E3D REVO Thermal Model

[3d-gussner]

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.

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

2. 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

3. Once you have flashed and updated your printers firmware Run both the PID and TM calibration from the LCD Calibration menus of your machine.
4. 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.

5. 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

[mhouse1]

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.

So far its working great on the 3 printers I updated a week ago; fw3.14 for mk3s and mk3s+ with revo.

I think the main difference was running the reset_revo.gcode , I didnt have to factory reset any printer. I tried this on printers as old as 2019 with 982days of print time and new printer built in late 2023 with 40days of print time.

The older printer starts thermal model cal right away after firmware update, newer one didnt. printer number 49 was stuck at PID cal 0/5 but I just restarted the printer and tried again.

Details:

====================================
printer #50 built 9/10/23
flash new mk3s revo hex firmware 3.14
shows prusa i3 MK3S+R ok on LCD

printer  statistics total filament 2766.26m
total print time 40d

use reset_revo.gcode on sd card
response: file incomplete continue anyway?
yes
Press to reset REVO
Press to Save
0 hours 1 minutes

next, performed PID  calibration to 250

thermal model calibration
TM: initial C  est.

====================================
printer #8 built 9/21/19
flash new mk3s revo hex firmware 3.14
after flashing it automatically started thermal model cal
shows prusa i3 MK3S+R ok on LCD
52453.14m filament, 
total print time 982d

use reset_revo.gcode on sd card
response: file incomplete continue anyway?
yes
Press to reset REVO
Press to Save
0 hours 1 minutes

next, performed PID  calibration to 250

thermal model calibration

====================================
printer #49 built 9/10/23
print meters, days (5781.49m,86 days)
ran reset_revo.gcode
continue anyway? > yes
Press to reset REVO 
press to save

flash new mk3s revo hex firmware 3.14

next, performed PID  calibration to 250
pid cal 0/5 stuck at 31C extruder 26c bed
reset the printer
ran reset_revo.gcode
retry PID cal to 250C

next, thermal model cal

We'll start updating the rest of the printers and report back if issues.

[Leopere]

awesome I haven't been having trouble with mine either on this version but I was waiting because when I had a previous version I didn't have trouble until I did and I don't really know what had changed so I wanted to hear it from someone else before saying anything.

[3d-gussner]

@mhouse1 Thanks for sharing the information :hugs: . Always nice to see that kind of feedback. :crossed_fingers: The rest of the printers updates are also going that "smoothly"

[capsulecorplab]

Been running 3.14.0 firmware for the Mk3S with Revo for a couple of days now. Seems to be working so far without errors!

Though, the option to load filament when autoload is turned off seems to have disappeared. Should I open an issue for this?

[3d-gussner]

@capsulecorplab Thanks for the positive feedback.

The "Load filament" and "Unload filament" menus are shown depending on the state of the filament sensor.

• When filament is detected and printer is idle "Unload filament" is shown and "Load filament" is hidden.
• When NO filament is detected and printer is idle "Load filament" is shown and "Unload filament" is hidden.
• When the FSensor is disabled both "Load filament" and "Unload filament" are shown as the printer doesn't "know" if there is any filament and the user has to be able to use both menus.

Hope that it makes clear.

If you have an question or issue with it, then please open a new Issue to keep this one "clear" to one topic.

[mhouse1]

So far I have 4 printers running new fw3.14 successfully Two printers are getting thermal anomaly with firmware 3.14 after updating and is unable to perform PID cal. One printer I also tried factory reset to no help. Today, the print farm is running so the room is hot, maybe this is interfering with calibration. I will try this again later when print farm is off.

====================================
printer #10 built 12/16/19
print meters, days (44092.22m,945 days)
ran reset_revo.gcode
file incomplete continue anyway? > yes
Press to reset REVO 
press to save

flashed fw 3.14 thermal model cal
 starts automatically after flashing
fails right away, menu shows Clear TM error above print from sd
cleared TM error

