Skip to content
New issue

Have a question about this project? Sign up for a free GitHub account to open an issue and contact its maintainers and the community.

By clicking “Sign up for GitHub”, you agree to our terms of service and privacy statement. We’ll occasionally send you account related emails.

Already on GitHub? Sign in to your account

E3D REVO Thermal Model #4451

Open
3d-gussner opened this issue Oct 16, 2023 · 80 comments
Open

E3D REVO Thermal Model #4451

3d-gussner opened this issue Oct 16, 2023 · 80 comments
Labels
REVO E3D REVO

Comments

@3d-gussner
Copy link
Collaborator

3d-gussner commented Oct 16, 2023

  1. Verify firmware version installed on your printer , to check this on the printers start screen the firmware version will be indicated you can also check which firmware version you already have via the following process LCD menu -> Support. Scroll down and you will see the firmware version.

If your printer displays a firmware version prior to 3.13.0 or it does not start with E3DREVO_fw_ or E3DREVO_HF_60W_ we would advise that you install the latest Revo supported firmware release via the following link and proceed with the next steps: https://github.com/prusa3d/Prusa-Firmware/releases

If you are using a E3D Revo firmware, please check that this matches the Revo Hotend you have installed as there are different versions.

  • For a Standard 40W Revo heater core please use the. HEX file starting with E3DREVO_fw_ ensuring you chose the correct. HEX file for the printer model you have.
  • For a High flow 60W HeaterCore please use the. HEX file starting with E3DREVO_HF_60W_ ensuring you chose the correct. HEX file for the printer model you have.

If you do have an E3D Revo Firmware installed and it matches the Revo HotEnd you have please go to step 4.

  1. Once you have downloaded the firmware this Zip file and extracted it , please use the applicable. HEX file for both your printer model and the version of HeaterCore you have.
    • For a Standard 40W Revo heater core please use the. HEX file starting with E3DREVO_fw_ ensuring you chose the correct. HEX file for the printer model you have.
    • For a High flow 60W HeaterCore please use the. HEX file starting with E3DREVO_HF_60W_ ensuring you chose the correct. HEX file for the printer model you have.

If you are unsure as to how to update your printers firmware with the .HEX file please refer to the Flashing procedure within the following guide: https://help.prusa3d.com/article/firmware-updating-mk3s-mk3s-mk3_2227

  1. Once you have flashed and updated your printers firmware Run both the PID and TM calibration from the LCD Calibration menus of your machine.
  2. If step 2 fails however please Use the Revo_Reset G-code files to force setting changes. There are 2 versions of this g-code that will need to be used based on the HeaterCore you have installed.
    • reset_revo.gcode.txt: for a 40W HeaterCore. Please rename the file form reset_revo.gcode.txt to reset_revo.gcode
    • reset_revo_hf_60W.gcode.txt: for a 60W High Flow HeaterCore. Please rename the file form reset_revo_hf_60W.gcode.txt to reset_revo_hf_60W.gcode

These files will need to be copied to an SD card and installed , to Install the G-code select it from the print from the SD menu on your printer and follow the on-screen instructions.

  1. Once the G-code has been installed re-run both a PID and TM calibration from the LCD Calibration menus of your machine.

Optional step: If the above steps fail you may wish to factory reset the machine and run the setup wizard. Please note that as the process suggests this will reset the printer and its firmware to a factory state and any setting will be lost.

Link to E3D ticket

@acothebraco
Copy link

acothebraco commented Nov 12, 2023

Hello,

I have the same issute that my MK3S+ beeps three times with Thermal Anomaly and at the next time it stops with Thermal Error. I use the Revo Six Hotend and have never a problem with THERMAL ANOMALY. But since I put the MK3S+ in the Original Prusa Enclosure it shows up after 1-2 hours printing. I did also PID and Thermal Cal. on the 3.13.2 and the older 3.13.0 and I also tired to do a Revo_Reset G-Code without scuccess. Only when I put the Printer outside of the Enclosure the Error will not apear.

IMG_7431

@Lino77
Copy link

Lino77 commented Nov 17, 2023

same problem for me. I updated from 3.13.0 to 3.13.2, set the printer to factory settings, I can't even do the first layer of calibration. without the printer screaming, revo six for mk3

@Ezrae
Copy link

Ezrae commented Nov 17, 2023

Adding my voice to this. I went through each step carefully. I reset TM and PID multiple times. I ran the gcode. And when I finally decided to factory reset, I was unable to finish the wizard due to the thermal errors I was continuing to get.

