Solved Temp Fall/Fail Error and fix?

Hi all, been a while since I've had any thing go wrong with printer (R1 kickstarter version). Upgrades include E3Dv6, XXL LCD.

Lately, I've been printing (via sdcard) PETG @235C with bed @80C. The last few prints have temp fall or fail about 75% complete.
After the first fail, I attempted to restart the print and it would heat up as usual, then home, then freeze with temp fall error. Thinking loose connection I moved it to a elevated position and set temps then shook wires. No fluctuations in temp. I lifted the printer to check connections and good there too.

Little back history, last time this happened I searched and read about possible faults do I ordered a new thermister and it went away until now. I've got some new heaters (40w) on the way to try and see if the change from the 25w stock E3Dv6 will fix it.

If it doesn't, I'd like to be able to monitor the running code and errors real time but not sure what software to use. If not, any suggestions on changing firmware settings like changing #define Heater_0_mintemp 5 to say 30?
Or #define thermal_protection_hotends under configuration_adv.h file settings?

Thanks I advance, hoping this is a simple solution. - Jim

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Well, I didn't want to disable the protection just adjust the amount of time before it kicks in (if possible). I'm running the V3 firmware which did help other functions.

As for the thermistor, I think my first one failed because it was too tight. When I swapped it, it had the set screw dent in it. This one I was more careful installing it and just firmed it up. I gave it a little tug and had checked all my connections prior to posting since there are so many posts about this issue.

Good to know that maybe just a weak heater. They are cheap to buy the 40w versions.

What about monitoring the code while printing from the LCD via Sdcard? Suggestions on that or adjusting the heater temp setting?

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Yeah, so mine never autoleveled so I'm good there I guess. Lol
Kickstarter version ftw.

I'll take a look at Merlin 1.10 as suggested. Thanks for the rest of the info to. I might change the temp swing to 10 from 5 to see if its less sensitive over the long term.

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I really do like this printer. TBH I picked this printer up about a year or so ago for $150 from a guy who had given up on it. It was missing a hotend and needed a full going through. After testing it with a Hexagon head, the E3Dv6 was a no brainer.

Yep, I'll definitely be running the PID Autotune again when I install the replacement heater. Thanks for the reminder. I did run it when I swapped out the thermistor.

What is this MESH you speak of?



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So I've replaced the heater to the 12v 40w version. Unfortunately, it didn't sold my temp fall error. After running the autotune 2x times (10 cycles each), I can watch the temp still jump multiple degs.

Any suggestions on where I can start to modify the firmware to increase temp tolerances?

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Any thoughts of changing these settings?


//Check for thermistor temerature freefall during the print,
//This usually indicates that the thermistor has been removed from the head.
#define TEMP_SENSOR_DISCONNECT_CHECK 1
#define TEMP_SENSOR_DISCONNECT_LIMIT 10

I can't seem to find any information on the Marlin wiki about them. Are these a on/off number for the check or a 1 sec/min rule?
Can I assume the 10 for the limit is 10 secs or min? Any info. would be helpful.

 

Well, I think I have good news. I've had the time to play with both the settings and printer. I finally got a good PID tune on it. It appears the autotune feature is best as a reference and not as "perfect". It took me maybe about 10 runs of 5 cycles to get it zero'ed in enough that the temp now only jumps less then +/- 1 deg C.

Once I got it there, I was able to try find if I had a loose connection. I traced out the lines, re-ran them from the board up. There were no breaks or weak spots until I reached the "quick disconnect" that comes with the thermistors. As soon as I touched it temp fluctuations were intense. So, I just removed the thermistor and cut off the plug. I had some JST connectors (from drones I build) and soldered one of those in it's place. Repeated the testing from board back and ZERO issues. It now stays within the same tolerance as expected.

I should not that I was monitoring via Repeater-Host the entire time for all my work. That's a great piece of software for the graphing. It's too bad Cura doesn't have the same feature set. I'd like to take manual control, see the scrolling commands/info and watch the graph so I can really see what's happening.

Thanks for the help, Closing this issue and setting resolved.