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Firmware for Original Prusa i3 3D printer by PrusaResearch
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Thermal model for E3D REVO #4105

Closed 3d-gussner closed 1 year ago

3d-gussner commented 1 year ago

First we want to thank everyone here for providing feedback, testing and reporting log files in https://github.com/prusa3d/Prusa-Firmware/issues/3636. :heart: :clap: :fireworks:

As the issue got very long I would like to continue collecting data log files here.

We have a new firmware release FW 3.12.2 which includes some PTC / REVO improvements see https://github.com/prusa3d/Prusa-Firmware/releases/tag/v3.12.2

It would be great if you could run the tests below and give us some feedback.

Please don't use Pronterface/printrun as it UPPER-CASES D3 commands which are case sensitive. Please use Putty, OctoPrint (with D3 as exception to be UPPER CASED), or other serial terminal scripts:

Octopi Blacklist is in Settings -> Features-> Terminal Auto Uppercase Blacklist add here the D3 gcode.

Here the steps our internal test team was following.

Task 1

  1. Ensure printer is "cold" :cold_face:
  2. Connect serial logging
  3. Perform a Factory reset by pressing the knob during boot/start up (you don't have to but makes things easier to compare)
  4. Skip wizard
  5. Send M503 to show current settings
  6. Send M310 S0 to temporary disable TM for PID cal
  7. Got to LCD -> Calibration -> PID cal.
  8. M310 S1 to enable TM
  9. Wait until the printer is cold :cold_face: before you continue.
  10. Send `G28 W" to home all without mesh bed level
  11. Send G1 X125 Y105 Z1 to move the hotend to the middle of the bed
  12. Send M155 S1 C3 to auto report temps and fans
  13. Send M310 P40 U-0.0014 V1.05 D0.15 L270 to set REVO values
  14. Send D70 S1 to enable tml debug code
  15. Send M310 A F0 to run Thermal model cal. without checking existing TM settings
  16. Send M500 to store TM values
  17. Send D3 Ax0ca6 C1 to check calibration v2 status
  18. Send D3 Ax0f5f X01 to set Wizard active
  19. Close serial logging
  20. Start new terminal session to log the wizard
  21. Printer should restart during connection and show the Wizard
  22. Follow the wizard steps
  23. The TM cal should be ignored as it already passed
  24. Print something to verify that no THERMAL ANOMALY messages are shown, ideally with serial logging

Check TM simulation vs real REVO

  1. Lower the TM warning values in 0.1 steps with M310 W1.1 , M310 W1.0 ... M310 W0.4 during a print. The default warning is set to 1.2 and error to 1.74
  2. Set warning value back to default M310 W1.2
  3. Try to force TM error
  4. Hold nozzle (without silicone ring) during preheat with a big wrench
  5. Blow compressed air on nozzle / block (without / with silicone ring)

Task 2 This task is for users who have provided the log files and have a well calibrated REVO MK3/S printer.

Goal is to find the narrowest TM Warning settings to detect issues as fast as possible while preventing false positives.

To simulate an issue it is needed to remove heat from the system that is unusual:

  1. Continue only if your last few prints have been printed without TM warnings or errors
  2. Start with cold printer
  3. Enable serial logging and terminal
  4. Home printer G28 W and move it to the middle of the bed G1 X125 Y105 Z1
  5. Enable temperature and fan auto report with M155 S1 C3
  6. Set the Thermal model warning value very low with M310 W0.1
  7. Preheat the printer nozzle with M104 S230
  8. As soon the THERMAL ANOMALY is shown on LCD or TM: error .... is serial log 8.1. increase the TM warning in to the highest warning value you see in the log file Example: 
    M104 S230
T:19.8 /0.0 B:20.1 /0.0 T0:19.8 /0.0 @:0 B@:0 P:0.0 A:22.8
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
T:19.5 /0.0 B:20.0 /0.0 T0:19.5 /0.0 @:0 B@:0 P:0.0 A:22.7
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
ok
T:19.8 /230.0 B:20.0 /0.0 T0:19.8 /230.0 @:0 B@:0 P:0.0 A:22.9
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
T:19.8 /230.0 B:20.1 /0.0 T0:19.8 /230.0 @:127 B@:0 P:0.0 A:22.9
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
TM: error |-0.128510|>0.100000
LCD status changed
T:21.2 /230.0 B:19.9 /0.0 T0:21.2 /230.0 @:127 B@:0 P:0.0 A:22.9
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
TM: error |-0.128510|>0.100000
T:26.2 /230.0 B:20.0 /0.0 T0:26.2 /230.0 @:127 B@:0 P:0.0 A:23.0
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
TM: error |0.146289|>0.100000
TM: error |0.276878|>0.100000
TM: error |0.369785|>0.100000
TM: error |0.354879|>0.100000
T:32.4 /230.0 B:20.0 /0.0 T0:32.4 /230.0 @:127 B@:0 P:0.0 A:22.9
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
TM: error |0.412588|>0.100000
TM: error |0.492126|>0.100000
TM: error |0.537168|>0.100000
T:37.4 /230.0 B:20.2 /0.0 T0:37.4 /230.0 @:127 B@:0 P:0.0 A:23.0
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
TM: error |0.617816|>0.100000
TM: error |0.640872|>0.100000
TM: error |0.640521|>0.100000
TM: error |0.662439|>0.100000
T:43.8 /230.0 B:20.1 /0.0 T0:43.8 /230.0 @:127 B@:0 P:0.0 A:23.0
E0:0 RPM PRN1:0 RPM E0@:0 PRN1@:0
TM: error |0.671063|>0.100000
TM: error |0.704903|>0.100000
TM: error |0.760007|>0.100000
TM: error |0.759591|>0.100000
T:50.2 /230.0 B:20.3 /0.0 T0:50.2 /230.0 @:127 B@:0 P:0.0 A:22.9
E0:0 RPM PRN1:0 RPM E0@:255 PRN1@:0
TM: error |0.748378|>0.100000
TM: error |0.753847|>0.100000
TM: error |0.736684|>0.100000
TM: error |0.759366|>0.100000
T:56.1 /230.0 B:20.1 /0.0 T0:56.1 /230.0 @:127 B@:0 P:0.0 A:23.0
E0:6120 RPM PRN1:0 RPM E0@:255 PRN1@:0
TM: error |0.758709|>0.100000
TM: error |0.776785|>0.100000
TM: error |0.782815|>0.100000
T:60.6 /230.0 B:20.0 /0.0 T0:60.6 /230.0 @:127 B@:0 P:0.0 A:23.1
E0:6120 RPM PRN1:0 RPM E0@:255 PRN1@:0
TM: error |0.751269|>0.100000
TM: error |0.729433|>0.100000
TM: error |0.726179|>0.100000
TM: error |0.714466|>0.100000
T:66.1 /230.0 B:20.1 /0.0 T0:66.1 /230.0 @:127 B@:0 P:0.0 A:23.1
E0:6120 RPM PRN1:0 RPM E0@:255 PRN1@:0
TM: error |0.707799|>0.100000
TM: error |0.707810|>0.100000
TM: error |0.698669|>0.100000
TM: error |0.675214|>0.100000
T:71.6 /230.0 B:20.0 /0.0 T0:71.6 /230.0 @:127 B@:0 P:0.0 A:23.0
E0:6120 RPM PRN1:0 RPM E0@:255 PRN1@:0
TM: error |0.647182|>0.100000
TM: error |0.627840|>0.100000
TM: error |0.618382|>0.100000
TM: error |0.597126|>0.100000
T:76.8 /230.0 B:20.0 /0.0 T0:76.8 /230.0 @:127 B@:0 P:0.0 A:22.9
E0:6120 RPM PRN1:0 RPM E0@:255 PRN1@:0
TM: error |0.592377|>0.100000
TM: error |0.588639|>0.100000
TM: error |0.566763|>0.100000

    8.2 The highest value in this example is TM: error |0.782815|>0.100000 so set the new TM warning to next 0.x value here a M310 W0.8 8.3 Please watch your serial log and try to find the highest TM Warning value and use that one.

  9. Let the printer cool down with M104 S0
  10. Verify the warning value with a full cycle of heat up M109 230 and cool down M104 S0 if needed adjust the TM warning value, so it is not triggered.
  11. Save the value with M500 in case you have to restart the test at some point.
  12. Let the printer preheat with M109 S230
  13. Turn on the fan with M106 12.1 Try to create a blow back of the part cooling fan. Placing something behind extruder or so. hard to describe who to force a blow back.
  14. Try some cold air, if needed to have access with tools just move the Z up, but don't forget to go back to Z1 if you try it again. 14.1 If you have a better way to "suck" out heat from the system try that
  15. If it doesn't trigger lower the TM warning value by 0.1 with M301 W<old value - 0.1> to check when it triggers
  16. Let the printer cool down with M104 S0 and full fan blowing at Z1 height
  17. Stop fan with M107
  18. Verify the value again with a full heat up M109 S230 and cool down M104 S0 cycle
  19. Repeat verification with full on fan M106 followed M109 S230 , M104 S0 and M107
  20. Save the new warning value that fits you best with M500
  21. Print multiple things to verify your TM warning values (ideally with serial log files)
  22. Report these values and log files here.
Task 2 results: User TM W good TM W too narrow final after some prints
snafu1282 0.8 0.7 TBD
0.8 0.7 TBD

[UPDATE 30-05-2023]

Here the tasks and steps for the users getting the new firmware via email.