I've downgraded back to 3.11, and I'll try again with the next REVO firmware update.

@nemith
Copy link

nemith commented Nov 25, 2023

Two printers, did all the steps here. All had the same issue. One seems to actually finish the model but still fails later, the other can't even calibrate the model.

Going to downgrade back to 3.11 this feature seems half baked and not suited for revo hotends.

@nemith
Copy link

nemith commented Nov 25, 2023

why , you can disable it.

I am selling this printer and it need to "just work". Disabling until next restart isn't an option.

@Lino77
Copy link

Lino77 commented Nov 25, 2023

M500 safe it and it will remain disable afer restart

@LoakAudio
Copy link

LoakAudio commented Nov 29, 2023

@3d-gussner , In the step 4 of your first post, isn't it "if step 3 fails" rather than "step 2" ? because it appends to me : changing the firmware went fine, reboot OK with the new firmware but PID calibration fails and TM calibration fails too. The gcode saved me.

@3d-gussner
Copy link
Collaborator Author

@LoakAudio Thanks for the feedback I will check again.
Glad that the new firmware and gcode files saved you. 🎉

@jamesdehart
Copy link
Contributor

jamesdehart commented Nov 30, 2023

I'm in the same boat as others here. I have opened a ticket with E3D and will post back with any findings that might help others.

Update - I still have not heard back from E3D but I checked the Thermistor extension cable and it seems the wire has come lose from the housing. Here are the docs if anyone is wondering.

@jamesdehart
Copy link
Contributor

jamesdehart commented Nov 30, 2023

@3d-gussner I happen to do a factory reset and after the calibration this happened

IMG_1961.mov

Should I open a different Github issue? Please advise.

@3d-gussner
Copy link
Collaborator Author

@jamesdehart Which calibration caused this screen?

@Skilbo
Copy link

Skilbo commented Dec 4, 2023

After much head scratching, finally got it working, used the E3DREVO_fw version and everything worked first time. Thanks to @3d-gussner for laying out the procedures very much appreciated.

@jamesdehart
Copy link
Contributor

jamesdehart commented Dec 11, 2023

@jamesdehart Which calibration caused this screen?

So it turned out my entire issue was because the thermal cable connector from the Hot-end to the cable that goes to the motherboard failed. The image shows the failed cable & connecor. One of the two wires were connected.

image

For others who are running in to issues related to this hotend. It would be good to check there cable to see if there are any issues like I had. When contacting E3D it took them about a week to respond to the support tickets. They are really backed up.

I hope this helps.

@3d-gussner
Copy link
Collaborator Author

3d-gussner commented Dec 12, 2023

@jamesdehart Thanks for sharing! This is an example why we implemented the Thermal model to detect issues like this and other.
Well done to investigate 🏅 instead of disabling the TM!

Side note: Try to add some more strain relief so all motions of the cable loom are possible without "pulling" cables at the connectors.

@acothebraco
Copy link

acothebraco commented Dec 12, 2023

Thanos for sharing. I checked my printer six times and I don’t have any cable or hardware issues. The point is that like I wrote in a other post that TM have problems when the printer is in a enclosure.

Also I’d explained in this post how the problem occur in my setup #4431 (comment)

@ndemarco
Copy link

ndemarco commented Jan 8, 2024

I'm chasing down the same THERMAL ANOMALY trouble,

  • Verified the wiring is correct and in working order
  • run reset_revo.gcode.txt
  • recalibrated PID
  • recalibrated TA
  • hard reset, followed by the usual recalibrations from the wizard

The PID and TA calibrations finished properly. Upon the next PLA preheat, BEEP-BEEP THERMAL ANOMALY.

@3d-gussner
Copy link
Collaborator Author

@ndemarco Thanks for the update.
Is your printer in an enclosure?
Can you please try to capture the print in a logfile? Do you have a host system like Octoprint running?

@stevenbennett
Copy link

stevenbennett commented Jan 12, 2024

I'm also experiencing the issue described by users in this thread. Installed the Revo variant of 3.13.2 on two MK3S+ and now encounter consistent thermal anomaly errors. Things I've tried:

  • verified heater/thermister cable and cable extension integrity
  • ran reset_revo gcode mentioned in E3D REVO Thermal Model #4451 (comment)
  • performed full factory reset
  • re-ran PID calibration
  • re-ran thermal model calibration

After these steps I still encounter frequent thermal anomaly errors. Sometimes these occur right after initiating a preheat, sometimes right before a print begins, sometimes during a print. (I'm not using an enclosure). Going to try rolling back to 3.11 as other have suggested.

