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prusa3d / Prusa-Firmware

Firmware for Original Prusa i3 3D printer by PrusaResearch
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E3D REVO Thermal Model #4451

Open 3d-gussner opened 9 months ago

3d-gussner commented 9 months ago
  1. Verify firmware version installed on your printer , to check this on the printers start screen the firmware version will be indicated you can also check which firmware version you already have via the following process LCD menu -> Support. Scroll down and you will see the firmware version.

If your printer displays a firmware version prior to 3.13.0 or it does not start with E3DREVOfw or E3DREVO_HF60W we would advise that you install the latest Revo supported firmware release via the following link and proceed with the next steps: https://github.com/prusa3d/Prusa-Firmware/releases

If you are using a E3D Revo firmware, please check that this matches the Revo Hotend you have installed as there are different versions.

If you do have an E3D Revo Firmware installed and it matches the Revo HotEnd you have please go to step 4.

  1. Once you have downloaded the firmware this Zip file and extracted it , please use the applicable. HEX file for both your printer model and the version of HeaterCore you have.
    • For a Standard 40W Revo heater core please use the. HEX file starting with E3DREVOfw ensuring you chose the correct. HEX file for the printer model you have.
    • For a High flow 60W HeaterCore please use the. HEX file starting with E3DREVO_HF60W ensuring you chose the correct. HEX file for the printer model you have.

If you are unsure as to how to update your printers firmware with the .HEX file please refer to the Flashing procedure within the following guide: https://help.prusa3d.com/article/firmware-updating-mk3s-mk3s-mk3_2227

  1. Once you have flashed and updated your printers firmware Run both the PID and TM calibration from the LCD Calibration menus of your machine.
  2. If step 2 fails however please Use the Revo_Reset G-code files to force setting changes. There are 2 versions of this g-code that will need to be used based on the HeaterCore you have installed.
    • reset_revo.gcode.txt: for a 40W HeaterCore. Please rename the file form reset_revo.gcode.txt to reset_revo.gcode
    • reset_revo_hf_60W.gcode.txt: for a 60W High Flow HeaterCore. Please rename the file form reset_revo_hf_60W.gcode.txt to reset_revo_hf_60W.gcode

These files will need to be copied to an SD card and installed , to Install the G-code select it from the print from the SD menu on your printer and follow the on-screen instructions.

  1. Once the G-code has been installed re-run both a PID and TM calibration from the LCD Calibration menus of your machine.

Optional step: If the above steps fail you may wish to factory reset the machine and run the setup wizard. Please note that as the process suggests this will reset the printer and its firmware to a factory state and any setting will be lost.

Link to E3D ticket

acothebraco commented 8 months ago

Hello,

I have the same issute that my MK3S+ beeps three times with Thermal Anomaly and at the next time it stops with Thermal Error. I use the Revo Six Hotend and have never a problem with THERMAL ANOMALY. But since I put the MK3S+ in the Original Prusa Enclosure it shows up after 1-2 hours printing. I did also PID and Thermal Cal. on the 3.13.2 and the older 3.13.0 and I also tired to do a Revo_Reset G-Code without scuccess. Only when I put the Printer outside of the Enclosure the Error will not apear.

IMG_7431

Lino77 commented 8 months ago

same problem for me. I updated from 3.13.0 to 3.13.2, set the printer to factory settings, I can't even do the first layer of calibration. without the printer screaming, revo six for mk3

Ezrae commented 8 months ago

Adding my voice to this. I went through each step carefully. I reset TM and PID multiple times. I ran the gcode. And when I finally decided to factory reset, I was unable to finish the wizard due to the thermal errors I was continuing to get.

I've downgraded back to 3.11, and I'll try again with the next REVO firmware update.

nemith commented 7 months ago

Two printers, did all the steps here. All had the same issue. One seems to actually finish the model but still fails later, the other can't even calibrate the model.

Going to downgrade back to 3.11 this feature seems half baked and not suited for revo hotends.