If you are using the RPi Port please skip the wizard after Factory reset and switch to RPi Port in Settings.

Task 1: Save some config

  1. Connect via USB and log the serial output
  2. Send M503 and save this information somewhere to compare later
  3. Report your existing values
  4. In case you have defined sheets use M850 S0 to M850 S7 to save the data

Task 2: Test if default PID and TM REVO values are working

  1. Connect via USB and log the serial output
  2. Perform a Factory reset
  3. Skip wizard
  4. Send M503
  5. Run LCD -> Calibration -> Selftest
  6. Run LCD -> Calibration -> Calibrate XYZ
  7. Run LCD -> Calibration -> First Layer calibration
  8. Print some prints with the default REVO values
  9. Report back
  10. In case you have defined sheets use M850 to restore them

Task 3: Test PID and TM cal.

  1. Connect via USB and log the serial output
  2. Run LCD -> Calibration -> PID calibration
  3. Run LCD -> Calibration -> Thermal Model cal.
  4. Send M503
  5. Print some prints with the default REVO values
  6. Report back

Task 4: Test factory reset + wizard

  1. Connect via USB and log the serial output
  2. Perform a Factory reset
  3. Complete wizard
  4. Run LCD -> Calibration -> PID calibration
  5. Send `M503
  6. Compare the default `M310 values from Task 1 and Task 3
  7. Print some prints with the new values
  8. report back

Task 5: TM Warning value not tuned yet and we need your feedback

  1. Connect via USB and log the serial output
  2. Send M310 W0.8
  3. Report back if that is working for you
  4. Try to lower the value even more where it works without false positives
User Task 1 Task 2 Task3 Task 4 Task 5
WhiterRice :heavy_check_mark: :heavy_check_mark: :heavy_check_mark: :heavy_check_mark: :heavy_check_mark: W0.7
3d-gussner commented 1 year ago

Here the plots From @alexiri alexiri

From @kromeninja kromeninja

From @ulab ulab Update 24/03/2023 From @ulab balu_calibration_2

From @JWvP JWvP

From @snafu1282 snafu1282 Update 24/03/2023 From @snafu1282 snafu1282_20230323_1

From @matthiazzz matthiazzz

From @sdh2 sdh2

ulab commented 1 year ago

balu_logs-v2.zip

PS: I had a lot of crash detections with my Y axis during the benchy print. I'm not sure if I just never noticed it before since I mostly print in stealth mode, but I guess I have to look into that.

jdrozdz commented 1 year ago

Unfortunately, in my case, THERMAL ANOMALY was raised :( Recv TML 0 1 7f 435472ab 41e8b555.log

snafu1282 commented 1 year ago

My latest logs. No anomalies encountered.

snafu1282_20230323.zip

snafu1282 commented 1 year ago

@3d-gussner I tried the M301 W1.1.... 1.0.... 0.9..... etc. and got no warnings again. This happened before and you pointed out something I needed to do to get it to work. Unfortunately, I don't have a reference to what that was. Can you refresh my memory please?

3d-gussner commented 1 year ago

Unfortunately, in my case, THERMAL ANOMALY was raised :( Recv TML 0 1 7f 435472ab 41e8b555.log

Thanks, Your log file is very short and I can't see everything. Please follow the steps above and report back. That your printer went into HOTEND THERMAL RUNAWAY isn't good.

3d-gussner commented 1 year ago

@alexiri @kromeninja @ulab @JWvP @snafu1282 @matthiazzz @sdh2 Hi, can you please try Task 2 from the top comment?

Everyone else who didn't provide complete log files please start with Task 1 to get more data.

snafu1282 commented 1 year ago

Here is my Task 2 log file. It's a long one.

My basic result is that M310 W0.8 works for me. W0.7 almost works, but it's a tiny bit unstable.