@slaesh
Copy link

slaesh commented Feb 1, 2024

had the same issue. it works now, maybe change the order of your steps 2 and 3 @stevenbennett :)

  1. update firmware
  2. factory reset
  3. ran the gcode magic
  4. PID calibration
  5. thermal calibration

seems to work, step 3 was the magic sauce for me though! ;)

@3d-gussner
Copy link
Collaborator Author

3d-gussner commented Feb 1, 2024

had the same issue. it works now, maybe change the order of your steps 2 and 3 @stevenbennett :)

1. update firmware

2. factory reset

3. ran the gcode magic

4. PID calibration

5. thermal calibration

seems to work, step 3 was the magic sauce for me though! ;)

After the factory reset you don't need to run any gcode as it set identical values as are used in the E3D . hex files https://github.com/prusa3d/Prusa-Firmware/blob/v3.13.2/Firmware/thermal_model/e3d_REVO.h

The gcode files are for users that don't want to factory reset or got "bad" values at some point.

@3d-gussner
Copy link
Collaborator Author

@capsulecorplab Thanks for the positive feedback.

The "Load filament" and "Unload filament" menus are shown depending on the state of the filament sensor.

  • When filament is detected and printer is idle "Unload filament" is shown and "Load filament" is hidden.
  • When NO filament is detected and printer is idle "Load filament" is shown and "Unload filament" is hidden.
  • When the FSensor is disabled both "Load filament" and "Unload filament" are shown as the printer doesn't "know" if there is any filament and the user has to be able to use both menus.

Hope that it makes clear.

If you have an question or issue with it, then please open a new Issue to keep this one "clear" to one topic.

@mhouse1
Copy link

mhouse1 commented Jul 11, 2024

So far I have 4 printers running new fw3.14 successfully
Two printers are getting thermal anomaly with firmware 3.14 after updating and is unable to perform PID cal. One printer I also tried factory reset to no help. Today, the print farm is running so the room is hot, maybe this is interfering with calibration. I will try this again later when print farm is off.

====================================
printer #10 built 12/16/19
print meters, days (44092.22m,945 days)
ran reset_revo.gcode
file incomplete continue anyway? > yes
Press to reset REVO 
press to save

flashed fw 3.14 thermal model cal
 starts automatically after flashing
fails right away, menu shows Clear TM error above print from sd
cleared TM error

start PID cal to 250C
stuck at nozzle 50/0 bed 28/0 PID cal. 0/5
nozzle is cold
performed power cycle
when i flipped powering switch extruder moves left for some reason
when powering on it tries to resume a print
restart printer using LCD X button
detects thermal model not set
click lcd to continue tries resuming print again, use menu to "Stop Print"
restart printer using LCD X button again
detects thermal model not set, but  does not try to resume print
use reset_revo.gcode
start PID cal to 250C
stuck at nozzle 52/0 bed 28/0 PID cal. 0/5
Perform factory reset all data using instructions at (https://help.prusa3d.com/article/full-system-refresh-original-prusa-i3_133258)
start PID cal to 250C
stuck at nozzle 58/0 bed 28/0 PID cal. 0/5
removed sd card
start calibration > wizard
while extruder is up, realize revo nozzle is a little loose, tightened it
wizard  starts searching bed calibration point
wizard completes and starts thermal model cal
thermal model cal results in thermal anomaly within 1 second
try PID cal to 250 again
PID cal ramps nozzle to 80C then stuck at nozzle ~52/0 bed 28/0 PID cal. 0/5
====================================
printer #40 built 4/26/21
print meters, days (m, days)
ran reset_revo.gcode
file incomplete continue anyway? > yes
Press to reset REVO 
press to save

flashed fw 3.14 thermal model cal
 starts automatically after flashing
next, performed PID  calibration to 250
cannot complete PID cal stuck at PID cal. 0/5
when trying to print from SD LCD Shows PAUSED THERMAL ERROR
restored to fw 3.11 for now so i can use the printer
performed PID cal to 250 and started a print

