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[BFW-5406] [BUG] Nozzle Cleaning Error with 6.0.0 #3818

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BillC58 opened this issue Mar 9, 2024 · 40 comments
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[BFW-5406] [BUG] Nozzle Cleaning Error with 6.0.0 #3818

BillC58 opened this issue Mar 9, 2024 · 40 comments
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@BillC58
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BillC58 commented Mar 9, 2024

Printer - XL 5TH

Firmware - 6.0.0

After a week or so printing with the alpha firmware, I started to get a nozzle cleaning error on TH1.

After a successful print, on the next print job, the printer would try to clean the nozzle with around 50 taps and then fail.

If I reset the printer and reprint, it works fine without any further action from me. It only took 3 or 4 cleaning taps for the printer to continue on.

Then after the successful print, the same nozzle cleaning error occurs on the next print.

I worked with Chat Support and after a few steps, they asked me to downgrade to 5.1.2. This solved the issue.

Chat support has the 8 minute video of this condition.
@BillC58 BillC58 added the bug Something isn't working. label Mar 9, 2024
@brettvitaz
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I am experiencing a similar problem. After a successful print, nozzle cleaning fails for the subsequent prints and requires restarting the printer before a print can start.

@plucker
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plucker commented Mar 31, 2024

Same problem here on two separate machines

@BillC58 BillC58 mentioned this issue Apr 17, 2024
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This was referenced Apr 18, 2024
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@danopernis danopernis added known issue Our developers are aware of the issue. They will eventually work on it. unable to reproduce We need to be able to reproduce the issue in order to help. labels Apr 18, 2024
@danopernis
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@bgyarfas @mikelane @alphen87 @shledge @TheYang @BillC58 @brettvitaz @plucker all of you seem to have the same issue, which I am unable to reproduce. So far, it seems that the issue is:

  • after successful print, another print fails at the nozzle cleaning stage and it is only fixed by the reset of the printer
  • related to 6.0.x series and fixed by reverting to 5.1.x series
  • related to multiple printers, including at least XL and MK4

Can we find some similarities shared in all of your cases? Like the nozzle, material, anything else? Is there a minimal gcode to reproduce the issue? For example just G28 and then G29 P9. I would love to fix this issue but I don't have enough data...

@danopernis danopernis changed the title XL Nozzle Cleaning Error with 6.0.0 [BFW-5406] [BUG] Nozzle Cleaning Error with 6.0.0 Apr 18, 2024
@shledge
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shledge commented Apr 18, 2024 •
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Mine has been working fine since final 6.0 release. Previously it happened even with no filament in nozzle at all, and it also was failing to even level properly, as in it kept probing the same 1st point over and over non stop.

As a result, I can't really reproduce it at the moment.

@BillC58
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BillC58 commented Apr 18, 2024 via email

@TheYang
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TheYang commented Apr 18, 2024 •
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@bgyarfas @mikelane @alphen87 @shledge @TheYang @BillC58 @brettvitaz @plucker all of you seem to have the same issue, which I am unable to reproduce. So far, it seems that the issue is:

* after successful print, another print fails at the nozzle cleaning stage and it is only fixed by the reset of the printer

* related to 6.0.x series and fixed by reverting to 5.1.x series

* related to multiple printers, including at least XL and MK4

Can we find some similarities shared in all of your cases? Like the nozzle, material, anything else? Is there a minimal gcode to reproduce the issue? For example just G28 and then G29 P9. I would love to fix this issue but I don't have enough data...

I have been trying to reproduce the issue for 3 prints now, for now it's working on my 2TH XL.
After upgrading to 6.0 RC3 on my XL I did have a similar issue once. But it turned out that the Nozzle (V6 Adapter + e3d hardened v6) was loose.
The nozzle cleaning / bed leveling stage failed, I reset the printer, and it passed, printing the whole model with a bit of leakage, which prompted me to check the nozzle - which was loose.

I'll have to report back once I got rid of my habit to reset the printer after each print and can reproduce the issue reliably.

One note that I have is that sometimes (rarely) the printer did pass cleaning, and failed on the bed leveling.

@cplmayo
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cplmayo commented Apr 18, 2024 •
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I had this error as well and was able to correct however I am now getting a bed leveling error. My assumption is could be related to this considering they both used the loadcell; could totally be wrong. If it would be easier I can open a new issue as I didn't see anything close already; my search foo could have been lacking.

So far to troubleshoot I have washed the build plate, replaced nozzles, and recalibrated everything. Let me know if there is anything else I need to do or can do to help troubleshoot.

Dual head model that has been working prior to flash to 6.0.0-RC3.

Edit: Wanted to update without bumping everyone's email. The bed level issue could be related to the size of the print. Running a smaller print with same filament; ABS. It is printing but I did get one nozzle clean error. After a retry it worked. Print is going without a problem at the moment. Will have to try another large print or other areas of the bed to try and investigate.

