Stops Printing and Shows Temperature Warning

[DrFailbucket]

Application Version

4.9.0

Platform

Windows 10

Printer

Ender 3 Pro

Reproduction steps

I Sliced my Model with my Settings that i know it is working. I alredy Printed this Model 3 times without any issue, sliced with 4.8.0.

I was changing only one Setting: from Skirt to Brim.

After doing the same change in the setting with Cura 4.8.0 it worked fine again

Actual results

The printer starts and put down the first Layer. It moves to Z location for Layer 2 then it moves 5-10mm in X, Stops Printing, Starts Beeping and Shows the Temperature Warning on the LCD

Expected results

I expected to be printed like the other 3 ones.

Additional information

Here you can find the Project Files, and also the Sliced GCode Files

Sliced_Files.zip

[DrFailbucket]

I forgot the Log files, so here they are.

cura_4.8.0.log cura_4.9.0.log

[GregValiant]

I read the gcode files into AutoCAD (to take Cura out of the loop). I didn't see any odd moves. The image below shows the 4.8 brim file overlayed onto the 4.9 brim file. The file sizes are different so they aren't identical but they are pretty darn close. (The two green lines that go to X0 Y235 are the "present print" moves at the end of each file.)

Temperatures In both the 4.8 and 4.9 files are identical. There are 3 M104 lines in each. The first sets the Initial Layer Print Temperature to 230. The second at around line 3943 lowers the temp to 220. The final M104 turns the hot end off at the end of the gcode. So I don't see any problems with the Gcode. I dry ran the 4.9 file on my Ender 3 Pro from 1/2 way through the first layer and into the 2nd layer and there weren't any problems. The temperature changed as it should.

[fvrmr]

Hi @DrFailbucket thank you for your report. Like @GregValiant I can't see anything strange that will cause this. So it could be that your firmware can't work with the temperature settings. Maybe you could change the temperature and see if that doesn't break the print.

[DrFailbucket]

Hi, thanks for the response.

I was trying some simple shapes,Calibration Cubes, Stringing Tower and Temp Tower. All shows the same issue. Then i Printet 10x an Calibration X what is just 1 layer tall and it printed fine. When i try to Print the X with 5layers (stacked on eachother) then it shows the also the issue.

I'll try and run an PID tune and see if it causes the Problem.

[DrFailbucket]

OK so after running the PID it Prints.

But what i don't understand is, why is the gcode sliced with 4.8.0 running without problems even when i didnt do a PID?

[GregValiant]

I don't get it either. The two files are virtually identical. You can tell in my previous image that something is different because the two prints end up in different places before going into "present print". But everything referring to temperatures is near identical. At any rate it appears to be fixed. EDIT: Since the PID appears to be involved and since the heater floats between it's hysteresis points (which I think are affected by the PID) then the only thing I can think of is that when the 4.8 version ran maybe the hot end was already cooling from say 230.5 (heater off) and the M104 S220 just kept it off. When the 4.9 version ran, maybe the hot end was heating from say 229.5 and when the M104 S220 was acted on it confused the heater circuit logic...somehow...maybe...dunno. When I changed hot ends on my Ender 3 Pro I ran the Auto-Tune and the PID numbers were a lot different for the new heater.

[GregValiant]

__

[GregValiant]

@patrickmollohan - If you would post that problem gcode file from 4.9 and a good one from 4.8 somebody will take a look. Once the printer sees an M104 or an M109 the temperature is set and it remains at that set point until another M104 or M109 changes the temperature. If there is a problem in the printer the temperature can vary, but the only way to get it to float by +/-10° using gcode is to have a boatload of M104's/M109's in the gcode.

[GregValiant]

Just looking through the 4.9 gcode file the following are the Hot End Temp commands (preceded by the gcode line number):

      21 M104 S215  ;The beginning of the file and is the Initial Print Temperature.
      22 M109 S215
      23 M109 R215
   14521 M104 S215  ;This is at the start of the second layer and is the Print Temperature.
 1270052 M104 S0  ;At the end of the file.

That's it. All the temperature commands are for the Hot End at 215. An "M109 S" is wait for heating to complete. An "M109 R" is wait for either heat-up or cool-down to complete (whichever applies). Typically an "M109 R" is not generated by Cura BUT it is also present in the 4.8 file. I'm not sure what setting would trigger M109 R to be inserted in the gcode. Maybe someone from the Cura team can address that.

[GregValiant]

The M109 R appears to be in your default startup gcode. It comes from your printer definition file and is present in 4.8 and 4.9.

"But let there be no doubt: this is an issue with 4.9, not my printer." You sound very positive, and yet I'm not convinced that is true. My searches and your graph are saying that the temperature is 215 and it isn't being varied by any gcode command in that file.

[GregValiant]

Thinking about this, there is one thing that could affect temperature and be different between versions and that might be Flow Rate. Varying flow rates could cause the hot end to appear to fluctuate do to the cooling effect of filament passing through. I don't know enough about the inner workings of Cura to address that (or even to know if it is really a possibility) but I thought I would throw it up here. I think if we were discussing the Arachne version which does alter flow rate for different extrusion paths, that it would be more likely, but again, I don't really know. Maybe @Ghostkeeper, @jellespijker, or another member of the Cura Team might have an idea.

[Ghostkeeper]

Varying flow rates could cause the hot end to appear to fluctuate do to the cooling effect of filament passing through. I don't know enough about the inner workings of Cura to address that (or even to know if it is really a possibility) but I thought I would throw it up here.

Slightly. We generally print the fast quality profile ~5C hotter than the normal profile at Ultimaker, because the flow rate is doubled. Otherwise the filament isn't molten all the way to the core by the time it reaches the nozzle chamber (since the filament moves much faster though the heat zone). I don't expect you'd be able to measure the effect on the nozzle temperature though, and you won't notice the effect on the filament temperature either if you have less than 30% flow rate difference.

You can calculate the average flow rate pretty easily and decently accurately from the printing time and material usage in the header of the g-code files. In 4.8, your g-code indicates an average extrusion rate of 0.806788mm/s (in filament length per second). In 4.9 that is 0.811847mm/s. So the extrusion rate increased by 0.627%. That's not significant at all.

Realistically, there's not a lot we can do to help here unless you can specifically point out what is wrong with the g-code. As far as I can see, the g-code files are fine. The temperature commands are all the correct temperatures at the correct times in the print. It's all according to spec. If your printer doesn't deal with that g-code well, I'd consider that a problem in the printer, not in Cura.

If there is something you could point out like "Cura is switching temperatures every 5 seconds, which causes my PID regulator to freak out" then we'll know what we could do to improve support for your printer. But otherwise I have no idea how to support your printer. I don't have your printer to test with, after all.

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