Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Have questions? Want advice?
eirikso
Posts: 13
Joined: Sun Jan 24, 2016 2:31 am

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by eirikso » Sat Mar 03, 2018 11:11 am

Or. If my problem actually IS a thermistor issue. Can I get to the thermistor and fix this myself. What is the issue? Bad connections?

Nate3D
Posts: 3
Joined: Mon Mar 12, 2018 8:23 pm

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by Nate3D » Mon Mar 12, 2018 8:50 pm

eirikso wrote:
Sat Mar 03, 2018 11:11 am
Or. If my problem actually IS a thermistor issue. Can I get to the thermistor and fix this myself. What is the issue? Bad connections?
@eirikso Yes it sounds like it is a thermistor issue. Check Lulzbot's service bulletin here to see if you might be affected - https://www.lulzbot.com/sites/default/f ... etin_2.pdf

If so, call them (phone support > online tickets) and provide them the info they request and you should get a free replacement setup. I am unfortunately also in the bad batch by SN however I crimped my thermistor connections and put a silicon sock on the extruder and things have almost reached my OCD levels of perfection. Good luck & happy printing! -Nate

eobie
Posts: 5
Joined: Thu Mar 29, 2018 3:42 pm

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by eobie » Thu Mar 29, 2018 3:52 pm

Has this issue been fixed with all newly shipped units. Mine should be here tomorrow, ordered directly from you.

Galadriel
Aleph Objects | LulzBot
Posts: 257
Joined: Mon Sep 25, 2017 10:23 am

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by Galadriel » Sat Mar 31, 2018 3:08 am

eobie wrote:
Thu Mar 29, 2018 3:52 pm
Has this issue been fixed with all newly shipped units. Mine should be here tomorrow, ordered directly from you.
All the new toolheads that are above the serial range listed in the service bulletin will have already been checked to make sure they aren't affected by this issue.

elgullitch
Posts: 19
Joined: Mon Apr 29, 2013 7:31 pm

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by elgullitch » Sun May 27, 2018 7:44 pm

I just started having this problem when printing above 240C. I have Mini Aerostruder sn: KT-CP0129-0276 so I'm definitely in the problem range. However, I checked the crimp connectors and they seem fine - When I just heat the extruder and wiggle the wires I don't see any noticeable noise. This makes me wonder if this is a firmware issue (e.g. PID/slew rate) per GJennings.
Does Lulzbot have a firmware revision forthcoming?

elgullitch
Posts: 19
Joined: Mon Apr 29, 2013 7:31 pm

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by elgullitch » Sun May 27, 2018 7:47 pm

P.S. I ordered this Aerostruder direct from Lulzbot on 4/21/18 so either it was checked/repaired or one of the old ones slipped through...

elgullitch
Posts: 19
Joined: Mon Apr 29, 2013 7:31 pm

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by elgullitch » Mon May 28, 2018 10:06 am

There's definitely no problem with the thermistor in my Mini Aerostruder.
After a number of tests and reading several related posts on this topic, here's the conclusion I've come to:
1. Printing at temperatures above 235C, you can't run the cooling fan without compromising the hot end temperature. This is partly due to the design of the print cooling duct which blows a substantial amount of air directly onto the hot end block. However, it is also due in part to the PID settings which are not optimized for the Aerostruder printing at these elevated temperatures. You can increase printing temperatures up to around 260C with very low fan speeds but the hot end will run around 10-12C below the set temperature. Here you start running into sketchy territory where the controller may decide that you have runaway and will shut down. The block heater can deliver enough energy to drive the hot end even with the cooling fan on. However, the PID settings won't drive it hard enough to get there.
2. With no print cooling fan, you can easily maintain any temperature up to and beyond 260C
3. Users who have installed the standard E3D silicone sock have pretty much solved this problem.

I suspect that Lulzbot only tested the Aerostruder with high temperature filaments for which cooling is undesirable (e.g. ABS). Unfortunately we print a lot of CPE and CPE + for which cooling is necessary in order to get the best resolution. I strongly recommend that this toolhead be provided with the E3D sock. Further, I would really like to see Lulzbot modify the cooling duct design to direct the majority of the airflow downwards rather than directly at the hotend. In addition, I think Lulzbot should optimize the PID and related settings to work reliably with higher temperature filament.
With the roll out of the new Mini, this issue is going to have to be taken very seriously.

b-morgan
Posts: 175
Joined: Fri Aug 11, 2017 8:53 am

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by b-morgan » Mon May 28, 2018 11:53 am

Providing the E3D silicone sock should be a no brainer. Socks for the Dual Extruder should also be designed and available.

Galadriel
Aleph Objects | LulzBot
Posts: 257
Joined: Mon Sep 25, 2017 10:23 am

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by Galadriel » Thu May 31, 2018 7:20 am

elgullitch wrote:
Mon May 28, 2018 10:06 am
However, it is also due in part to the PID settings which are not optimized for the Aerostruder printing at these elevated temperatures.
We have actually optimized the PID settings for the Aerostruders more powerful fans. To have those new settings be enacted you have to first flash the firmware then through the console enter first M502 then M500 this will restore settings to default and save those settings allowing the new PID settings to be enabled

b-morgan
Posts: 175
Joined: Fri Aug 11, 2017 8:53 am

Re: Service Bulletin: Thermistor Issue in Aerostruder and Dual Extruder v3 Tool Heads

Post by b-morgan » Fri Jun 01, 2018 5:42 pm

Galadriel wrote:
Thu May 31, 2018 7:20 am
We have actually optimized the PID settings for the Aerostruders more powerful fans. To have those new settings be enacted you have to first flash the firmware then through the console enter first M502 then M500 this will restore settings to default and save those settings allowing the new PID settings to be enabled
Would you be so kind as to give us the minimum version number of the firmware that contains these changes?

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