@alphen87
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@bgyarfas @mikelane @alphen87 @shledge @TheYang @BillC58 @brettvitaz @plucker all of you seem to have the same issue, which I am unable to reproduce. So far, it seems that the issue is:

  • after successful print, another print fails at the nozzle cleaning stage and it is only fixed by the reset of the printer
  • related to 6.0.x series and fixed by reverting to 5.1.x series
  • related to multiple printers, including at least XL and MK4

Can we find some similarities shared in all of your cases? Like the nozzle, material, anything else? Is there a minimal gcode to reproduce the issue? For example just G28 and then G29 P9. I would love to fix this issue but I don't have enough data...

I tried 3 different tools, all perfect clean .4 brass nozzles and PETG, ASA and PLA filament, and sliced with PS 2.7.4. All jobs have this issue, so i guess there is no specific gcode to reproduce it. Is there some way I can dump/export the memory before and after a print? Perhaps we can find something like a shift in offset?

@CZDanol
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CZDanol commented Apr 18, 2024

You guys are lucky (and I am unlucky) :D One of my home printers started doing it, so now we have a reproducer!

@brettvitaz
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I am on a 5 tool XL:

  • tool: 5
  • nozzle: 0.8mm brass
  • material: PETG
  • firmware: 6.0.0 alpha and 6.0.0 rc3

here is an offending file:
Cat Spike v3_0.8n_0.3mm_PETG_XLIS_2h39m.bgcode.zip

Yesterday I did a factory reset on the printer and reflashed rc3 firmware. The problem still exists for that file, but I have had other prints that work properly.

@brettvitaz
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brettvitaz commented Apr 19, 2024 •
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Here is a smaller print that exhibits the same behavior:
Shape-Cylinder_0.8n_0.3mm_PETG_XLIS_1m.bgcode.zip

This file can not be printed twice in a row on my XL without resetting the printer.

@bgyarfas
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bgyarfas commented Apr 19, 2024 •
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@danopernis

So far, it seems that the issue is:

  • after successful print...

I haven't been able to get a successful print with 6.0.0, it always fails nozzle cleaning

  • related to 6.0.x series and fixed by reverting to 5.1.x series

correct

Can we find some similarities shared in all of your cases? Like the nozzle, material, anything else?

Prusament PLA, Satin sheet, Official Prusa v6 adapter with a diamondback 0.6 nozzle. I will check everything is tight as I noticed @TheYang mentioned his v6 nozzle was loose.

On a whim, I monitored the loadcell sensor output on the LCD while the nozzle cleaning was being attempted. On 5.1.x the value appears to peak to approximately -400 while on 6.0.0 it only peaks to -100. It's difficult to see exactly since it's only a single frame at most. Is there a way to log the loadcell sensor output during nozzle cleaning?

I can also try a minimal gcode file that only has the G28 & G90 commands. Do I need any of the preamble that's in a typically generated gcode? I'm assuming I'd also need M17 for instance...

@CZDanol CZDanol removed the unable to reproduce We need to be able to reproduce the issue in order to help. label Apr 19, 2024
@cplmayo
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cplmayo commented Apr 19, 2024 •
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To help diagnose I wanted to share these files:

They both are using the same ABS filament profiles loaded in the same toolheads; only difference is size and number of models. Edit: Forgot the sumo-print I changed the infill to gyroid.

@BillC58
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BillC58 commented Apr 21, 2024 via email

@shledge
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shledge commented Apr 21, 2024 •
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Just happened to my mk4 just now, on 6.0 - same issue that I had when on 6.0 RC1. Reset needed to make it work again.

Printing in PLA, stock nozzle probe temps (170c). Nozzle is tight and hotend is not loose overall.

@CZDanol
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CZDanol commented Apr 23, 2024

Hey guys, we hopefully have a fix, should get out in the next release. It is purely a firmware issue.

@plucker
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plucker commented Apr 24, 2024 via email

@cplmayo
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cplmayo commented Apr 25, 2024

I upgraded to the latest version today; attempted the print that has been giving me problems. Nozzle Clean finished without issue but still reporting a bed leveling error. Should I create a new issue for this?

@BillC58
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BillC58 commented Apr 25, 2024 via email

@shledge
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shledge commented Apr 25, 2024

I noticed it goes away after a while without resetting, but it will happen again on the 2nd print.

Likely an issue with whatever resets/tares the loadcell, leading to it being delayed rather than straight after the previous print?

@brettvitaz
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After updating I am still getting "Nozzle Cleaning Failed"

@danopernis
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danopernis commented Apr 26, 2024 •
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Just to prevent speculations, 6.0.0-RC3 for XL is the same as the final 6.0.0 and as such does not contain any functional changes on top of the 6.0.0-RC3. There are still known issues, including this one. We are working on fixing this, but didn't want to postpone important features like the phase stepping. We will be releasing fix for this issue once we implement it.