I could not get an anomaly by trying to create backflow from the fan. I was able to repeatably trigger an anomaly by using a small air compressor with a finger trigger nozzle from about 500mm away. What I noticed is that the anomaly gets triggered at between 227C and 229C.

snafu1282_20230324_2_TASK-2.zip

jdrozdz commented 1 year ago

Unfortunately, in my case, THERMAL ANOMALY was raised :( Recv TML 0 1 7f 435472ab 41e8b555.log

Thanks, Your log file is very short and I can't see everything. Please follow the steps above and report back. That your printer went into HOTEND THERMAL RUNAWAY isn't good.

I hope it will be good at this time.

BTW. There is something wrong with the thermistor because on hotend I have 13deg and on the bad I have 20deg. I'm not sure, but there is an incorrect value for the Revo thermistor to calculate the temperature, I think.

revo6_250320231055.log

3d-gussner commented 1 year ago

Unfortunately, in my case, THERMAL ANOMALY was raised :( Recv TML 0 1 7f 435472ab 41e8b555.log

Thanks, Your log file is very short and I can't see everything. Please follow the steps above and report back. That your printer went into HOTEND THERMAL RUNAWAY isn't good.

I hope it will be good at this time.

BTW. There is something wrong with the thermistor because on hotend I have 13deg and on the bad I have 20deg. I'm not sure, but there is an incorrect value for the Revo thermistor to calculate the temperature, I think.

revo6_250320231055.log

Sorry but this is not a complete log file. What concerns me more is that your thermistor reads 13°C while the bed is 20°C they should be quiet close when the printer is turned on after few hours. Please check the REVO forums, website which resistance at which temperature it should have. I would guess your thermistor is broken. Please check if the wires are okay, I saw one wire insulation being scabbed off by the heater connectors.

EVERYONE: Do you know what this could cause?

3d-gussner commented 1 year ago

@snafu1282 Thanks for the log files of Task2 :1st_place_medal: After looking at your log file I will update the Task 2 steps to get "faster" to some results.

Please check steps 8 and if that makes sense in your opinion to speed up finding the correct value.

Tip for putty and sending gcode files:

I could not get an anomaly by trying to create backflow from the fan. I was able to repeatably trigger an anomaly by using a small air compressor with a finger trigger nozzle from about 500mm away. What I noticed is that the anomaly gets triggered at between 227C and 229C.

Yes the REVO compared to the E3Dv6 catches up very fast with blow backs and drafts so it is hard to trigger. Nice that you found a repeatable way to trigger the TM. :+1: This is very important that we find a value BUT also insure that it can be triggered, otherwise the TM makes no sense. As you observed it triggers if the expected temp isn't close what is read by the thermistor after few seconds.

snafu1282 commented 1 year ago

@snafu1282 Thanks for the log files of Task2 🥇 After looking at your log file I will update the Task 2 steps to get "faster" to some results.

Please check steps 8 and if that makes sense in your opinion to speed up finding the correct value.

Tip for putty and sending gcode files:

  • prepare the gcode files in notepadd++
  • when needed copy (with line feed {next line break}) from notepad++ and paste it into putty This should make the log files more readable as typing by hand the gcode is split into multiple lines.

I could not get an anomaly by trying to create backflow from the fan. I was able to repeatably trigger an anomaly by using a small air compressor with a finger trigger nozzle from about 500mm away. What I noticed is that the anomaly gets triggered at between 227C and 229C.

Yes the REVO compared to the E3Dv6 catches up very fast with blow backs and drafts so it is hard to trigger. Nice that you found a repeatable way to trigger the TM. 👍 This is very important that we find a value BUT also insure that it can be triggered, otherwise the TM makes no sense. As you observed it triggers if the expected temp isn't close what is read by the thermistor after few seconds.

Yeah, PuTTY not having a command input box like those in Pronterface or OctoPrint is a bit of a pain. I had hoped that PuTTY would keep all the typed text together, so it shows up as a single command line, but nope. Maybe, for the next round, I should use OctoPrint. That would provide a slightly different test to confirm the results from PuTTY. And, of course, it would keep the command lines together. Another issue is the long cool down times, which leads to a ton of temperature report lines in the log file. I've been wondering if I should use the compressor to speed up the cooling. What do you think?

On another question, if I find the W value needs to be at 0.8, shouldn't the E value also be changed (i.e. lowered to something like 1.35)??

sdh2 commented 1 year ago

Task 2: I did several heat/cool cycles but unfortunately do not have time for a print at the moment. I will follow up with that later.

