Heating failed Taz Workhorse trouble at temps +200c

I recently started a print job on Octoprint and encountered a heating failed which resulted in an abortion.
I thought that since my machine is +5yr old it probably just took too long to heat up from 215c to 225c and resulted in an error with Octoprint.
I took the failed print off the bed and heated up the extruder to 210c (no problem).
I restarted the print with the SD card on the machine.
It almost seems as if the machine was printing at the wrong temperature because the material looks glossier on the bottom (normal) to a matte finish and over-extrusion further into the print. In addition, the over-extrusion caused the nozzle to vibrate over the existing material like rumble strips. I tried to lower the temperature starting with 218c in 30 second intervals, then 216c, 208c (extruder has trouble pushing filament out 208c), and then to 220c.
I tried once more to print the object because it seemed like the material was too hot on the 2nd try. Things got worse. I couldn’t quite get the print to stick to the bed anymore with the first layer unless the nozzle was very close to the bed.

I’m wondering if the thermistor is acting up or if the heater is the problem. I might need to replace one or the other. But the question is which one?

I have a multimeter but don’t know much about how to use it because its only use is for the printer. Can you test the wires to tell if the heater or thermistor is not working? If so how do you do that?


Toolhead:
MET285 - 2.85mm
0.8mm nozzle

Since you have OctoPrint I’d suggest that we try an experiment or two before replacing any parts. First, let’s take a look at the temperature graph as you use the Target controls to heat the Tool to 220 degrees (the built-in ABS value). While you are waiting to things to heat up, here’s a couple of topics to read:
https://forum.lulzbot.com/t/taz-5-e1-err-maxtemp-printer-halted-please-reset/26987/5
https://forum.lulzbot.com/t/taz-5-extruder-not-reaching-set-temp/21657/18

After viewing the results of this experiment, we may want to consider a PID tune. In the first topic above, I linked an article and in the second topic above, there is a link to a video.

Here’s what I’m looking for:

I would guess that the apparent “over-extrusion” later on is from the part warping upward.

The pattern here reminds me of a partially-clogged or worn nozzle, or trying to extrude a line thinner than your actual nozzle size (either wrong nozzle in the slicer, or a nozzle worn to have a bigger opening):

It could also be from the heater issue, having to push out colder filament.

I got “PID Autotune failed! Bad heater id”

Did you try and do E1 instead of E0?

E-1 heater bed
E0 first extruder
E1 second extruder

From PID autotune | Marlin Firmware
Auto-tune hotend at 210 °C for 8 cycles:

M303 E0 C8 S210

I did E1 and E0 both had same results!

Does this mean anything to you?

Recv: Hotend Idle Timeout
Recv: //action:notification Hotend Idle Timeout

How can my hotend be idle if its at 210 and still at 210 after the message?

Send: M303E0C8S210
Recv: PID Autotune failed! Bad heater id
Recv: ok P15 B3
[…]
Send: M503
Recv: echo:; Linear Units:
Recv: echo: G21 ; (mm)
Recv: echo:; Temperature Units:
Recv: echo: M149 C ; Units in Celsius
Recv: echo:; Filament settings (Disabled):
Recv: echo: M200 S0 D2.85
Recv: echo:; Steps per unit:
Recv: echo: M92 X100.00 Y100.00 Z500.00 E439.00
Recv: echo:; Max feedrates (units/s):
Recv: echo: M203 X300.00 Y300.00 Z25.00 E40.00
Recv: echo:; Max Acceleration (units/s2):
Recv: echo: M201 X9000.00 Y9000.00 Z100.00 E9000.00
Recv: echo:; Acceleration (units/s2) (P R T):
Recv: echo: M204 P500.00 R3000.00 T500.00
Recv: echo:; Advanced (B<min_segment_time_us> S<min_feedrate> T<min_travel_feedrate> X<max_jerk> Y<max_jerk> Z<max_jerk> E<max_jerk>):
Recv: echo: M205 B20000.00 S0.00 T0.00 X10.00 Y10.00 Z0.40 E10.00
Recv: echo:; Home offset:
Recv: echo: M206 X0.00 Y0.00 Z0.00
Recv: echo:; Auto Bed Leveling:
Recv: echo: M420 S0 Z0.00 ; Leveling OFF
Recv: echo: G29 W I0 J0 Z2.26500
Recv: echo: G29 W I1 J0 Z1.97100
Recv: echo: G29 W I0 J1 Z2.23300
Recv: echo: G29 W I1 J1 Z1.16000
Recv: echo:; Material heatup parameters:
Recv: echo: M145 S0 H180.00 B60.00 F0
Recv: echo: M145 S1 H220.00 B110.00 F0
Recv: echo: M145 S2 H200.00 B60.00 F0
Recv: echo: M145 S3 H145.00 B0.00 F0
Recv: echo:; Bed PID:
Recv: echo: M304 P286.02 I54.55 D374.90
Recv: echo:; Controller Fan:
Recv: echo: M710 S255 I120 A1 D60 ; (100% 47%)
Recv: echo:; Power-loss recovery:
Recv: echo: M413 S0OFF
Recv: echo:; Retract (S F Z):
Recv: echo: M207 S3.00 W13.00 F2700.00 Z0.00
Recv: echo:; Recover (S F):
Recv: echo: M208 S0.00 W0.00 F480.00
Recv: echo:; Auto-Retract (S):
Recv: echo: M209 S0
Recv: echo:; Z-Probe Offset:
Recv: echo: M851 X0 Y0 Z-0.66 ; (mm)
Recv: echo:; Hotend Idle Timeout:
Recv: M86 B0 E0 S600 T150
Recv: echo:; Linear Advance:
Recv: echo: M900 K0.05
Recv: echo:; Stepper motor currents:
Recv: echo: M907 X175 Y175 Z180 E155
Recv: echo:; Filament load/unload:
Recv: echo: M603 L40.00 U50.00 ; (mm)
Recv: echo:; Backlash compensation:
Recv: echo: M425 F0.00 S3.00 X0.02 Y0.11 Z0.08
Recv: echo:; Filament runout sensor:
Recv: echo: M412 S1 ; Sensor ON
Recv: echo:; Model predictive control:
Recv: echo: M306 E0 P50.00 C15.44 R0.1128 A0.0622 F0.1844 H0.0056
Recv: ok P15 B3
[…]
Recv: Hotend Idle Timeout
Recv: //action:notification Hotend Idle Timeout