@mhouse1
Copy link

mhouse1 commented Jul 16, 2024

so far 2 out of 9 printers can't be updated to fw3.14 due to PID cal and thermal model failing right away even though both printers are functional on fw3.11 and is used everyday . Some inconsistencies, some printers starts thermal model cal right away after flashing fw3.14, some doesn't, printer number 10 built 12/16/19 I reverted back to fw3.11 because it kept failing to calibrate on fw3.14 even after factory reset and reset_revo.gcode, when I tried flashing fw3.14 again a few days later it starts self test after flashing.

for now any printer that accepts fw3.14 I'm updating to that otherwise they get updated to fw3.11

Details:


====================================
printer #10 built 12/16/19 attempting fw upgrade again
has fw 3.11
after flashing 3.14  it starts self test ("First, I will run the selftest to check most common assembly….)
starts thermal cal
fails right away with LCD showing print aborted
run reset revo.gcode
start PID cal, cannot complete PID cal  LCD shows PID cal. 0/5 LCD  menu cannot scroll
reset using LCD button
revert to fw 3.11

====================================
printer #35 built 1/15/21
has fw 3.11
print meters, days (?m, ?days)
after flashing 3.14 it starts thermal cal right away
successful
next, performed PID  calibration to 250
successful

====================================
printer #39 built 4/26/21
has fw 3.11
print meters, days (23681.91m, 386days)

after flashing 3.14 it starts thermal cal right away
next, performed PID  calibration to 250
started small print 33min
successful
====================================
printer #42 built 5/3/21
has fw 3.11
after flashing 3.14 does not auto thermal cal , LCD shows PRUSA i3 MK3S+R Ok.
Start PID cal to 250 … completes successfully
wait for cool down
next, performed thermal model cal
successful

@capsulecorplab
Copy link

Been running 3.14.0 firmware for the Mk3S with Revo for a couple of days now. Seems to be working so far without errors!

Though, the option to load filament when autoload is turned off seems to have disappeared. Should I open an issue for this?

I spoke too soon. I forgot I had disabled thermal model protection while running v3.13.2 before updating to v3.14.0. Factory resetting the printer brought back the thermal anomaly error until I reran the gcode to disable thermal model protection.

@3d-gussner
Copy link
Collaborator Author

3d-gussner commented Jul 18, 2024

@capsulecorplab Thanks for the feedback. Did the TM cal after the factory reset work?

@capsulecorplab
Copy link

@capsulecorplab Thanks for the feedback. Did the TM cal after the factory reset work?

I tried running TM cal after the reset, but couldn't get the thermal anomaly error to go away, so I ended up just disabling the TM protection

@mhouse1
Copy link

mhouse1 commented Jul 18, 2024

@capsulecorplab Thanks for the feedback. Did the TM cal after the factory reset work?

I tried running TM cal after the reset, but couldn't get the thermal anomaly error to go away, so I ended up just disabling the TM protection

which one is safer, disabling TM protection and using fw3.14 or using fw3.11 ?

@capsulecorplab
Copy link

which one is safer, disabling TM protection and using fw3.14 or using fw3.11 ?

I don't recall TM issues with fw3.11, but I also haven't printed on that fw enough to tell. I think I've had the best experience with fw3.13.2 (with TM protection disabled) so far - in part due to the fact that fw3.11 lacks filament runout sensing and fw3.14's "load filament" option seems to disappear for me when autoload is disabled, granted that's a separate issue.

@mhouse1
Copy link

mhouse1 commented Jul 18, 2024

no TM issues with fw3.11 but I thought the TM that was added after 3.11 improves on detecting TM anomalies, I wonder if disabling the new TM means we still have whatever safety feature that was in 3.11. Theres definitely lots of improvements in 3.14 that I'd like to use but if disabling the TM model means its less safe than 3.11 then I won't risk it.

With TM model disabled in 3.14 can it still detect extruder thermal runaway events? 3.11 has been great in detecting thermal runaways which I've see happen 8 times so far in the last 4 years on a print farm of 50+ mk3s printers.

@3d-gussner 3d-gussner removed their assignment Aug 8, 2024
@3d-gussner
Copy link
Collaborator Author

@mhouse1 Sorry for the late answer.

With TM model disabled in 3.14 can it still detect extruder thermal runaway events?

Yes the default thermal protection is always active.
With the TM active, but you might not see it as the TM reacts in seconds while thermal runaway takes longer.

Did you contact E3D support as they should be able to help you with REVO and TM issues,

@ndemarco
Copy link

ndemarco commented Aug 8, 2024

As you might imagine, E3D ran out of ideas, and directed me to contact Prusa for support.