Lino77 commented 7 months ago

why downgrade , you can disable it. The thermal model protection can be disabled by connecting the printer to your computer (Octoprint, PuTTY...), and sending M310 S0. An additional M500 will save the setting and the Thermal model protection will remain disabled after the next restart.

nemith commented 7 months ago

why , you can disable it.

I am selling this printer and it need to "just work". Disabling until next restart isn't an option.

Lino77 commented 7 months ago

M500 safe it and it will remain disable afer restart

LoakAudio commented 7 months ago

@3d-gussner , In the step 4 of your first post, isn't it "if step 3 fails" rather than "step 2" ? because it appends to me : changing the firmware went fine, reboot OK with the new firmware but PID calibration fails and TM calibration fails too. The gcode saved me.

3d-gussner commented 7 months ago

@LoakAudio Thanks for the feedback I will check again. Glad that the new firmware and gcode files saved you. :tada:

jamesdehart commented 7 months ago

I'm in the same boat as others here. I have opened a ticket with E3D and will post back with any findings that might help others.

Update - I still have not heard back from E3D but I checked the Thermistor extension cable and it seems the wire has come lose from the housing. Here are the docs if anyone is wondering.

jamesdehart commented 7 months ago

@3d-gussner I happen to do a factory reset and after the calibration this happened

https://github.com/prusa3d/Prusa-Firmware/assets/6137749/24a2215f-4de8-4e8a-a89c-a9ace7ca4f83

Should I open a different Github issue? Please advise.

3d-gussner commented 7 months ago

@jamesdehart Which calibration caused this screen?

Skilbo commented 7 months ago

After much head scratching, finally got it working, used the E3DREVO_fw version and everything worked first time. Thanks to @3d-gussner for laying out the procedures very much appreciated.

jamesdehart commented 7 months ago

@jamesdehart Which calibration caused this screen?

So it turned out my entire issue was because the thermal cable connector from the Hot-end to the cable that goes to the motherboard failed. The image shows the failed cable & connecor. One of the two wires were connected.

image

For others who are running in to issues related to this hotend. It would be good to check there cable to see if there are any issues like I had. When contacting E3D it took them about a week to respond to the support tickets. They are really backed up.

I hope this helps.

3d-gussner commented 7 months ago

@jamesdehart Thanks for sharing! This is an example why we implemented the Thermal model to detect issues like this and other. Well done to investigate :medal_sports: instead of disabling the TM!

Side note: Try to add some more strain relief so all motions of the cable loom are possible without "pulling" cables at the connectors.

acothebraco commented 7 months ago

Thanos for sharing. I checked my printer six times and I don’t have any cable or hardware issues. The point is that like I wrote in a other post that TM have problems when the printer is in a enclosure.

Also I’d explained in this post how the problem occur in my setup https://github.com/prusa3d/Prusa-Firmware/issues/4431#issuecomment-1807171123

ndemarco commented 6 months ago

I'm chasing down the same THERMAL ANOMALY trouble,

The PID and TA calibrations finished properly. Upon the next PLA preheat, BEEP-BEEP THERMAL ANOMALY.

3d-gussner commented 6 months ago

@ndemarco Thanks for the update. Is your printer in an enclosure? Can you please try to capture the print in a logfile? Do you have a host system like Octoprint running?

stevenbennett commented 6 months ago

I'm also experiencing the issue described by users in this thread. Installed the Revo variant of 3.13.2 on two MK3S+ and now encounter consistent thermal anomaly errors. Things I've tried:

After these steps I still encounter frequent thermal anomaly errors. Sometimes these occur right after initiating a preheat, sometimes right before a print begins, sometimes during a print. (I'm not using an enclosure). Going to try rolling back to 3.11 as other have suggested.

slaesh commented 5 months ago

had the same issue. it works now, maybe change the order of your steps 2 and 3 @stevenbennett :)

  1. update firmware
  2. factory reset
  3. ran the gcode magic
  4. PID calibration
  5. thermal calibration

seems to work, step 3 was the magic sauce for me though! ;)

3d-gussner commented 5 months ago

had the same issue. it works now, maybe change the order of your steps 2 and 3 @stevenbennett :)