Ah, you’re running a firmware with MPC for the hotend. Model Predictive Temperature Control | Marlin Firmware

Try M306 T, then save with M500.

1 Like

Without some additional information about your OctoPrint setup, I’m going to guess that you have the BetterHeaterTimeout plugin installed and that is where that message came from.

I changed the toolhead this week because I needed to print. It printed fine but still seemed inconsistent with the temperature.
Then today when I printed again I got the same error message!

Heating failed, system stopped! Heater_ID: E0 - echo:busy: processing

It seems like this issue isn’t related to the toolhead since I changed it. So it’s either a bad wire somewhere or something wrong with the motherboard (in the past I had a loose fan connection).

@Wrathernaut, I don’t know if I have MPC but I will give (M306 T, M500) it a try.

@b-morgan, I don’t think so.
I haven’t installed any plugins personally. I’m assuming these are the stock ones.

My bad assumption… Your firmware has M86 and that is where the Recv: Hotend Idle Timeout comes from.

Gcode documentation can be found at https://marlinfw.org/meta/gcode/ or https://reprap.org/wiki/G-code. The description for the M86 explains what actions reset the timer and also how to disable it (M86 S0 or M87). The Model predictive control, M306 description might also be worth a read (note: the RepRap documentation is for a Smoothie command, not the Marlin one).

It might be useful to post the output (please use the </> tool or triple tick marks) of the M115 command.

That right there says you have MPC-enabled firmware. It’s not an octoprint thing.

@Wrathernaut,
I think I did it correctly. (M306T) then (M500)
I don’t know what to look for but to me it looks like my printer is working?

Recv: MPC_autotuner::measure_ambient_temp() Completed
Recv: =====
Recv: ambient_temp 22.06
Recv: Heating to over 200C
Recv: //action:notification Heating to >200C
[…]
Recv: MPC_autotuner::measure_heatup() Completed
Recv: =====
Recv: t1_time 32.00
Recv: sample_count 9
Recv: sample_distance 4
Recv: sample 0 : 102.45
Recv: sample 1 : 115.24
Recv: sample 2 : 127.14
Recv: sample 3 : 138.72
Recv: sample 4 : 150.67
Recv: sample 5 : 161.93
Recv: sample 6 : 173.36
Recv: sample 7 : 184.12
Recv: sample 8 : 194.67
Recv: t1 102.45 t2 150.67 t3 194.67
Recv: asymp_temp 653.61
Recv: block_responsiveness 0.0057
Recv: Measuring ambient heatloss at 225.63
[…]
Recv: MPC_autotuner::measure_transfer() Completed
Recv: =====
Recv: power_fan0 11.81
Recv: power_fan255 37.05
Recv: Refining estimates for:
Recv: asymp_temp 881.14
Recv: block_responsiveness 0.0040
Recv: MPC Autotune finished! Put the constants below into Configuration.h
Recv: MPC_BLOCK_HEAT_CAPACITY 14.57
Recv: MPC_SENSOR_RESPONSIVENESS 0.1370
Recv: MPC_AMBIENT_XFER_COEFF 0.0582
Recv: MPC_AMBIENT_XFER_COEFF_FAN255 0.1825
Recv: //action:notification LulzBot Taz Workhorse Ready.
Recv: echo:busy: processing
Recv: //action:notification LulzBot Taz Workhorse Ready.
Recv: ok P15 B3

Send: M500
Recv: echo:Settings Stored (649 bytes; crc 37808)
Recv: //action:notification Settings Saved!
Recv: ok P15 B3

So MPC went from:
M306 E0 P50.00 C15.44 R0.1128 A0.0622 F0.1844 H0.0056
to
M306 E0 P50.00 C14.57 R0.1370 A0.0582 F0.1825 H0.0056

The math on the documentation is a bit above my level, so I don’t know how significant the changes are, but if it’s working now, great!

Going by the documentation, the H value (heat capacity of the filament) needs to be updated if you’re not running a 1.75mm toolhead. H0.0056 corresponds to 1.75mm PLA.

Do you know how to access the settings on the printer and edit (Configuration.h)?
I’m a little confused because there is a “configuration” option in the main menu but I couldn’t find a way to access the (Configuration.h)?
Is there a guide on how to change (FILAMENT_HEAT_CAPACITY_PERMM)?

Editing configuration.h is for doing a custom compiled marlin firmware build. If it’s saved to your EEPROM, that’s about as good as you’ll need. Just remember to do the MPC tuning after a firmware update.

Did you try a heat purge?