E3D as a supplier of retrofit parts is ultimately responsible for making their parts are compatible.

I have offered to assist by providing logged data if properly instructed.

image

@mhouse1
Copy link

mhouse1 commented Aug 15, 2024

Yes the default thermal protection is always active.

I think the confusion from the community is fw3.11 was such a stable fw (no thermal issues in our years of use) why mess with it when it introduces complexity such as having to manage multiple fw builds. And the fact that a printer that prints completely fine on fw3.11 might experience odd thermal anomalies when using fw3.14: in some cases, a "PAUSED thermal anomaly" will appear on the LCD and prevent the print from starting but a reboot fixes it, in other cases "thermal anomaly" appears during print start with audible alarm but does not prevent print. Although a majority of the printers running fw3.14 are running good, it will take me a few more months of runtime to conclude whether updating from 3.11 to 3.14 was worth it.

I will try disabling thermal protection on fw3.14 just for those printers (2 out of 12) that are completely functional on fw3.11 but errors out ASAP on fw3.14 preventing the printer from being used.

@3d-gussner
Copy link
Collaborator Author

Yes the default thermal protection is always active.

I think the confusion from the community is fw3.11 was such a stable fw (no thermal issues in our years of use) why mess with it when it introduces complexity such as having to manage multiple fw builds. And the fact that a printer that prints completely fine on fw3.11 might experience odd thermal anomalies when using fw3.14: in some cases, a "PAUSED thermal anomaly" will appear on the LCD and prevent the print from starting but a reboot fixes it, in other cases "thermal anomaly" appears during print start with audible alarm but does not prevent print. Although a majority of the printers running fw3.14 are running good, it will take me a few more months of runtime to conclude whether updating from 3.11 to 3.14 was worth it.

I will try disabling thermal protection on fw3.14 just for those printers (2 out of 12) that are completely functional on fw3.11 but errors out ASAP on fw3.14 preventing the printer from being used.

@mhouse1 Thanks for the feedback and sorry to hear that 2 of your 12 printers keep be difficult with TM enabled.

The thermal model already proved that it is useful as some users had broken or semi broken thermistor or heater cables and found the issue. It reacts to issues way faster that the regular thermal protection but is also way more "sensitive" which can cause false positive warnings and errors.

For the stock E3D V6 we had tons of data and test machines internally and I think that the values are working great.

For the REVO we had just few community members submitting their values and E3D provided some other values for the REVO within their performance tolerances.

@mhouse1 Did you try to raise the W and E values?

@3d-gussner
Copy link
Collaborator Author

As you might imagine, E3D ran out of ideas, and directed me to contact Prusa for support.

E3D as a supplier of retrofit parts is ultimately responsible for making their parts are compatible.

I have offered to assist by providing logged data if properly instructed.

image

Hi, sorry to hear that E3D couldn't help you.

My time on this 3rd party issue is very limited but please try #4105 and provide there your results?

@mhouse1
Copy link

mhouse1 commented Aug 20, 2024

The thermal model already proved that it is useful as some users had broken or semi broken thermistor or heater cables and found the issue. It reacts to issues way faster that the regular thermal protection but is also way more "sensitive" which can cause false positive warnings and errors.

thank you for all the work put into this , I do believe I have some bias towards changing from fw3.11

We have some printers on fw3.14 that throws thermal anomally errors during startup, perhaps the firmware response is a sign that the printer wires or revo is wearing out, or its caused by a draft at that corner of the room and moving printer location will improve it, time will tell.

@3d-gussner
Copy link
Collaborator Author

Draft can cause some TM issues. I expected the REVO having less issues with draft because of the design of it. Or are these printers next to an walk-in freezer with -40°C? 😉

If I remember correctly testing the TM on REVO wasn't as easy to trigger as with the E3D v6 see as an example #4105 (comment)

Copy link

Thank you for your contribution to our project. This issue has not received any updates for 60 days and may be considered "stale." If this issue is still important to you, please add an update within the next 7 days to keep it open. Administrators can manually reopen the issue if necessary.

@mhouse1
Copy link

mhouse1 commented Oct 25, 2024

I ended up updating all printers to fw3.14 and disabled thermal model on more than half of the printers (12+ printers); due to thermal model either being annoying or preventing prints. No issues so far operating this way. For most printers with thermal model disabled they on average had 30000 meters of filament and 500 to 600 total print time days (from printer's LCD statistics page).

