangled up in a mess. It was under the bed, over the axle's and generally everywhere. The print was immediately aborted, and the machine tried to home itself, due to the excessive amount of filament, it could not. The machine was turned off immediately to stop the printer breaking a stepper/axle/band etc. 

 

What'd you do? 

1. Replace bowden tubes and couplers/clamps

2. Check axles for play 

3. Check steppers for play 

4. Check belt tension

4. Calibrate lift switch 

5. Manual bed levelling 

6. XY Calibration 

 

Now what? 

After printing the XY Calibration and adjusting, I went to print a larger clamp clip to ensure the new bowden tubes were not going anywhere, and.. Nozzle probe offset failure, or/and ER38 - Active leveling correction failed, and/or Difference between detected height of both PrintCores exceeds realistic values are now coming up.

 

What'd you do? 

1. Check cores to see if they were in correctly 

2. Check fan is clear of debris 

3. Check the soldering is good for the back of print head is good

4. Clean bed and nozzle

5. Changed cores

6. XY Calibration attempt (Difference between detected height of both PrintCores exceeds realistic values)

7. Lift switch calibration

8. Manually level

9. XY Calibration 

10. Try print again (Nozzle probe offset failure)

11. Cry

 

Speculation

Gremlins

 

I look forward to everyone's comments.