1. update firmware

2. factory reset

3. ran the gcode magic

4. PID calibration

5. thermal calibration

seems to work, step 3 was the magic sauce for me though! ;)

After the factory reset you don't need to run any gcode as it set identical values as are used in the E3D . hex files https://github.com/prusa3d/Prusa-Firmware/blob/v3.13.2/Firmware/thermal_model/e3d_REVO.h

The gcode files are for users that don't want to factory reset or got "bad" values at some point.

slaesh commented 5 months ago

I am pretty sure I did the factory reset first. And then doing the PID calibration it started and immediately stopped and was in a weird state afterwards. Seems like I did the factory reset with the old "normal" firmware though 🤔🙈. Sh*t. Thanks for the hint. will start all over again with a factory reset now and see what happens! ;) Sorry for the confusion 🤫

3d-gussner @.***> schrieb am Do., 1. Feb. 2024, 13:57:

had the same issue. it works now, maybe change the order of your steps 2 and 3 @stevenbennett https://github.com/stevenbennett :)

  1. update firmware

  2. factory reset

  3. ran the gcode magic

  4. PID calibration

  5. thermal calibration

seems to work, step 3 was the magic sauce for me though! ;)

After the factory reset you don't need to run any gcode as it set identical values as are used in the E3D . hex files https://github.com/prusa3d/Prusa-Firmware/blob/v3.13.2/Firmware/thermal_model/e3d_REVO.h

— Reply to this email directly, view it on GitHub https://github.com/prusa3d/Prusa-Firmware/issues/4451#issuecomment-1921269657, or unsubscribe https://github.com/notifications/unsubscribe-auth/ANHZHR3ME63METSIUH6IQW3YROGLVAVCNFSM6AAAAAA6CIVLGCVHI2DSMVQWIX3LMV43OSLTON2WKQ3PNVWWK3TUHMYTSMRRGI3DSNRVG4 . You are receiving this because you commented.Message ID: @.***>

jake-carpenter commented 4 months ago

I just installed a REVO because it sounded like this has been sorted out, unfortunately I got errors immediately with v3.13.3-Revo.

Steps I have taken:

  1. Flashed v3.11 and tried factory reset then PID calibration, as some old posts have recommended. a. Ran a print on v3.11 to confirm everything does work fine.
  2. Flashed 3.13.3-Revo (7094).
  3. Performed a full factory reset. a. I let the first-time setup run and calibrate everything. TM and PID were calibrated. b. At this point, prints would start but would not go for long before I got a thermal error.
  4. Performed the Task 1 steps in #4105 (via Octoprint). a. Thermal error almost immediately after a print started.
  5. Ran the reset_revo.gcode provided above from my SD card. a. Still have thermal errors within seconds of starting the print.

Not sure what else to do at this point. I'd be willing to re-check all the wiring for bad connections, except everything is fine on v3.11. In fact, it's printing on v3.11 as I write this. I'm happy to provide some logs if it will help here. I'll just need a link on what/how to pull them.

3d-gussner commented 4 months ago

@jake-carpenter

I'm doing my FW flashing from Octoprint, if that has any bearing.

Please don't update your MK3/S/+ firmware with OctoPrint firmware flasher. It is still missing the extension for the MK3/S/+ language packs https://github.com/OctoPrint/OctoPrint-FirmwareUpdater/pull/325

Ensure that you flash the correct firmware version for the E3D Revo which is in the https://github.com/prusa3d/Prusa-Firmware/releases/download/v3.13.3/e3d_REVO_fw_MK3_MK3S_MK3S+_3_13_3_7094.zip Looks like you did it in Step 2

The reset_revo.gcode writes the default E3D Revo TM and PID values to eeprom so you don't have to factory reset the printer. When you run this gcode you need to run PID and TM calibration again to get values for your printer.

Please also contact E3D Support for more help https://e3d-online.zendesk.com/hc/en-us/requests/new?ticket_form_id=11304553253917 check also their discord.

You can enable in OctoPrint save logfiles to get more information during the print. These logfiles should help E3D support to narrow down your issue.