To give you some background information, nozzle cleaning error seems to be a timing issue related to analyzing the buffer containing the loadcell samples. On XL the issue seems to be more pronounced, probably due to latency introduced by modbus communication with dwarf daughterboard. Quick fix which should work for most of the cases is to increase the buffer size, but we want to also look at other options for more proper fix.

@ChrisXLprint
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I have just finished with Prusa support chat, the developers are aware of the bug and are working on it. Currently only able to reslove by reseting printer on the LCD push button or downgrading firmware.

@einarbey
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einarbey commented May 6, 2024

do we have some ETA for this bug fix ? i can´t get passed this nozzle cleaning error on my printer. only works if i downgrade to firmware 5.1.3.

@djcody1
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djcody1 commented May 7, 2024

Same issue on my MK3.9, but can’t get past the error without downgrading to 5.1.3. Resetting the printer did not fix the issue. Prusa tech support chat is aware. Itching for the firmware update to drop soon - my MMU3 arrives tomorrow and I’ve already waited so long to use it!

@SebLaus
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SebLaus commented May 9, 2024 •
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Having the same issue on my MK4.
Since upgrading to 6.00 with MMU3 it does two rows of 15 Calibration taps for nozzle cleaning and then failing. It's not even possible to start a single print. After having contact with Supportchat, we were not able to fix the issue. With 5.1.3 and without MMU3 The printer itself prints fine. But unfortunately not possible with MMU3. With 6.0.0-RC2 it's the same issue.

@Prusa-Support
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The problem is mentioned as a known problem in the most recent release notes FW 6.0.0-xl as the release for Prusa XL was slightly deferred, but this is also valid for Prusa MK4.

The problem is very slightly more likely to be appreciated on Prusa XL due to slightly higher latency of the data that travels through multiple boards, and it is at "buffer" level, which means it can be temporarily solved by "hitting reset".
More technical details have already be disclosed by our developer above at #3818 (comment).

The fix will be available in short and we don't need to collect further data at the moment.
The fix will supposedly be implemented in the next firmware release but there is no estimated time available at the moment.
Until then, a quick reset should get rid of the problem. We apologize for the trouble.

Thank you all for bringing this to our attention and for bearing with us.

Michele Moramarco
Prusa Research

@BillC58
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BillC58 commented May 10, 2024 via email

@danopernis
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FYI v6.0.1 was just released, can you please retest? Sorry for all the inconveniences and let's hope the fix works for you 🤞

@SebLaus
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SebLaus commented May 17, 2024

First impression is looking good so far

@I-max-ctrl
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I have a Prusa XL printing ABS on extruder 1 .04 mm nozzle continue to have the same problems as everybody else on the 6.0.0 software once I updated to 6.0.1 it worked once I’m finished with this print. I will let you know how another print goes, glad it wasn’t only happening to m.

@djcody1
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djcody1 commented May 17, 2024

My MK3.9 is behaving perfectly on 6.0.1 after two prints so far. Thanks for the quick fix!

@CZDanol CZDanol added the solved label May 18, 2024
@BillC58
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BillC58 commented May 20, 2024 via email

@CZDanol CZDanol self-assigned this May 21, 2024
@CZDanol
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CZDanol commented May 21, 2024

Great, thanks :) Closing the issue then.

@CZDanol CZDanol closed this as completed May 21, 2024
@brettvitaz
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I have just experienced this again, with the latest firmware. It has been working well until today when the nozzle cleaning failed and I had to reset the printer to start a new print.

@CZDanol
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CZDanol commented Jun 20, 2024

@brettvitaz is it now happening less, or did the update do nothing for you?

@brettvitaz
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It is happening much less. This is the first time it has happened since the fix.

@danopernis danopernis removed the known issue Our developers are aware of the issue. They will eventually work on it. label Jun 27, 2024
@Prusa-Support
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In that case, I'm afraid we are not talking about the issue at firmware level originally discussed in this thread.

Here is a brief list of possible causes of the problem (non-firmware related).

  • loose nozzle (or incorrectly positioned)
  • debris between sheet and bed
  • tense/pulled filament (friction opposing the filament unwinding)
  • external resonation (e.g. vibrations from other operating devices, people/pets moving around...)
  • loose/wobbly bed (or expansion joints, or bearings, or bars)
  • noticeably dirty nozzle
  • partially clogged nozzle (especially after using high-temp materials)
  • inaccurate XYZ movements...
  • deformed, too loose, or too tense extruder assembly...
  • other "external" causes of the problem... (including problems based on the specific print, or filament...)

This list may not tell much without proper guidance so please contact our Customer Support to get adequate help.

Michele Moramarco
Prusa Research

@brettvitaz
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While some of these factors this may be true, the issue was solved by restarting the printer. This tells me that there is something wrong in the firmware level. I will attempt to reproduce it since the conditions were largely different from my normal prints (0.8 mm nozzle, using spool join).

@mgrn0
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mgrn0 commented Aug 8, 2024

I also do still have nozzle cleaning issues with my mk4, will try to reproduce (or eliminate it), hopefully..

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