Before the fan is turned on, W0.5 seems to work for heating and cooling. But, this is too tight when the fan cools it down. W0.6 & W0.7 almost works, but triggers until about 180C. W0.8 seems to do ok cooling with the fan on.

I was able to trigger the anomaly with a can of compressed air, and during the latter half of the tests I had a large floor fan pointed at the printer to simulate a draft. task2_sdh2.zip

@3d-gussner There are a couple typos in Task 2 above in lines 10 & 15. Took me a couple minutes to figure out why my values weren't changing, I'm not terribly fluent in this stuff!

jdrozdz commented 1 year ago

Unfortunately, in my case, THERMAL ANOMALY was raised :( Recv TML 0 1 7f 435472ab 41e8b555.log

Thanks, Your log file is very short and I can't see everything. Please follow the steps above and report back. That your printer went into HOTEND THERMAL RUNAWAY isn't good.

I hope it will be good at this time. BTW. There is something wrong with the thermistor because on hotend I have 13deg and on the bad I have 20deg. I'm not sure, but there is an incorrect value for the Revo thermistor to calculate the temperature, I think. revo6_250320231055.log

Sorry but this is not a complete log file. What concerns me more is that your thermistor reads 13°C while the bed is 20°C they should be quiet close when the printer is turned on after few hours. Please check the REVO forums, website which resistance at which temperature it should have. I would guess your thermistor is broken. Please check if the wires are okay, I saw one wire insulation being scabbed off by the heater connectors.

EVERYONE: Do you know what this could cause?

By incomplete log you mean that, the process was interrupted by THERMAL ANOMALY?

snafu1282 commented 1 year ago

Here are log files from Task 2; the initial step through of the procedure, plus 3 more logs with values of W0.7, W0.75, and W0.8.

snafu1282_20230325_TASK-2_W0.75.log.zip snafu1282_20230325_TASK-2_W0.8.log.zip snafu1282_20230325_TASK-2_W0.7.log.zip snafu1282_20230325_1_TASK-2.zip

Just finished a Cali Dragon in PETg (235C/75C) It came out pretty clean. Here are 3 shots of it. I'm including them as I think the Cali Dragon is a reasonable test of what could happen with blowback cooling, which didn't happen.

_MG_4323 _MG_4324 _MG_4326

sdh2 commented 1 year ago

Task 2: I did several heat/cool cycles but unfortunately do not have time for a print at the moment. I will follow up with that later.

Here is my print log. With a setting of W0.8, I didn't have any issues on a four hour print.

sdh2_long-print.zip

peschkaj commented 1 year ago

Task 1; steps 1-24. putty-peschkaj-2023-03-25-130449.zip

Thermal anomaly occurred at W0.4

Compressed air from a can took about 15 seconds from 15cm to cause a thermal anomaly

zuidwijk commented 1 year ago

My MK3S+ with E3D Revo isn't printing at all with the new firmware. It keeps failing on the wizard. When heating up to PLA, it aborts at 70-ish C and nothing is working. How can I help to provide more data? This isnt working for me now.

3d-gussner commented 1 year ago

@zuidwijk Hi, thanks that you want to help and contribute. Please read https://github.com/prusa3d/Prusa-Firmware/issues/4105#issue-1637097652 and start with Task 1, provide the Thermal Model Debug serial log, this helps to fine tune the REVO default values.

3d-gussner commented 1 year ago

@peschkaj Thanks for the Thermal model debug log and feedback of your findings of warning value. I will add your data to the calculated default values. Is the M310 W0.4 working for you with regular prints?

peschkaj commented 1 year ago

@peschkaj Thanks for the Thermal model debug log and feedback of your findings of warning value. I will add your data to the calculated default values. Is the M310 W0.4 working for you with regular prints?

M310 W0.4 prints well for me with two weird events.

  1. Each print start with four beeps during the warm up. Three beeps occur at ~49C and one beep at 58. No message appears on the display.
  2. Each print informs me that the gcode was sliced for a different model of printer. Which isn't true, I only have two MK3S+ :)

Update I take that back, M310 W.04 generates a lot of thermal warnings, but 0.5 is fine.

SimGas commented 1 year ago

M310 W.04

Not sure if it was a typo here or during testing: Please note that M310 W.04 is quite different from M310 W0.4

peschkaj commented 1 year ago

M310 W.04

Not sure if it was a typo here or during testing: Please note that M310 W.04 is quite different from M310 W0.4

'Twas but a typo

MarcelTh commented 1 year ago

Hi,

attached my Task 1 logs from my MK3S, freshly serviced and upgraded with MK3S+ upgrade kit and the Revo Hotend. Thermal anomaly warning during a 30 minute test print only occurred when warning treshold was set to M310 W0.4 . Test Print is included in the log.