IndustrialCADWorks commented 3 months ago

I just had this problem. Went back, went through everything listed above and other forums. What I might have figured out is on step 40 on the E3D instructions.

https://e3d-online.zendesk.com/hc/en-us/articles/4410028113169-Revo-Six-Prusa-MK3-MK3S-MK3S-upgrade-guide

It mentions PID tuning at 240 degrees if you plan to use materials other than PLA. When running the PID calibration through the wizard it runs at 230. I went back Calibrated PID to 240, ran through all the steps and no thermal issues or haults through the calibration. So I'm assuming you have to run the PID calibration prior to running the configuration wizard?? I don't know if that is true, but I know it worked for me. Hope this helps.

mhouse1 commented 3 months ago

I just had this problem. Went back, went through everything listed above and other forums. What I might have figured out is on step 40 on the E3D instructions.

https://e3d-online.zendesk.com/hc/en-us/articles/4410028113169-Revo-Six-Prusa-MK3-MK3S-MK3S-upgrade-guide

It mentions PID tuning at 240 degrees if you plan to use materials other than PLA. When running the PID calibration through the wizard it runs at 230. I went back Calibrated PID to 240, ran through all the steps and no thermal issues or haults through the calibration. So I'm assuming you have to run the PID calibration prior to running the configuration wizard?? I don't know if that is true, but I know it worked for me. Hope this helps.

Does it still work after a week? In my experience, it'll work a few prints but eventually it starts erroring out during the middle of a print, you can restart and print again but with the risk of failure we reverted to 3.11

IndustrialCADWorks commented 3 months ago

I've been printing everyday and no problems, (pla, PE / CF, Nylon, PETG) multiple nozzle changes, no issues so far. Like I said not sure if it helps, but just posting my experience. If I have any issues I'll have to revert to 3.11, but for now no problems so far. Fingers Crossed...

ndemarco commented 2 months ago

@3d-gussner in reply to your earlier comment.

I am not printing in an enclosure, though I tried this also - same result. I am running via Octoprint, but have tried printing from a card - same result.

E3D support had me go through some big steps to verify the integrity of the wiring and the electrical properties of their 'HeaterCore' part. I did this on video, posted here. In this video, the thermisistor responded exactly as specified in the datasheet. The heater's resistance matches E3D's specification, too.

The TM error occurs seconds after starting the run. I'm confused as to how the TM error is raised so quickly, when the thermisistor and heater are performing properly electrically.

One commentor on my video gave a detailed procedure to manually recalibrate. I plan to try that procedure on camera later, and will post a follow-up video.

3d-gussner commented 2 months ago

@ndemarco This is a very detailed report and video, really appreciated. Makes troubleshooting sooo much easier.

Please try to connect your RPi (guess OctoPrint) enable serial logging in Octoprint and connect to the printer. Serial logs help a lot while troubleshooting.

You can use the https://github.com/prusa3d/Prusa-Firmware/files/12917795/reset_revo.gcode.txt (change filename extension to gcode) to reset to the default REVO PID and Thermal Model values.

To fine tune the PID and REVO on your machine

  1. Let it cool down
  2. LCD Calibration -> PID calibration
  3. Let it cool down
  4. LCD Calibration -> Thermal Model cal.

If that doesn't help please do a factory reset.

In your video you do a Factory reset BUT you only reset the language. You need to scroll down to "All Data" to reset everything. Keep in mind that it will delete your statistics.

The comment from https://www.youtube.com/@n.neves1776 is good but only needed if you don't get it working with the steps above.

Why it may have failed on your printer: I think that you

3d-gussner commented 2 months ago

@ndemarco Your PID calibration in the Video probably TM ERROR kicked in and stopped.

The reset_revo.gcode contains the default values which are the same as in the factory reset and E3D Revo firmware version. This will reset any values you previously calibrated, so be careful with that.