@mhouse1
Copy link

mhouse1 commented Nov 23, 2024

update: we started reverting to fw3.11

on the initial two printers that I disabled thermal model on, after a few months of using fw3.14 prints wont start, now it errors out with thermal error right a way. Reverting to 3.11 allowed printing again.

Observed something dangerous on a separate fw3.14 revo printer (2021 mk3s) this morning; this printer also did not have thermal model disabled. a 12hr print was stuck overnight 80% finished with the printer not moving, mid print, with fully heated nozzle, filament, and bed; im not sure how long it was stuck like this but seems rather dangerous, the LCD displayed no signs of error messages. I think safety should be added that if motors are not being moved for some time disable heating.

some other random fw3.14 issues:

  • sometimes the nozzle size setting changes on its own, a bit annoying but doesnt cause issues
  • theres more sd and fw crash issues, maybe our sd card is wearing out but i did not see as many on fw3.11

@3d-gussner
Copy link
Collaborator Author

@mhouse1

this printer also did not have thermal model disabled. a 12hr print was stuck overnight 80% finished with the printer not moving, mid print, with fully heated nozzle, filament, and bed; im not sure how long it was stuck like this but seems rather dangerous, the LCD displayed no signs of error messages. I think safety should be added that if motors are not being moved for some time disable heating.

Was it a SD card print or a host print like from Octoprint?

@mhouse1
Copy link

mhouse1 commented Nov 25, 2024

@mhouse1

this printer also did not have thermal model disabled. a 12hr print was stuck overnight 80% finished with the printer not moving, mid print, with fully heated nozzle, filament, and bed; im not sure how long it was stuck like this but seems rather dangerous, the LCD displayed no signs of error messages. I think safety should be added that if motors are not being moved for some time disable heating.

Was it a SD card print or a host print like from Octoprint?

this was printing from SD card

@JeffWDH
Copy link

JeffWDH commented Dec 4, 2024

For better or for worse, the only way I could get my Revo 6 (40 watt) to work in anything later than 3.11 on my MK3S was to disable the thermal model using a serial console. I did a factory reset and it would always fail when the nozzle was heated up.

M310 S0
ok
M500
echo:Settings Stored
ok

My printer works flawlessly on 3.11. I need to do some testing on whether it actually works well on 3.14.1 or if it just passed the initial wizard.

For completeness, this is the error I get from the console:

TM: calibr. failed!
echo:Thermal Model settings:
echo:  M310 I0 R25.30
echo:  M310 I1 R23.90
echo:  M310 I2 R22.50
echo:  M310 I3 R19.60
echo:  M310 I4 R19.00
echo:  M310 I5 R18.30
echo:  M310 I6 R17.70
echo:  M310 I7 R17.10
echo:  M310 I8 R16.80
echo:  M310 I9 R16.50
echo:  M310 I10 R16.30
echo:  M310 I11 R16.00
echo:  M310 I12 R15.90
echo:  M310 I13 R15.70
echo:  M310 I14 R15.60
echo:  M310 I15 R15.40
echo:  M310 P40.00 U-0.0014 V1.05 C8.77 D0.1500 L270 S1 B0 E1.23 W0.85 T-7.00
TM: error |1.315643|>0.850000
TM: error triggered!
//action:cancel
echo:Printer stopped due to errors. Supervision required.

So far I've done a Calicat in PLA and it turned out as I would expect with no errors. I'd love to re-enable the new thermal model functionality but for now this is working.

@mhouse1
Copy link

mhouse1 commented Dec 5, 2024

For better or for worse, the only way I could get my Revo 6 (40 watt) to work in anything later than 3.11 on my MK3S was to disable the thermal model using a serial console. I did a factory reset and it would always fail when the nozzle was heated up.

thats what I observed as well but after a few months of continuous printing it stopped working and would immediately error out when print starts, but reverting to 3.11 it functions and prints parts just fine. If it was truly an thermal issue i'd expect the parts to have defects

@JeffWDH
Copy link

JeffWDH commented Dec 14, 2024

I suspect hardware failure in my case. I was printing tonight and had a thermal runaway event and could smell a hot electric smell coming from the hotend. When looking for a new one I noticed the Prusa 40w heater cores all now come with blue thermistor wires and mine is white. I suspect mine was one of the early units, potentially other people with this issue may have similar hardware?

After further investigation, while doing a PID calibration the same thing happened and the temperature reading stalled around 180. After jiggling the thermistor wire near the thermistor the temperature reading jumped to 300(!) at which point I aborted.

