Filament Issues On AD5X With Guppyscreen: A Troubleshooting Guide

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Filament Issues on AD5X with Guppyscreen: A Troubleshooting Guide

Hey guys,

Having some issues with your AD5X and Guppyscreen setup? Let's dive into a common problem: filament loading and runout detection. This guide will walk you through a real-world scenario, potential causes, and how to troubleshoot them. We'll break it down so it's super easy to follow. I hope you find it helpful!

The Problem: Filament Runout and Jamming

In this scenario, the printer starts with no filament loaded. The user inserts the filament into the spool holder, and it goes all the way through, but isn't loaded into the extruder yet. Upon starting a new print and mapping the slicer filament to the installed spool, the expectation is that the printer should recognize the empty extruder and load the filament. However, the printer throws a "Filament runout detected (Head)" error on the Guppyscreen (but no message in the console). Even with this error, the printer continues with bed leveling. After leveling, it attempts to create a purge line but fails, displaying a "Filament jam detected (IFS)" error on both the screen and the console. This is a common problem, so let's start troubleshooting to resolve it.

Understanding the Initial State

Before we dive into the troubleshooting steps, it's crucial to understand the initial state of your printer. Ensure that no filament is loaded in the extruder when you begin the process. This starting condition helps us isolate the issue and focus on the loading mechanism. Always double-check this, as residual filament can sometimes cause false detections or jams.

Diagnosing the Filament Runout Error

The "Filament runout detected (Head)" error typically indicates that the printer's sensor believes there's no filament present. However, if the filament is correctly inserted into the spool holder, this could point to a few potential issues:

  1. Sensor Malfunction: The filament runout sensor might be faulty or overly sensitive. Sometimes, a slight misalignment or a loose connection can trigger false positives.
  2. Filament Path Obstruction: Even if the filament is inserted correctly, there might be an obstruction in the filament path, preventing it from reaching the sensor.
  3. Software Configuration: Incorrect settings in your printer's firmware or ZMOD configuration could lead to misinterpretations of the sensor data.

Analyzing the Filament Jam Error

The subsequent "Filament jam detected (IFS)" error suggests that the printer is trying to push filament through, but something is blocking its path. Here are a few common causes:

  1. Nozzle Clog: A partially or fully clogged nozzle can prevent filament from extruding, leading to a jam.
  2. Extruder Issues: Problems with the extruder motor, gears, or tension can prevent the filament from being properly fed.
  3. Filament Quality: Low-quality filament or filament that has absorbed moisture can cause inconsistencies in diameter and lead to jams.

Troubleshooting Steps

Let's go step-by-step, guys, to figure out what's going on. Here's how we can tackle these errors:

1. Checking the Filament Runout Sensor

First things first, let's make sure that filament runout sensor is working correctly. A faulty sensor can cause a lot of headaches, so this is a good place to start.

  • Visual Inspection: Take a close look at the sensor. Is it clean? Is it properly aligned? Make sure there's no dust or debris that could be interfering with its operation. Sometimes, a simple cleaning can do the trick.
  • Connection Check: Ensure that all the wires connected to the sensor are securely in place. A loose connection can cause intermittent issues, leading to false positives. Give those connectors a good wiggle to make sure they're snug.
  • Manual Test: Most filament runout sensors have a manual test function. Consult your printer's documentation to find out how to trigger this test. If the sensor fails the test, it might be time to replace it.

2. Inspecting the Filament Path

Next up, let's investigate the filament path. Even if everything looks good on the surface, there could be hidden obstructions that are causing problems. A clear path is essential for smooth printing.

  • Unload and Reload: Try unloading the filament completely and then reloading it. Sometimes, this simple step can clear minor obstructions. Make sure you're doing it slowly and steadily to avoid any kinks or bends.
  • Manual Feed: Manually feed the filament through the extruder to see if you feel any resistance. If you encounter a snag, that's a sign that something is blocking the way.
  • Disassemble and Clean: If you suspect a more significant obstruction, you might need to disassemble the filament path. Clean each component thoroughly, removing any debris or residue. Pay close attention to the extruder gears, as they can accumulate filament dust over time.