Regards, Marcel

MarcelTh_Logs_Task1.zip

zuidwijk commented 1 year ago

My 1st logging... I couldnt print, when loading filament and therefore pre-heating I got "THERMAL ANOMALITY" 1st_logging_mk3s+.txt.zip

Edit: I forced reheating after each error and now it starts printing (with z-layer at 0.000 hahahaha)

Logging during printing: 1st_logging_printing.txt.zip

rnbarrett commented 1 year ago

Do you still need logs? I have a 1 year old MK3S+ Kit with a Revo. No mods other than a different part cooling duct.

guido66611x commented 1 year ago

Do you still need logs? I have a 1 year old MK3S+ Kit with a Revo. No mods other than a different part cooling duct.

Yes they do.

bakerjvb commented 1 year ago

I wonder if its worth saying to Revo users that the prusa3d_fw_MK3S_MK3S+_3_11_0_4955 firmware version works fine and, if they need to print before this is fixed, simply reflash with this firmware.

arekm commented 1 year ago

Note: 3.12.2 works fine too if you disable new TM feature (via M310 S0; M500) and it would be a pity to loose all fixes by downgrading to 3.11. This issue is about helping Prusa team to get TM working even with modded printers like with revos (by providing logs, testing etc).

davejhilton commented 1 year ago

Hey all—jumping into the conversation here, in case I can be helpful.

I actually have a Revo Hotend sitting brand new in its box. So far, I have been waiting to install it on my MK3S+, until either: (a) this issue gets resolved, or (b) the MK4 I ordered shows up, and can take over as my main printer—likely around 2-3 weeks from now.

But... from following this ticket, I'm getting the sense that there really is a desperate need for additional data & logs before the issue can be addressed in a future firmware update.

Previous comments suggest that installing the Revo wouldn't completely prevent me from printing, so long as I disable the thermal model feature.

So my question is this, I guess: Would providing my data/logs be helpful enough "to the cause" to make it worth installing the Revo sooner vs later? Or, realistically, would I just more than likely be asking for instability and problems by doing so?

EDIT to add:

I also have an MMU2S installed on my MK3S+, in case that makes a difference. (And as such, I'm no stranger to triaging issues and finding ways to make things work 🙂). But I've also got things rigged up in a way that I can easily "turn off" the MMU when needed, and just use the printer as a normal MK3S+.

alexiri commented 1 year ago

For what it's worth, I have no problems at all printing with the Revo and v3.12.2 with TM enabled. I think upgrading and providing some more logs is worth it and low risk.

guido66611x commented 1 year ago

For what it's worth, I have no problems at all printing with the Revo and v3.12.2 with TM enabled. I think upgrading and providing some more logs is worth it and low risk.

For many/most people, it's completely non-functional, without disabling the TM. The TM calibration gets a few seconds in, and errors. We don't have a single MK3S+Revo that will calibrate or print with v3.12.2 (without disabling the TM).

guido66611x commented 1 year ago

Hey all—jumping into the conversation here, in case I can be helpful.

I actually have a Revo Hotend sitting brand new in its box. So far, I have been waiting to install it on my MK3S+, until either: (a) this issue gets resolved, or (b) the MK4 I ordered shows up, and can take over as my main printer—likely around 2-3 weeks from now.

But... from following this ticket, I'm getting the sense that there really is a desperate need for additional data & logs before the issue can be addressed in a future firmware update.

Previous comments suggest that installing the Revo wouldn't completely prevent me from printing, so long as I disable the thermal model feature.

So my question is this, I guess: Would providing my data/logs be helpful enough "to the cause" to make it worth installing the Revo sooner vs later? Or, realistically, would I just more than likely be asking for instability and problems by doing so?

EDIT to add:

I also have an MMU2S installed on my MK3S+, in case that makes a difference. (And as such, I'm no stranger to triaging issues and finding ways to make things work 🙂). But I've also got things rigged up in a way that I can easily "turn off" the MMU when needed, and just use the printer as a normal MK3S+.

The Revo is awesome, and worth installing just to switch nozzles quickly and never be able to get E3D V6 oozing ever again. Just put the commands to disable the TM into a .gcode file, and run it whenever you reboot the printer.

alexiri commented 1 year ago

For many/most people, it's completely non-functional, without disabling the TM.