I contacted E3D support with my findings and they confirmed my heater core was an old model and offered to send out a replacement. I will update this comment when I install it and retry the thermal model code.

@3d-gussner
Copy link
Collaborator Author

@JeffWDH Thanks for sharing, glad nothing happened to you and your printer. The thermal model triggered a warning and you did the right thing to investigate why and not just disable the TM.

@JeffWDH
Copy link

JeffWDH commented Dec 19, 2024

Update: After installing a new (blue thermistor cable) heater core I was able to successfully perform a PID tune and calibrate the thermal model. I still have to do some test prints when I have time to babysit the printer but so far it's an improvement.

start
echo: 3.14.1-8237_74a577bc0
MMU is Off
SpoolJoin is Off
echo: Last Updated: 2024-09-24 14:54:47 | Author: prusa3d
echo: Free Memory: 2509  PlannerBufferBytes: 1760
echo:Stored settings retrieved
adc_init
Hotend fan type: NOCTUA
CrashDetect ENABLED!
Sending 0xFF
echo:SD card ok
//action:dump_available
echo:enqueing "M303 E0 S210"
LCD status changed
PID Autotune start
T:23.75 @:127
T:33.28 @:127
T:45.50 @:127
T:55.55 @:127
T:65.00 @:127
T:75.15 @:127
T:83.39 @:127
T:92.31 @:127
T:99.70 @:127
T:107.09 @:127
T:115.35 @:127
T:122.26 @:127
T:129.96 @:127
T:136.68 @:127
T:144.18 @:127
T:150.37 @:127
T:156.69 @:127
T:163.66 @:127
T:169.15 @:127
T:176.37 @:127
T:181.96 @:127
T:187.73 @:127
T:194.28 @:127
T:199.28 @:127
T:205.54 @:127
T:211.30 @:0
T:215.47 @:0
T:214.27 @:0
T:211.61 @:0
T:208.57 @:127
T:209.55 @:127
T:215.73 @:0
T:219.69 @:0
T:219.69 @:0
T:216.82 @:0
T:214.22 @:0
T:210.83 @:0
 bias: 84 d: 84 min: 208.04 max: 219.79
T:208.62 @:84
T:209.38 @:84
T:213.02 @:0
T:214.53 @:0
T:213.18 @:0
T:210.78 @:0
 bias: 75 d: 75 min: 208.39 max: 214.69
T:208.21 @:75
T:209.73 @:75
T:211.88 @:0
T:213.07 @:0
T:210.99 @:0
 bias: 72 d: 72 min: 208.21 max: 213.18
 Ku: 36.94 Tu: 10.80
 Classic PID
 Kp: 22.17
 Ki: 4.10
 Kd: 29.92
T:208.13 @:72
T:208.35 @:72
T:210.00 @:72
T:212.66 @:0
T:210.78 @:0
 bias: 72 d: 72 min: 207.86 max: 212.66
 Ku: 38.20 Tu: 10.26
 Classic PID
 Kp: 22.92
 Ki: 4.47
 Kd: 29.40
T:208.44 @:72
T:208.39 @:72
T:210.00 @:72
T:212.14 @:0
T:211.04 @:0
 bias: 72 d: 72 min: 207.86 max: 212.14
 Ku: 42.86 Tu: 10.26
 Classic PID
 Kp: 25.71
 Ki: 5.01
 Kd: 32.98
PID Autotune finished! Put the last Kp, Ki and Kd constants from above into Configuration.h
LCD status changed
echo:enqueing "M301 P25.71 I5.01 D32.98"
echo:enqueing "M500"
ok p:25.71 i:5.01 d:32.98
echo:Settings Stored
LCD status changed
M310 S1
ok
M500
Command not found!
echo:Settings Stored
ok
echo:enqueing "G28 W"
echo:enqueing "G1 X125 Y105 Z1 F8000"
tmc2130_home_enter(axes_mask=0x04)
tmc2130_home_exit tmc2130_sg_homing_axes_mask=0x04
tmc2130_home_enter(axes_mask=0x01)
echo:busy: processing