3. Addressing Nozzle Clogs

A clogged nozzle is a common culprit when it comes to filament jams. Even a tiny blockage can prevent filament from extruding properly. Here's how to tackle a nozzle clog:

  • Cold Pull: A cold pull involves heating the nozzle to a specific temperature, then quickly pulling the filament out. This can often remove debris that's stuck inside. Look up the recommended temperature for your specific filament type.
  • Nozzle Cleaning Filament: Use a specialized nozzle cleaning filament to clear out any stubborn clogs. These filaments are designed to grab onto debris and pull it out as they're extruded.
  • Needle Cleaning: Gently insert a thin needle into the nozzle to dislodge any blockages. Be careful not to damage the nozzle in the process. Use a needle that's specifically designed for nozzle cleaning.
  • Nozzle Replacement: If all else fails, it might be time to replace the nozzle. Nozzles are relatively inexpensive, and a fresh nozzle can often resolve persistent clogging issues.

4. Checking Extruder Components

The extruder is the heart of your printer's filament feeding system. If something is amiss with the extruder, it can lead to jams and inconsistent extrusion. Here's how to check the extruder components:

  • Extruder Motor: Ensure that the extruder motor is functioning correctly. Listen for any unusual noises or vibrations. If the motor seems weak or unresponsive, it might need to be replaced.
  • Extruder Gears: Inspect the extruder gears for wear and tear. Make sure they're properly aligned and that the teeth are in good condition. Worn or misaligned gears can cause the filament to slip.
  • Extruder Tension: Adjust the extruder tension to ensure that the filament is being gripped firmly but not too tightly. Too little tension can cause slippage, while too much tension can deform the filament.

5. Reviewing ZMOD Configuration

Incorrect settings in your ZMOD configuration can sometimes lead to misinterpretations of sensor data. Let's review those settings, guys.

  • Double-Check Settings: Make sure all the relevant settings are configured correctly. Pay close attention to any settings related to filament runout detection or jam detection.
  • Consult Documentation: Refer to the ZMOD documentation for guidance on configuring these settings. The documentation can provide valuable insights into how each setting affects printer behavior.
  • Community Forums: Check online forums and communities for tips and advice on configuring ZMOD for your specific printer model. Other users may have encountered similar issues and found solutions.

6. Analyzing Start and End G-Code

Your start and end G-code can sometimes influence printer behavior. Let's take a look at your current G-code to see if there's anything that might be causing issues.

  • Review Start G-Code: Examine your start G-code for any commands that might be related to filament loading or priming. Make sure these commands are appropriate for your printer and filament type.
  • Review End G-Code: Check your end G-code for any commands that might be interfering with the filament unloading process. Remove any unnecessary commands that could be causing issues.

7. Using the Correct Start Code and End Code

Make sure that you are using the correct start and end codes. If you are not sure, here is an example:

Start Code:

Put your printer start G-code here
START_PRINT EXTRUDER_TEMP=[nozzle_temperature_initial_layer] BED_TEMP=[bed_temperature_initial_layer_single]
SET_PRINT_STATS_INFO TOTAL_LAYER=[total_layer_count]

End Code:

Put your printer end G-code here
END_PRINT

Specific Configuration Analysis

Based on the provided SAVE_ZMOD_DATA parameters, a few things stand out:

  • SAVE_ZMOD_DATA WIFI=0: Disabling WiFi might not directly affect filament loading, but it's worth noting.
  • SAVE_ZMOD_DATA FIX_E0017=1 and SAVE_ZMOD_DATA FIX_E0011=1: These fixes suggest previous error occurrences, so ensuring these are correctly applied is crucial.
  • SAVE_ZMOD_DATA REMOVE_FILAMENT=1: This setting should automatically remove filament after printing, but if the initial loading fails, it might not be relevant.
  • SAVE_ZMOD_DATA USE_TRASH_ON_PRINT=0: This shouldn't directly impact the loading process.
  • SAVE_ZMOD_DATA AUTOINSERT=1: This parameter is intended to automatically insert the filament, so it's essential to ensure this function is working correctly and not conflicting with other settings.
  • SAVE_ZMOD_DATA PRINT_LEVELING=1 and SAVE_ZMOD_DATA MESH_TEST=1: Bed leveling and mesh testing are performed after the start code but before printing, so these are unlikely to be direct causes of the filament loading issue.

Final Thoughts

Alright guys, that's all I have for you today. Troubleshooting filament loading and runout detection can be a bit of a journey, but with these steps, you should be well-equipped to tackle the problem. Take it one step at a time, and don't be afraid to experiment. Good luck, and happy printing!