Rostock Max V2 arms going nuts

[jakubsvec]

After posting this, I will try to make a video of the issue presented below:

I recently got a Rostock Max V2, set it up as instructed in the guide and added an E3D V6 hot end (I have the Kysan steppers and have modified the configuration.h file accordingly). I printed a few parts and it was working well for a while. However, after about 30 hours of total print time and without adjusting any settings, the behavior of the machine began to change. At random intervals in a print the arms will completely lose their position and the print is ruined. I went through a spool of filament trying to trace down this problem. It does not appear to be a mechanical issue with the printer since I am able to jog the head without a problem at various speeds. Also, the hot end does not hit the print before going crazy. Moreover, many times I will level the bed, then start the print and the hot end will attempt to start printing but be several inches above the build plate and will be moving diagonally!

Another issue that is likely related is the behavior of the macros used to level the bed to the x,y,z towers. I used the G-Code provided in the manual and they worked well initially, but now when select any tower, for example the X Tower Adjustment, and then select the Bed Center macros, it will not go to the center but instead will move to the previous tower selected. This behavior is consistent with whichever tower I previously selected.

What I have already done:

Allowed the printer to sit for 12 hours without power.

I have already cleared the EEProm through the Arduino IDE and reinstalled the master Repetier code, then tweeked it as instructed in the build guide.
This did not fix the problem.

I also uninstalled and reinstalled Mattercontrol. I also installed a new copy of Mattercontrol on my laptop.
Neither attempts fixed the problem. Interestingly, Mattercontrol remembered all of my settings after uninstalling and reinstalling the software. I made sure that the Mattercontrol file under "Program Files (x86)" was completely deleted. I don't know how it remembers the custom settings!

Any help is appreciated. At the moment, this 3D printer is worthless.

[mhackney]

That sounds like:

one or more loose connectors on the tower steppers or

mechanical binding on one or more towers at high speeds that cause the steppers to lose steps or

one or more loose set screws on the stepper pulleys




Reinstalling matter control will have no effect on this or similar problems.

[da40flyer]

@jakubsvec, I am experiencing the exact same thing. New V2 Max. Has been perfect for the first few weeks... But now at random times the arms will go crazy, or just jam the nozzle into the part for no apparent reason. I have already checked all connections and modified travel speeds (per J.J.), nothing binding. Would still occur.

The only way I have been able to avoid it recently: I go into MatterControl, warm up the printer, slice model, make necessary settings, save model. Then quit out of MC turn off V2. Turn V2 back on for fresh reboot. Once V2 is back up, restart MC, once connected, Print.

Very frustrating....

[mhackney]

If you suspect matter control why not switch to repetier host and try it for a bit or print from an SD card from the lcd and take mc out of the loop.

Always pay attention to which arm or arms are going bonkers. That's valuable info for diagnosing.

Intermittent connector issues are very difficult to diagnose but that would be my #1 suspect for these problems.

[jakubsvec]

Yesterday, I became frustrated and tried to print a different part and it worked well. I'm working on a second print today. The major change I made was in printing a smaller piece. As such, I suspect that the problem has to do with printing at the extremes of the build platform.

It works for now and that is good enough I suppose. When I have time I will try to figure out why I can't use the entire build platform.

I have checked all the connections and they are tight. The problem does not appear to be with just one tower because the print has failed in different areas of the build platform. Once it was opposite the Y axis and another time opposite the x axis.

Printing over an SD card is a great suggestion to rule out software issues! I will look into how that is done since the build guide did not describe the operation and I am new to 3D printing.

Thank you all for the replies! If anyone has any other suggestions I'll try them out. If I find the problem, I will post it.

[mhackney]

Make sure your bowden tube/harness is not pulling on the effector at the edge of the build plate. It's a relatively common problem. The tension pulls up on the effector and can actually cause missed steps that compounds the problem.

[jakubsvec]

I may have found the fix. It was likely a software issue.

I contacted Matterhackers/Mattercontrol support and was directed to their Wiki FAQ section "How do I clear the application data?" I cleared the temp file as instructed to clear all the settings. I then manually reapplied all the prior settings as I like them. I ran a large diameter test ring and it worked. Hasn't failed since, so I can hesitantly say the problem may have been fixed.

http://wiki.mattercontrol.com/Frequentl ... _Questions

Jakub

[mhackney]

I don't recall anyone having issues like this with Repetier Host or Pronterface. What the heck is MC doing to cause these sorts of problems?