  0 step=62 mscnt= 992
tmc2130_goto_step 0 45 2 1000
tmc2130_home_exit tmc2130_sg_homing_axes_mask=0x01
tmc2130_home_enter(axes_mask=0x02)
  0 step= 1 mscnt=  31
tmc2130_goto_step 1 33 2 1000
tmc2130_home_exit tmc2130_sg_homing_axes_mask=0x02
echo:busy: processing
echo:busy: processing
echo:enqueing "M310 A F1"
TM: calibration start
LCD status changed
TM: cool down <50C
TM: initial C est.
TM iter:0 v:10.73 e:0.330
TM iter:1 v:8.54 e:0.256
TM iter:2 v:8.54 e:0.158
TM iter:3 v:8.54 e:0.098
TM iter:4 v:8.54 e:0.060
TM iter:5 v:8.54 e:0.037
TM iter:6 v:8.54 e:0.023
TM iter:7 v:8.54 e:0.014
TM iter:8 v:8.54 e:0.009
TM: initial R 230C
TM iter:0 v:22.19 e:0.479
TM iter:1 v:22.19 e:0.296
TM iter:2 v:22.19 e:0.183
TM iter:3 v:22.19 e:0.113
TM iter:4 v:22.19 e:0.070
TM iter:5 v:22.19 e:0.043
TM iter:6 v:22.19 e:0.027
TM iter:7 v:22.19 e:0.016
TM iter:8 v:22.41 e:0.010
TM iter:9 v:22.41 e:0.006
TM: cool down <50C
TM: refine C est.
TM iter:0 v:10.73 e:0.330
TM iter:1 v:8.54 e:0.256
TM iter:2 v:8.54 e:0.158
TM iter:3 v:8.54 e:0.098
TM iter:4 v:8.54 e:0.060
TM iter:5 v:8.54 e:0.037
TM iter:6 v:8.54 e:0.023
TM iter:7 v:8.54 e:0.014
TM iter:8 v:8.47 e:0.009
TM: R[15] estimate.
TM iter:0 v:15.76 e:0.261
TM iter:1 v:15.76 e:0.161
TM iter:2 v:14.19 e:0.111
TM iter:3 v:13.22 e:0.073
TM iter:4 v:13.22 e:0.045
TM iter:5 v:13.59 e:0.027
TM iter:6 v:13.59 e:0.017
TM iter:7 v:13.45 e:0.011
TM iter:8 v:13.45 e:0.007
TM: R[11] estimate.
TM iter:0 v:15.76 e:0.261
TM iter:1 v:15.76 e:0.161
TM iter:2 v:14.19 e:0.111
TM iter:3 v:14.19 e:0.068
TM iter:4 v:14.19 e:0.042
TM iter:5 v:13.82 e:0.027
TM iter:6 v:13.82 e:0.017
TM iter:7 v:13.96 e:0.010
TM iter:8 v:13.96 e:0.006
TM: R[7] estimate.
TM iter:0 v:15.76 e:0.261
TM iter:1 v:15.76 e:0.161
TM iter:2 v:14.19 e:0.111
TM iter:3 v:14.19 e:0.068
TM iter:4 v:14.79 e:0.041
TM iter:5 v:14.79 e:0.025
TM iter:6 v:14.79 e:0.015
TM iter:7 v:14.93 e:0.009
TM: R[3] estimate.
TM iter:0 v:15.76 e:0.261
TM iter:1 v:15.76 e:0.161
TM iter:2 v:15.76 e:0.100
TM iter:3 v:16.73 e:0.058
TM iter:4 v:16.73 e:0.036
TM iter:5 v:16.73 e:0.022
TM iter:6 v:16.96 e:0.014
TM iter:7 v:16.96 e:0.008
LCD status changed
echo:Thermal Model settings:
echo:  M310 I0 R22.41
echo:  M310 I1 R21.05
echo:  M310 I2 R19.69
echo:  M310 I3 R16.96
echo:  M310 I4 R16.46
echo:  M310 I5 R15.95
echo:  M310 I6 R15.44
echo:  M310 I7 R14.93
echo:  M310 I8 R14.69
echo:  M310 I9 R14.45
echo:  M310 I10 R14.21
echo:  M310 I11 R13.96
echo:  M310 I12 R13.84
echo:  M310 I13 R13.71
echo:  M310 I14 R13.58
echo:  M310 I15 R13.45
echo:  M310 P40.00 U-0.0014 V1.05 C8.47 D0.1500 L270 S1 B0 E1.23 W0.85 T-7.00
echo:enqueing "M500"
echo:Settings Stored

Sign up for free to join this conversation on GitHub. Already have an account? Sign in to comment
Labels
REVO E3D REVO
Projects
None yet
Development

No branches or pull requests