3d-gussner commented 2 months ago

@ndemarco I can understand the frustration, but the Thermal model saved already few users with broken cables and connectors. The TM runs a simulation based on the calibrated values and compares it to the real data of the thermistor and power provided to the heater cartridge, so if the TM and PID values are from the E3Dv6 and the real data is from REVO it will report TM warnings and Errors.

ndemarco commented 1 month ago

@3d-gussner I appreciate all the feedback. I am carefully trying each of your points. In this video, I show the firmware flashing (which fails the first time around and succeeds the 2nd time). I then show the whooooooole setup, so you may want to >> for some. When it tries to TM calibrate, everything fails - STOPPED.

Now, I am waiting for the nozzle to cool completely. I will then run the reset_revo.gcode, followed by your steps above - doing the PID calibration first.

ndemarco commented 1 month ago

The PID calibration completed normally. Unfortunately, the TM calibration fails within a few seconds of starting. For now, I reverted the firmware to 3.10.0, which is previous to the TM effort. I'm willing to help diagnose the issue with logs, etc. if it helps the community.

mhouse1 commented 1 month ago

fwiw 3.11 is the last stable version without the new thermal model, and really seems to be the only way forward if you want to use the much better revo six extruder.

Sp00k1Gh0st commented 1 month ago

Hi everyone I just wanted to share some information I found while diagnosing the thermal anomaly issue I was having with the revo. With mine I was finding that when the anomaly would happen I would have to disconnect the hot end from both jump wires and reconnect them before running the code provided above to reset everything successfully. I have found that a connection break is happening at the heater connection but not at the thermostat connection. After I cut the ends off of the jumper and hot end and soldered the wires together I was able to eliminate the problem all together and have been printing for over a week now without issue. I am sure there is more going on but hopefully this helps!

3d-gussner commented 1 month ago

@Sp00k1Gh0st Thanks for sharing the information. The thermal model triggered here correctly and you did the right thing: Look why it triggers and not just disable it. :clap: :medal_sports:

As you can see the thermal model is not to annoy users but to improve the safety of the hotend, which can get very very hot. It detected the broken/loose/unreliable connection and @Sp00k1Gh0st investigated the issue to solve it.

This is another report I have seen that some connectors may cause issue. But it isn't only a REVO thing, we also have seen that some wires broke somewhere in the loom and only were "faulty" at specific positions or movements.

ndemarco commented 1 month ago

@Sp00k1Gh0st Thanks for sharing the information. The thermal model triggered here correctly and you did the right thing: Look why it triggers and not just disable it. 👏 🏅

As you can see the thermal model is not to annoy users but to improve the safety of the hotend, which can get very very hot. It detected the broken/loose/unreliable connection and @Sp00k1Gh0st investigated the issue to solve it.

This is another report I have seen that some connectors may cause issue. But it isn't only a REVO thing, we also have seen that some wires broke somewhere in the loom and only were "faulty" at specific positions or movements.

This is most definitely not the issue with my Prusa + Revo printer. I've gone through the wiring and connections way more carefully than the Apollo 1 technicians did.

acothebraco commented 1 month ago

Like I say. I will no longer wait for prusa to solve my thermal problems with the MK3S+ in a enclosure. I sell my mk3s and switched to another printer. Important to know is that the mk3s is not designed to work in a enclosure.

mhouse1 commented 1 month ago

I will give these steps another try once 3.14.0 hex is released; it was tagged 3 weeks ago but not built as hex yet.

I will also try replacing the wires to the extruder if errors occur.

ndemarco commented 1 month ago

Latest update, captured on video:

Point me in a direction to solve this please.

mhouse1 commented 1 month ago

the instructions https://github.com/prusa3d/Prusa-Firmware/issues/4451#issuecomment-2075305893 above isnt clear but i assume you need to repeat these calibration steps after a factory reset; which you didnt do in your video, and im interpreting it as you dont need to run the reset_revo.gcode.txt if you do the factory reset. 

To fine tune the PID and REVO on your machine

Let it cool down
LCD Calibration -> PID calibration
Let it cool down
LCD Calibration -> Thermal Model cal.
ndemarco commented 1 month ago

I don't even get to the point of running PID or TM. I get a series of beeps and an o.

