S5 Leveling Sensor Test

[Pena 6]

Hey Guys,

 

I've had an issue off and on in regards to leveling results on my S5. 

I thought my leveling error had something to do with the magnets I installed on my build plate however, the error is repeated with a glass build plate and no magnets.

I have replaced both AA and BB nozzles with new nozzles and cleaned the nozzle seating areas.

 

I have completed the manual level procedure and leveling sensor test several time. When I reboot the S5 and repeat the manual leveling the error returns. Once I remove the New Print Head Nozzle and reinstall the same new nozzle the S5 will randomly level and start working.

 

My question is: how is the information received from the Leveling Sensor Test used or how can it be helpful?

 

Dan

 

Edited December 16, 2023 by Pena

[Torgeir 243]

Hi @Pena

 

The noise level test are made to insure that "noise" is not present much, as it can destroy the calibration of the bed.

When using a capacitive sensing system like this, nearby noise will cause problem if it exist!

This might be nearby WiFi or cellphone etc., but may also include any EMI created by the printer itself.

 

We've seen that the little cooling fan inside the front cover sometimes been the reason for such noise from the printer itself.

 

As your readings fluctuate quite a bit, it might be due to much noise from this cooling fan.

 

I've never seen any "values" that's become a limit causing a warning in this matter.

Maybe caused by every individual often have its own level that's change when parts are replaced.

Often an experience in the industries in general.

 

Thanks

Torgeir

 

[tomnagel 126]

I suspect your print head control pcb is broken, such noise values are really really bad. Please contact support or your reseller. 

[leeotts 0]

It could be the PCB or a bad front fan. Check the front fan wire and make sure it is not damaged.

 

Unplug the front fan from the back of the print head and run the test three more times. You need a new fan if the noise levels return to normal (under 8). If they stay high, you will likely need a new printhead PCB.

[Dustin 130]

If you have ever opened the print head assembly (removed the screws) 

Its also possible that a fan wire for one of the 3 fans has been smashed due to assembly error.. 
This also will cause the noise issue that the sensor is sensitive to..
If a wire is smashed, the fan in question must be replaced.

Also those are VERY wild sensor readings.. 
I agree something (bad fan) or external EMF is causing issues. 
Can also be from a defective/old print core as well

See the support article on this topic, 90% or so of issues can be resolved with its steps.
Usually if it cant solve the issue, its a bad print head pcb.
here: https://support.ultimaker.com/s/article/1667410781005

[Pena 6]

Thanks Guys!

With all the information everyone has provided, I've narrowed it down to the capacitive sensor board.

I found a Fan wire crossing directly over the PCB, the fan wire was being squeezed between the heating element wires of the print core and the PCB. I moved the fan wire, ran the test Level Sensor Test aging with the following results.

 

Again thanks!

Dan

[Pena 6]

[Pena 6]

Hey Guys

 

Now with everyones help, I understand the noise level results of the Level Sensor Test shouldn't exceed 8.0 

 

Your help is much appreciated!

Dan

[cyriaquer 1]

Hello,

On an UM3, there is a simple test to check the fans, and this solved my leveling issue :

 

- first i thank the capacitive sensor was faulty and replace it -> not better, erratic leveling sensing.

 

- without opening the head, just unplugging :

- I checked if the fans where responsible of the situation : by disconnecting all fans but one, i ran a diagnostic for leveling. I did this for all fans. One fan (the right one for me) the leveling diagnostic failed, repeatively, at all time, as the others just provide a good calibration level at each diagnostic.

- replaced the fan

 

--> Printing and printing and printing again :-).

 

Also, by precaution, i put the power supply as far away as i can from the printer.

 

This solved the issue for me.

 

I have to say that the design of the head would need some improvements : the cables are really compress with no space when closing the head. Also, the fan with an angle other than 90° is never good for rotative parts, especially the bearings.

 

Hope this will help the community.

 

Enjoy,

[Pena 6]

Hey Cyriaquer,

I took your advice and removed the Radial fans, see attached photos. The fans were horribly dirty which I think altered the fan blades by placing them out of tolerance or out of  balance. I used my shop air compressor to carefully blow the blades and being careful not to over clock or exceed RPM rating and break the blades. I then used a brush to rub off stuck on dust and gave them a final compressed air cleaning. I did this to the fan support housing as well.

I put everything back together and voila the printer is working. I've completed two prints back to back with no issues. 

 

I also ordered two knew radial fans (Print core side fans) or Model Cooling Fan Part #UM3/UM3X/S5/S3/S7 for my S5. and will replace the old fans if I have anymore leveling issues.

 

Thank you for your awesome advise and support!

 

Dan

 

 

 

Edited February 22 by Pena

[LePaul 322]

I’m having this issue.  
 

tried all the usual efforts to resolve.  Level sensor test came up at 177.5 

 

im guessing my only fix is replace the PCB?  Is there a video showing how?