Problem with heaters? Or bug?
Hi,
After years of using Repetier host with my machine (repetier f/w version 1.0.3), now I have a strange problem.
After ~15minutes into printing, the whole thing stops with error in red window (something like "sensors disconnected from heaters, continue with "9999"). And I couldn't continue, I had to abort the session and start again from the beginning. Sometimes the new session is successful, but most of the times it ends like the previous one.
On temperature logs I can't see any problem - everything behaves as it should, and I checked all connections.. no obvious problems found there either.
Anyone had similar issue and suggestion what to do next?
I was even thinking of replacing the RAMPS1.4 and/or MEGA board with new ones..
Comments
Modern firmwares check measured temperature versus expected response and as soon as they detect it they stop heaters with exactly that message. See log window for exact details when it happens. Typical reason is a broken sensor cable - especially at the beginning it might report good values most of the time, but at some positions where the cable is on most strain close to break it causes a disconnect triggering the error.
> 11:58:38.243 : Error:One heater seems decoupled from thermistor - disabling all for
safety!
> 11:58:38.246 : Error:Temp. raised to slow. Rise = -2.35 after 301018 ms
> 11:58:38.251 : Disabling all heaters due to detected sensor defect.
> 11:58:38.251 : DebugLevel:14
> 11:58:38.266 : RequestStop:
> 11:58:38.648 : T:234.62 /0 B:95.63 /0 DB:2 B@:0 @:0
> 11:58:39.734 : T:234.87 /0 B:95.63 /0 DB:2 B@:0 @:0
> 11:58:40.163 : busy:processing
> 11:58:40.836 : T:234.87 /0 B:95.56 /0 DB:2 B@:0 @:0
> 11:58:41.442 : TargetExtr0:0
> 11:58:41.446 : T:234.87 /0 B:95.56 /0 DB:2 B@:0 @:0
> 11:58:41.490 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to
this error. Fix error and restart with M999.
> 11:58:41.493 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to
this error. Fix error and restart with M999.
> 11:58:41.493 : ok 15453
< 11:58:41.495 : N15454 M104 T0 S0*32
> 11:58:41.511 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to
this error. Fix error and restart with M999.
> 11:58:41.511 : ok 15454
< 11:58:41.513 : N15455 M140 S0*101
> 11:58:41.527 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to
this error. Fix error and restart with M999.
> 11:58:41.527 : ok 15455
< 11:58:41.528 : N15456 G1 X0 Y-10 F4800*92
> 11:58:41.546 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to
this error. Fix error and restart with M999.
> 11:58:41.546 : ok 15456
< 11:58:41.546 : N15457 M84*29
> 11:58:41.560 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to
this error. Fix error and restart with M999.
> 11:58:37.540 : T:233.85 /235 B:95.63 /98 B@:255 @:20
safety!
> 11:58:38.246 : Error:Temp. raised to slow. Rise = -2.35 after 301018 ms
> 11:58:38.251 : Disabling all heaters due to detected sensor defect.
Is the critical part where firmware disabled heaters. So still firmware issue. It is one where timeout is 300s = 5min. So I think we are talking about your bed, extruders have normally a lower setting. Raised to slow is in heat up phase until target- PID_CONTROL_RANGE which is normally 20 so should not cause it here. Are you using 1.0.5 dev firmware with update lately? We added a own range for bed recently named PID_CONTROL_RANGE_BED which is set to PID_CONTROL_RANG if not set explicitly. Because if you were at 95.63°C at that time you should be in hold temperature mode so that error would not appear at that temperature.
>Bed Heat Manager</epr><epr pos="107" type="0" value="255"
>Bed PID drive max</epr><epr pos="124" type="0" value="80"
>Bed PID drive min</epr><epr pos="108" type="3" value="196.000"
>Bed PID P-gain</epr><epr pos="112" type="3" value="33.000"
>Bed PID I-gain</epr><epr pos="116" type="3" value="290.000"
>Bed PID D-gain</epr><epr pos="120" type="0" value="255"
>Bed PID max value</epr><epr pos="1020" type="0" value="1"
> 16:26:31.630 : Error:One heater seems decoupled from thermistor - disabling all for safety!
> 16:26:31.634 : Error:Temp. raised to slow. Rise = -5.29 after 301017 ms
> 16:26:31.638 : Disabling all heaters due to detected sensor defect.
> 16:26:31.638 : DebugLevel:14
> 16:26:31.646 : RequestStop:
> 16:26:32.236 : T:235.13 /0 B:92.70 /0 DB:2 B@:0 @:0
> 16:26:33.125 : TargetExtr0:0
> 16:26:33.129 : T:235.13 /0 B:92.70 /0 DB:2 B@:0 @:0
> 16:26:33.172 : fatal:Heater/sensor error - Printer stopped and heaters disabled due to this error. Fix error and restart with M999.
It is a known effect that fans can reduce temperature for a while. If heaters have enough power they catch up sooner or later. Normally the rang eis 20°C so when target is 100 at 80°C it would switch to hold temperature mode, which did not happen also you were at 93°C so I think that value is too low. Once holding you get a other like "Error:Could not hold temperature...". So once you reach 80°C with variance 20 only a drop down below 80 would trigger the message.
#define HEATED_BED_MAX_TEMP 120
#define SKIP_M190_IF_WITHIN 3
#define HEATED_BED_SENSOR_TYPE 1
#define HEATED_BED_SENSOR_PIN TEMP_1_PIN
#define HEATED_BED_HEATER_PIN HEATER_1_PIN
#define HEATED_BED_SET_INTERVAL 5000
#define HEATED_BED_HEAT_MANAGER 0
#define HEATED_BED_PID_INTEGRAL_DRIVE_MAX 255
#define HEATED_BED_PID_INTEGRAL_DRIVE_MIN 80
#define HEATED_BED_PID_PGAIN 196
#define HEATED_BED_PID_IGAIN 33
#define HEATED_BED_PID_DGAIN 290
#define HEATED_BED_PID_MAX 255
#define MIN_EXTRUDER_TEMP 150
#define MAXTEMP 275
#define MIN_DEFECT_TEMPERATURE -10
#define MAX_DEFECT_TEMPERATURE 290