#ender 5 stopping mid print?

1 messages · Page 1 of 1 (latest)

white abyss
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As the title says.

Updated to most recent firmware yesterday.

Prior to the firmware update this was not an issue (it had others, just not this)

Attached is a picture of the print vs a complete print and the screen

rn_image_picker_lib_temp_2ebf20df-23e2-4d82-85ab-3e6775732625.jpg rn_image_picker_lib_temp_6dd2bc4f-0dcf-4c52-b614-2196dc90fc18.jpg rn_image_picker_lib_temp_043f3f51-91d9-4237-b71e-e62a435876fb.jpg
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Media was removed after print failure. The SD card has been used to print recently without this issue. Had the same issue on the card before this.

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Mainboard is creality silent 4.2.2

silk fjord
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If the firmware thinks the SD card was removed, it's because it got an electrical signal indicating that the media was removed. There is no issue known that would lead to this spontaneously. It's hard to know if this is a firmware issue or a post-hoc fallacy without more testing and isolation of a cause. What version of the firmware were you using previously?

white abyss
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my bad, the sd card was removed after the print failure

white abyss
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I will reslice the print and retry with another SD card that is newer than the other two I tested on the Ender 5 (this newer SD card just completed a print last night so it is known working)

white abyss
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one thing of note is that the mainscreen shows a loss of print head posisition

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the print head and bed were not touched for the picture

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the x and y maxxed out and z was supposidly 0 although it was more accurately around 13-15mm

white abyss
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It would appear that this issue may have been related to a bad SD card.
I think 2 SD cards may have died at the same time

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the new one I tried worked so far for 2 prints

white abyss
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It's still happening

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On a literal handful of other SD cards

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It stopped for those two prints

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I was monitoring the printer when it happened, there was an error code for a split second

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Then it decided to clear itself so I couldn't read it

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I've been going crazy testing other SD cards

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It's costing so much filament and machine time

silk fjord
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If it keeps happening then it may just be a wiring issue with the SD card. Boards can have flaws, so it may very well be a broken trace or too much resistance or some other fabrication flaw with the board. If the SD card is on the display unit, electrical interference may be at play. There is some SD card error tolerance in the firmware, but when wiring problems exist we rely on the SD library that we use to catch issues and recover itself. There isn't any higher-level facility that tries to re-mount the SD card and re-try once file reading has failed. We might consider that for a future addition, but for now it relies on the SD card having good and reliable wiring.

white abyss
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Is there any way I can plug my laptop into the USB port and print from USB until the error may/may not occur and I get debug output through pronter face?

white abyss
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I believe this issue was due to thermal runaway protection. During a test print on the lab bench the nozzle thermal sensor was recording inaccurate data (40 degree swings within a couple of seconds when print head reaches certain location) After reseating my thermal probe the issue stopped occurring.
I believe I was getting thermal runaway warnings, but they self cleared. This would explain the message that was on the printer but disappeared.
The machine was not reset (to my knowledge) between the display of the warning message and the message disappearing.

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I am currently half way through a print on an SD card that was being used when the error was occuring and the issue has not yet repeated itself

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Could this be a bug where the thermal runaway message disappears shortly after being triggered?

silk fjord
white abyss
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I'm two successful prints in, I'm suspecting that the error was a thermal runaway error as it has not happened since I reseated the thermal probe (I used the same SD card that previously failed during prints)

Is it possible for the thermal runaway error to self clear and allow access to the printer without needing to reset?

silk fjord
white abyss
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on the last print before I implemented the fix I noticed significant temperature swings in the sensor reading, enough to trigger a thermal runaway.

On the one print I remember kind of catching the error the display was in a similar layout to a thermal runaway error (blank screen with text in the middle)

The fix I did to the printer was reseating the thermal probe and adding new connectors to my BL touch (as my old system had inconsistent connection leading to probe to not deploy on occasion)

I did a a coupld of look overs of the internal wiring for any additional issues and nothing popped out at me

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Prior to my fix I was able to influence the error in the temperature sensor reading by messing with the temp-sense wiring harness (moving it around) during the nozzle heat up

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all evidence I have points to a thermal runaway error that did not require a machine reset - unless there is something that can cause a similar error with the known issues above while still self clearing

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If the issue occurs again I can test the "bad" SD cards to see if I get similar results as initially reported

silk fjord
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The code to handle thermal runaway is quite straightforward and always ends up at KILL. As far as I know there is no LCD add-on code that overrides that.

white abyss
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I can't do much more testing right now as I need to get parts printed for a build

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do you know of any other error that would halt the printer mid-print and throw an error to the screen after moving the nozzle away from the print?

silk fjord
white abyss
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I would suspect the only other option to be something with the SD card, but even if there were an SD card failure wouldn't the nozzle just stop where it is?

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no runout sensor on this printer, filament is on a 10kg spool - although I did add a new tensioner system (to reduce the spool from free rolling and tangling itself). The tension isn't a significant amount, just enough to stop it from free spinning

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I did notice a bit of heat from the extruder motor on some of the few times I checked it mid print, just high enough for me to notice it when I put my hand to it but not high enough to hurt

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probably 30C-35C if I were to guess

white abyss
silk fjord
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Anything that ends up at Temperature::_temp_error subsequently ends up at loud_kill so it's hard to say otherwise. If the machine receives bogus G-code it could repond to that G-code and do anything. But when printing from host (not SD) all G-code has a checksum and line number so it can catch communication errors.

white abyss
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could an error like this be caught by a connected interface like octoprint or pronter face?

silk fjord
white abyss
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I mean would the error be spit out to a console

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so there is a record of what error occured

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the alternative seems to be to set up an action camera in a time lapse to watch the printer screen to try to catch the error the next time it happens

silk fjord
silk fjord
white abyss
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I'll look into octoprint after this batch of prints is done, these are high priority so I can't risk messing with machines that are currently working (even if temporarily lol). If I notice this behaviour occuring again i'll set up the camera so we have something to work with

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Thank you for your assistance and time Thinkyhead

silk fjord
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HTH. I'm off to another location for a change of scene. Still Marlining though.

white abyss
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Update, weird happenings.

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Started a print on the ender 5 and at 204c it made a clicking noise (from the software) for about 2 seconds then the screen flashed thermal runaway and print head moved to the corner, when it got there the printer reset itself

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Like the whole shebang, ender logo popped up on the screen and it was as if I had restarted it myself but I didn't

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204c out of 243c
Thermistor was replaced after this incident and the issue has appeared to be resolved. The concern is the self-reset behaviour