start PID cal to 250C
stuck at nozzle 50/0 bed 28/0 PID cal. 0/5
nozzle is cold
performed power cycle
when i flipped powering switch extruder moves left for some reason
when powering on it tries to resume a print
restart printer using LCD X button
detects thermal model not set
click lcd to continue tries resuming print again, use menu to "Stop Print"
restart printer using LCD X button again
detects thermal model not set, but  does not try to resume print
use reset_revo.gcode
start PID cal to 250C
stuck at nozzle 52/0 bed 28/0 PID cal. 0/5
Perform factory reset all data using instructions at (https://help.prusa3d.com/article/full-system-refresh-original-prusa-i3_133258)
start PID cal to 250C
stuck at nozzle 58/0 bed 28/0 PID cal. 0/5
removed sd card
start calibration > wizard
while extruder is up, realize revo nozzle is a little loose, tightened it
wizard  starts searching bed calibration point
wizard completes and starts thermal model cal
thermal model cal results in thermal anomaly within 1 second
try PID cal to 250 again
PID cal ramps nozzle to 80C then stuck at nozzle ~52/0 bed 28/0 PID cal. 0/5
====================================
printer #40 built 4/26/21
print meters, days (m, days)
ran reset_revo.gcode
file incomplete continue anyway? > yes
Press to reset REVO 
press to save

flashed fw 3.14 thermal model cal
 starts automatically after flashing
next, performed PID  calibration to 250
cannot complete PID cal stuck at PID cal. 0/5
when trying to print from SD LCD Shows PAUSED THERMAL ERROR
restored to fw 3.11 for now so i can use the printer
performed PID cal to 250 and started a print

[mhouse1]

so far 2 out of 9 printers can't be updated to fw3.14 due to PID cal and thermal model failing right away even though both printers are functional on fw3.11 and is used everyday . Some inconsistencies, some printers starts thermal model cal right away after flashing fw3.14, some doesn't, printer number 10 built 12/16/19 I reverted back to fw3.11 because it kept failing to calibrate on fw3.14 even after factory reset and reset_revo.gcode, when I tried flashing fw3.14 again a few days later it starts self test after flashing.

for now any printer that accepts fw3.14 I'm updating to that otherwise they get updated to fw3.11

Details:

====================================
printer #10 built 12/16/19 attempting fw upgrade again
has fw 3.11
after flashing 3.14  it starts self test ("First, I will run the selftest to check most common assembly….)
starts thermal cal
fails right away with LCD showing print aborted
run reset revo.gcode
start PID cal, cannot complete PID cal  LCD shows PID cal. 0/5 LCD  menu cannot scroll
reset using LCD button
revert to fw 3.11

====================================
printer #35 built 1/15/21
has fw 3.11
print meters, days (?m, ?days)
after flashing 3.14 it starts thermal cal right away
successful
next, performed PID  calibration to 250
successful

====================================
printer #39 built 4/26/21
has fw 3.11
print meters, days (23681.91m, 386days)

after flashing 3.14 it starts thermal cal right away
next, performed PID  calibration to 250
started small print 33min
successful
====================================
printer #42 built 5/3/21
has fw 3.11
after flashing 3.14 does not auto thermal cal , LCD shows PRUSA i3 MK3S+R Ok.
Start PID cal to 250 … completes successfully
wait for cool down
next, performed thermal model cal
successful

[capsulecorplab]

Been running 3.14.0 firmware for the Mk3S with Revo for a couple of days now. Seems to be working so far without errors!

Though, the option to load filament when autoload is turned off seems to have disappeared. Should I open an issue for this?

I spoke too soon. I forgot I had disabled thermal model protection while running v3.13.2 before updating to v3.14.0. Factory resetting the printer brought back the thermal anomaly error until I reran the gcode to disable thermal model protection.

[3d-gussner]

@capsulecorplab Thanks for the feedback. Did the TM cal after the factory reset work?

[capsulecorplab]

@capsulecorplab Thanks for the feedback. Did the TM cal after the factory reset work?

I tried running TM cal after the reset, but couldn't get the thermal anomaly error to go away, so I ended up just disabling the TM protection

[mhouse1]

@capsulecorplab Thanks for the feedback. Did the TM cal after the factory reset work?

I tried running TM cal after the reset, but couldn't get the thermal anomaly error to go away, so I ended up just disabling the TM protection

which one is safer, disabling TM protection and using fw3.14 or using fw3.11 ?

[capsulecorplab]

which one is safer, disabling TM protection and using fw3.14 or using fw3.11 ?

I don't recall TM issues with fw3.11, but I also haven't printed on that fw enough to tell. I think I've had the best experience with fw3.13.2 (with TM protection disabled) so far - in part due to the fact that fw3.11 lacks filament runout sensing and fw3.14's "load filament" option seems to disappear for me when autoload is disabled, granted that's a separate issue.

[mhouse1]

no TM issues with fw3.11 but I thought the TM that was added after 3.11 improves on detecting TM anomalies, I wonder if disabling the new TM means we still have whatever safety feature that was in 3.11. Theres definitely lots of improvements in 3.14 that I'd like to use but if disabling the TM model means its less safe than 3.11 then I won't risk it.

