[BUG] <5T XL Printer stops during color prints without error>

[corywagner]

Please, before you create a new bug report, please make sure you searched in open and closed issues and couldn't find anything that matches.

Printer type - [Prusa XL 5 toolhead (upgraded from 2T]

Printer firmware version - [6.0]

Original or Custom firmware - [Original]

Optional upgrades - [None]

USB drive or USB/Octoprint - [USB]
Please let us know if you print via USB flash drive or USB/Octoprint [USB]

Describe the bug

Prusa stops printing sometime during print. It only seems to happen with long, muti-color prints (I have a 5T XL). Stops randomly. Inducing power panic usually allows it to resume (for a while). There are no errors and the printer log does not indicate a failure. If I induce power panic, it will resume right where it left off. Sometimes it will complete the print, sometimes it will fail later.

Here is what I tried:

• Replaced thumb drive with 2 different "high reliability" drives. Prints still inevitably failed on each.

• Ensured that drive was formated for FAT32 and uncorrupted

• Bought a Triplight UPS in case power fluctuations were causing it. Again, problem remains.

• Used a USB extension cable

• Rigged a heat sink to the USB stick

• Completely reset and re-calibrated the printer

• Upgraded to 6.0 firmware

• Disabled PrusaConnect and PrusaLink and printed directly from USB drive

• Used different sliced models, so I don't think it is a gcode issue

How to reproduce
Unfortunately, I can't reproduce it at-will. It happens during long color prints. It does not see to happen with single color.

Expected behavior
I expect it to complete the print, or at least throw some error so we can troubleshoot.

G-code
Tried to attach bgcode, but would not let me.

Crash dump file
Please send the crash dump file to Prusa by emailing it to reports@prusa3d.com. Sharing this file is important and helps us investigate the bug.
Do not share the file publicly, as the crash dump contains a raw snapshot of the printer's memory and may include unencrypted sensitive information.

Unfortunately, there is no crash dump file to send because the printer does not know it crashedVideo

Please attach a video. It usually helps to solve the problem.
No video because I am never in the room when iit fails. Pic attached for what it is worth.

[Mr3Deee]

I have seen the same problem - BUT I didn't even need to do a multi color print for this. I had a simple PETG single color print which casued this. It happened many times (about every 30 minutes). In the end it wasn't even able to continue the print and it stopped.

My solution was to disable PrusaConnect. My feeling is/was that this was due to concurrency where multiple clients tried to access the same USB stick at the same time.

Someone else was raising the comment that there might be hardware problems. As I was assmbling the 3D printer, I know that the cabeling was a standard ribbon cable and as such it might be suceptibe to EMV. The stepper motors might therefore be feeding stray signals into the wire which will cause the USB bus to become unusable (and time out) for a short time. However I hope that this is not it. One thing to try is to use 6.0.0, turn Prusa connect and Prusa Link on buit the new "silent modes" off and see if it still happens.
IF this would be USB stick related, it MIGHT be a good idea to use an empty and / or a slow (or fast) stick. If there is enough power coming out of the port you might want to try using an external SSD drive(?) If it gets even worse (faster errors) it might be a good indication for HW problems.

[GeasyCreasy]

I have the same issue. There is a large thread on Prusa forums that describes the same problem. (https://forum.prusa3d.com/forum/original-prusa-xl-tool-changer-hardware-firmware-and-software-help/usb-error-mid-print/paged/4/)

The issue is maddening! Upvote to get this problem addressed quickly please!

[ddrl46]

I have also been running into this issue very consistently while attempting to print a fairly short single-material print. Every time the printer halts with a "USB drive or file error, reconnect the drive". Sometimes the print is recoverable from this point by reconnecting the USB stick, however quite often the USB stick is not recognized anymore until the printer is reset via the front panel.

Attempting to disable phase-stepping as well as prusa connect / networking all together did not resolve the issue. I've tried multiple types of USB stick, all with the same result.

As a last ditch effort I downgraded to 6.0.0-alpha, which is was previously running without issue, and after doing so I was able to print the same g-code I was previously having issues with multiple times without any issue. Attached is the g-code in case it helps.

Quarter Baseplate HBM Ladekast v1_0.4n_0.2mm_PETG_XLIS_1h56m.zip

[tsamisa]

I have the same issue. I downgraded to 5.1.2 to be able to print

[Blizzke]

I have the same issue with 6.0

4 color / 4 hour print stopped at 33% (halfway in a layer) without any message or error.
Knob was still active so I "paused". Status went to "pausing" right away, but it took almost 2 minutes before the printer actually responded by lowering the build-plate and parking the head.

Had a pretty huge blob of filament which I cut away as best as possible and then resumed.
The print finished without any further issues.

(Print was via connect, if that makes a difference)

[goodridm]

I had this happen the other day at the 48% point of a 3 day print. The printer just stopped at what seemed to be the end of a layer before color change. I noticed the nozzle temp was dropping and Prusa Connect said it was cooling to 70C from 250C. I set it back to 250C and it seemed to heat back up, but no printing resumed. I pressed Pause on the printer and it just seemed to stick at "Pausing...". I couldn't resume from Prusa Connect. The display responded via sound to my clicking, dial moving, but nothing happened. I pulled the plug and plugged back in to induce a power panic. The print job resumed! However, I ended up with a slight layer shift.

The model was 20MB 3mf file, 11.83x11.97x12.07, 1722592 facets, two colors, 1499 tool changes

[madnotangry]

I have had this happen on several different prints. The XL would pause during a print with toolhead changes or single color prints alike, sit for about a minute or two, and then park itself without an error or notification at all. It would let me resume it from the LCD, but I couldn't connect to the printer with Prusa Link or Prusa Connect unless I cycled power to the printer. I tried to alleviate the problem with a Hard Reset, reflashed the 6.0.0 firmware, and had the problem continue.

I downgraded to the 6 alpha firmware and have had no problems whatsoever.

[TheShuttlesworth]

Currently experiencing this issue. I have so far had two stoppages, within 10 minutes of each other, on a 4 hour total print. Multi-material (2), sent through Prusaslicer via Prusa Connect, running 6.0.0 firmware, Prusaslicer 2.7.4. It seems to happen on tool changes, right before it picks up to go to the back. I have cut power and it has started back. Trying the pause, pull USB stick, etc. has not worked. Firmware 6.0.1 just released, but I don't want to lose this print. I will report back if it comes up again in 6.0.1.

Edit: I did forget one detail. I have Variable Layer Height set for this print. I don't think that would cause the issue, but I wanted to include all the detail I could.

[Torx999]

Have the same issue with 6.0.1