On Wed, Jun 12, 2024, 5:15 PM Michael House @.***> wrote:

the instructions #4451 (comment) https://github.com/prusa3d/Prusa-Firmware/issues/4451#issuecomment-2075305893 above isnt clear but i assume you need to repeat these calibration steps after a factory reset; which you didnt do in your video, and im interpreting it as you dont need to run the reset_revo.gcode.txt https://github.com/prusa3d/Prusa-Firmware/files/12917795/reset_revo.gcode.txt if you do the factory reset.

To fine tune the PID and REVO on your machine

Let it cool down LCD Calibration -> PID calibration Let it cool down LCD Calibration -> Thermal Model cal.

— Reply to this email directly, view it on GitHub https://github.com/prusa3d/Prusa-Firmware/issues/4451#issuecomment-2163914401, or unsubscribe https://github.com/notifications/unsubscribe-auth/ABQISVUKML7M2Y4L2RIJGOTZHC263AVCNFSM6AAAAAA6CIVLGCVHI2DSMVQWIX3LMV43OSLTON2WKQ3PNVWWK3TUHMZDCNRTHEYTINBQGE . You are receiving this because you were mentioned.Message ID: @.***>

gouryellas commented 1 month ago

Latest update, captured on video:

  • Swapped Einsy Rambo board from a known good MK3
  • Verified all wiring 2x
  • Flashed firmware file E3DREVO_fw_MK3S_MK3S+_3_13_3_7094.hex
  • Factory reset all (more than language)
  • Begin wizard
  • Observe all tests pass
  • Observe 6+ beeps followed by 12 beeps.
  • Observe small circle in lower left, with center dot.

Point me in a direction to solve this please.

downgrade to 13.11 until they figure things out. been using it for a long time with no problems on the revo

Leopere commented 2 weeks ago

Is this fixed in the latest version as of today?

ndemarco commented 2 weeks ago

̶I̶ ̶c̶a̶n̶ ̶d̶o̶ ̶s̶o̶m̶e̶ ̶t̶e̶s̶t̶i̶n̶g̶ ̶o̶v̶e̶r̶ ̶t̶h̶e̶ ̶w̶e̶e̶k̶e̶n̶d̶.̶ The above was a reply-to-email. I assumed there was a newer version released.

No, it is not fixed as of version 3.13.3.

Clarity rules over ambiguity; cite a version number in place of a relative reference like 'as of today'.

On Thu, Jun 27, 2024, 6:33 PM Leopere @.***> wrote:

Is this fixed in the latest version as of today?

— Reply to this email directly, view it on GitHub https://github.com/prusa3d/Prusa-Firmware/issues/4451#issuecomment-2195774522, or unsubscribe https://github.com/notifications/unsubscribe-auth/ABQISVVJYUPMCQXEWSLRNSLZJSHM5AVCNFSM6AAAAAA6CIVLGCVHI2DSMVQWIX3LMV43OSLTON2WKQ3PNVWWK3TUHMZDCOJVG43TINJSGI . You are receiving this because you were mentioned.Message ID: @.***>

Leopere commented 2 weeks ago

I haven't had a thermal alert yet but I'm not sure what caused my first big one.

ndemarco commented 2 weeks ago

I will give these steps another try once 3.14.0 hex is released; it was tagged 3 weeks ago but not built as hex yet.

I will also try replacing the wires to the extruder if errors occur.

@mhouse1 Have you tried the RC 3.14.x yet? If you had good results, I'll also try it and report back.

mhouse1 commented 2 weeks ago

I will give these steps another try once 3.14.0 hex is released; it was tagged 3 weeks ago but not built as hex yet. I will also try replacing the wires to the extruder if errors occur.

@mhouse1 Have you tried the RC 3.14.x yet? If you had good results, I'll also try it and report back.

3.14 is tagged but there are no hex files included so I cant use it yet. https://github.com/prusa3d/Prusa-Firmware/releases/tag/v3.14.0

Leopere commented 2 weeks ago

Sounds close

mhouse1 commented 2 weeks ago

new firmware is ready, i will test this on July 4th and report back, looking forward to getting this resolved and especially the new reprint menu feature; it will really help with running the farm of 100's of files.