Really? Not sure where all those people are, but feel free to point them to https://github.com/prusa3d/Prusa-Firmware/issues/4105#issue-1637097652. 😄

snafu1282 commented 1 year ago

Hey all—jumping into the conversation here, in case I can be helpful.

I actually have a Revo Hotend sitting brand new in its box. So far, I have been waiting to install it on my MK3S+, until either: (a) this issue gets resolved, or (b) the MK4 I ordered shows up, and can take over as my main printer—likely around 2-3 weeks from now.

But... from following this ticket, I'm getting the sense that there really is a desperate need for additional data & logs before the issue can be addressed in a future firmware update.

Previous comments suggest that installing the Revo wouldn't completely prevent me from printing, so long as I disable the thermal model feature.

So my question is this, I guess: Would providing my data/logs be helpful enough "to the cause" to make it worth installing the Revo sooner vs later? Or, realistically, would I just more than likely be asking for instability and problems by doing so?

EDIT to add:

I also have an MMU2S installed on my MK3S+, in case that makes a difference. (And as such, I'm no stranger to triaging issues and finding ways to make things work 🙂). But I've also got things rigged up in a way that I can easily "turn off" the MMU when needed, and just use the printer as a normal MK3S+.

I have been using my MK3S+ with 3.12.2 and TM enabled for a number of months now, with zero issues. I went through the testing scenario and dialed in settings that work for my printer. Been using them ever since. I don't think my settings are sensitive enough to pick up a blob on the nozzle, but they don't error out either.

snafu1282 commented 1 year ago

For what it's worth, I have no problems at all printing with the Revo and v3.12.2 with TM enabled. I think upgrading and providing some more logs is worth it and low risk.

For many/most people, it's completely non-functional, without disabling the TM. The TM calibration gets a few seconds in, and errors. We don't have a single MK3S+Revo that will calibrate or print with v3.12.2 (without disabling the TM).

I'm with @alexiri. I'm using 3.12.2 every day, with TM enabled. It never errors out with a thermal anomaly.

davejhilton commented 1 year ago

Alright—after a busy weekend, I was finally able to get the Revo installed, and run the "Task 1" steps above.

Disclaimer: this was the first time I've played with manually sending commands over a serial connection to a printer, so forgive me if I've done anything wrong (let me know, and I can re-do things if needed).

I just used Octoprint (after setting the uppercase exception for D3). I followed the steps in Task 1, and the log file should contain all of the logs from doing that.

here's some additional info—I'm not sure what is useful to you and what's not.

Other details... which may or may not matter:

Let me know if there's anything I've done wrong, or if there's any additional info I can provide.

task-1-serial.log

PS: @guido66611x -- you mentioned "never [getting] E3D V6 oozing ever again"... does that mean you have less oozing with the revo than you did with the stock v6? For me, it's the exact opposite! I'm getting a lot more oozing with the revo. Like... when starting a print (fresh spool of Prusament PETG, default prusaslicer profile for it, and a 0.4mm nozzle), I end up seeing a 10-15mm string dangling from the nozzle by the time it finishes preheating, before the mesh bed leveling even starts. With PLA it's even worse. And then after the print completes, it leaves a 50-60mm string dangling from the nozzle by the time it finishes cooling down! Luckily, I'm not seeing any extra stringing during prints. So I think it'll be manageable, as long as I get rid of the giant dripping string each time a print starts, before the mesh leveling routine gets a chance to wad it up into a ball and glue it to the nozzle. But hey—maybe these thermal model tweaks will at least be able to detect that for me 😉

3d-gussner commented 1 year ago

@davejhilton Thank you for taking the time and the detailed report. Here your TM calibration graph davejhilton

davejhilton commented 1 year ago

@davejhilton Thank you for taking the time and the detailed report.

Here your TM calibration graph

You're welcome!

Forgive the ignorant question: is there something I am supposed to do with this graph?

3d-gussner commented 1 year ago

Short update on REVO Thermal model support.

3d-gussner commented 1 year ago

@davejhilton No you don't have to do anything with the graph. One (multiple) picture(s) say more than some values (i mean words)

davejhilton commented 1 year ago

Got this while printing last night:

2023-05-18 04:53:08,710 - Recv: TM: error |-1.944673|>1.200000
2023-05-18 04:53:08,711 - Recv: TM: error triggered!

And again this morning:

2023-05-18 08:32:53,264 - Recv: TM: error |-1.782580|>1.200000
2023-05-18 08:32:53,268 - Recv: TM: error triggered!