With TM model disabled in 3.14 can it still detect extruder thermal runaway events? 3.11 has been great in detecting thermal runaways which I've see happen 8 times so far in the last 4 years on a print farm of 50+ mk3s printers.

[3d-gussner]

@mhouse1 Sorry for the late answer.

With TM model disabled in 3.14 can it still detect extruder thermal runaway events?

Yes the default thermal protection is always active. With the TM active, but you might not see it as the TM reacts in seconds while thermal runaway takes longer.

Did you contact E3D support as they should be able to help you with REVO and TM issues,

[ndemarco]

As you might imagine, E3D ran out of ideas, and directed me to contact Prusa for support.

E3D as a supplier of retrofit parts is ultimately responsible for making their parts are compatible.

I have offered to assist by providing logged data if properly instructed.

[mhouse1]

Yes the default thermal protection is always active.

I think the confusion from the community is fw3.11 was such a stable fw (no thermal issues in our years of use) why mess with it when it introduces complexity such as having to manage multiple fw builds. And the fact that a printer that prints completely fine on fw3.11 might experience odd thermal anomalies when using fw3.14: in some cases, a "PAUSED thermal anomaly" will appear on the LCD and prevent the print from starting but a reboot fixes it, in other cases "thermal anomaly" appears during print start with audible alarm but does not prevent print. Although a majority of the printers running fw3.14 are running good, it will take me a few more months of runtime to conclude whether updating from 3.11 to 3.14 was worth it.

I will try disabling thermal protection on fw3.14 just for those printers (2 out of 12) that are completely functional on fw3.11 but errors out ASAP on fw3.14 preventing the printer from being used.

[3d-gussner]

Yes the default thermal protection is always active.

I think the confusion from the community is fw3.11 was such a stable fw (no thermal issues in our years of use) why mess with it when it introduces complexity such as having to manage multiple fw builds. And the fact that a printer that prints completely fine on fw3.11 might experience odd thermal anomalies when using fw3.14: in some cases, a "PAUSED thermal anomaly" will appear on the LCD and prevent the print from starting but a reboot fixes it, in other cases "thermal anomaly" appears during print start with audible alarm but does not prevent print. Although a majority of the printers running fw3.14 are running good, it will take me a few more months of runtime to conclude whether updating from 3.11 to 3.14 was worth it.

I will try disabling thermal protection on fw3.14 just for those printers (2 out of 12) that are completely functional on fw3.11 but errors out ASAP on fw3.14 preventing the printer from being used.

@mhouse1 Thanks for the feedback and sorry to hear that 2 of your 12 printers keep be difficult with TM enabled.

The thermal model already proved that it is useful as some users had broken or semi broken thermistor or heater cables and found the issue. It reacts to issues way faster that the regular thermal protection but is also way more "sensitive" which can cause false positive warnings and errors.

For the stock E3D V6 we had tons of data and test machines internally and I think that the values are working great.

For the REVO we had just few community members submitting their values and E3D provided some other values for the REVO within their performance tolerances.

@mhouse1 Did you try to raise the W and E values?

[3d-gussner]

As you might imagine, E3D ran out of ideas, and directed me to contact Prusa for support.

E3D as a supplier of retrofit parts is ultimately responsible for making their parts are compatible.

I have offered to assist by providing logged data if properly instructed.

Hi, sorry to hear that E3D couldn't help you.

My time on this 3rd party issue is very limited but please try https://github.com/prusa3d/Prusa-Firmware/issues/4105 and provide there your results?

[mhouse1]

The thermal model already proved that it is useful as some users had broken or semi broken thermistor or heater cables and found the issue. It reacts to issues way faster that the regular thermal protection but is also way more "sensitive" which can cause false positive warnings and errors.

thank you for all the work put into this , I do believe I have some bias towards changing from fw3.11

We have some printers on fw3.14 that throws thermal anomally errors during startup, perhaps the firmware response is a sign that the printer wires or revo is wearing out, or its caused by a draft at that corner of the room and moving printer location will improve it, time will tell.

[3d-gussner]

Draft can cause some TM issues. I expected the REVO having less issues with draft because of the design of it. Or are these printers next to an walk-in freezer with -40°C? :wink:

If I remember correctly testing the TM on REVO wasn't as easy to trigger as with the E3D v6 see as an example https://github.com/prusa3d/Prusa-Firmware/issues/4105#issuecomment-1483476002