Not sure whether that's useful—but I figured I'd report the values, since they certainly contrast the earlier numbers I was getting in the log file I sent just 2 days ago. I haven't made any changes to the printer since then.

Feel free to ignore this if it isn't useful to you—I can always disable TM and move forward if needed. Just thought I'd share the data points in case it's helpful

EDITING to add a little more info: between the original logs I sent you and getting the errors above, I successfully printed 9 objects—a total of about 23 hours of printing, with some PLA and some PETG, and with various nozzle sizes—but with a few warnings in the logs. Here's a more complete view of the various warnings/errors I have received:

pi@octopi:~ $ cat serial.log | grep 'TM: error |'

# these WARNINGS happened around hour 7 of a 9 hour print. Finished successfully (PLA, 0.8mm nozzle)
2023-05-17 04:19:41,609 - Recv: TM: error |-1.410522|>1.200000
2023-05-17 04:19:41,904 - Recv: TM: error |-1.410522|>1.200000
2023-05-17 04:19:42,146 - Recv: TM: error |-1.308174|>1.200000
2023-05-17 04:19:42,416 - Recv: TM: error |-1.308174|>1.200000
2023-05-17 04:19:42,957 - Recv: TM: error |-1.543684|>1.200000
2023-05-17 04:19:43,231 - Recv: TM: error |-1.543684|>1.200000
2023-05-17 04:19:49,978 - Recv: TM: error |-1.514766|>1.200000
2023-05-17 04:19:50,248 - Recv: TM: error |-1.514766|>1.200000

# These WARNINGS-->ERROR happened around 4 hours into an 8 hour print (PLA, 0.4mm nozzle)
2023-05-18 04:53:08,440 - Recv: TM: error |-1.409467|>1.200000
2023-05-18 04:53:08,710 - Recv: TM: error |-1.944673|>1.200000
2023-05-18 04:53:09,022 - Recv: TM: error |-1.944673|>1.200000

# These WARNINGS-->ERROR happened only 5 minutes after resuming the above print
2023-05-18 08:31:52,780 - Recv: TM: error |-1.596088|>1.200000
2023-05-18 08:31:53,050 - Recv: TM: error |-1.596088|>1.200000
2023-05-18 08:32:53,264 - Recv: TM: error |-1.782580|>1.200000
2023-05-18 08:32:53,562 - Recv: TM: error |-1.782580|>1.200000

happy to provide more complete logs (and/or turn on additional debugging for future prints) if that's useful.

WhiterRice commented 1 year ago

I have completed task 1 and was able to force a TM error at the end. I used a datavac to blow air on the nozzle and used my offhand as a backstop. Please see attached log. serial.log

NightSkySK commented 1 year ago

I've also suffered TM errors after changing to Revo. Here is output of my calibration according to list of commands in first post. First attempt failed as I get 2023-05-26 07:46:02,347 - Recv: TM: Cal. NOT IDLE I've restarted the printer after that with factory reset and second attempt went smoothly octoprint-logs.zip

3d-gussner commented 1 year ago

Hello, we have a new firmware for the REVO and I would like to ask you to send me an email so I can send it to you. Please don't forget to mention your github user name.

I hope I have not forgotten anyone who provided log files and contributed to this result.

@alexiri @kromeninja @ulab @JWvP @snafu1282 @matthiazzz @sdh2 @jdrozdz @peschkaj @MarcelTh @zuidwijk @arekm @davejhilton @WhiterRice @NightSkySK

davejhilton commented 1 year ago

I will email you momentarily. But I wanted to ask... will this firmware be compatible with the latest existing MMU2S firmware?

3d-gussner commented 1 year ago

I will email you momentarily. But I wanted to ask... will this firmware be compatible with the latest existing MMU2S firmware?

No, it is the new printer firmware which only works with the new MMU firmware. So if you don't have a printer without MMU2S (fw 1.0.6) it doesn't make sense for you. Please keep the FW 3.12.2 with your manual REVO TM calibration.

D-an-W commented 1 year ago

Due to house renovations I haven’t had time to do logs but should hopefully be able to test this week if I am ok to get the new firmware?

NightSkySK commented 1 year ago

... will this firmware be compatible with the latest existing MMU

My only printer which has installer Revo is also integrated with MMU2S (fw 1.0.6) which means I'm also out of the scope unfortunately

arekm commented 1 year ago

@3d-gussner Rename file.hex to file.hex.zip and upload here :-)