Rep2 x axis malfunction

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bill

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Nov 29, 2022, 7:59:46 AM11/29/22
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I have a Makerbot Rep2 that has been a wonderful reliable workhorse for years. Occasionally I have to fix or replace something and it works again. I have a problem now that I can't seem to fix. Partway into a build the gantry moves to X min (full left side) makes a grinding noise and the shifts back to the build area but about 75mm to the right of where it was when it shifted to the left. The print fails as the extruder is now printing in the air - not where it left off. It seems to happen about 5 minutes into the build. I have tried different models including some of the x3g files provided by Makerbot as samples. All of them fail after 5-7 minutes of normal printing.

I have replaced the full x-y-z motor wiring harness including the x axis cable extension and the x axis endstop cable extension.

When I go into the jog mode it moves properly.

Anyone know what the problem might be?

(I am certain it is not a slicer issue.)

Lukas Jakubisin

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Nov 29, 2022, 1:23:46 PM11/29/22
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Hi Bill,

When I got my Rep2 recently, I did some firmware updates as it was running older version. When I've used the MakerWare, it was working fine but I had no end of issues printing with Simplify3D. The offsets were all wrong and also the extruder stopped feeding the filament few minutes into the print. I couldn't figure it out so I gave up. Later the firmware crashed completely to a point where the printer wouldn't even switch on. I have managed to flash the firmware, done the updates and suddenly everything worked fine, the offsets were correct and also the extruder issue was fixed and now I only use simplify3d without any issues. I would suggest you try flashing firmware and see if that helps.
I'm not sure what version you are running but you can flash it to sailfish7.8 beat with cooling fan speed control via replicatorG using this link in settings as the source: http://s3.amazonaws.com/sailfish-firmware.polar3d.com/beta/firmware.xml

Thanks

bill

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Nov 30, 2022, 8:37:08 AM11/30/22
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Thanks Lukas but I don't want to go that route. And I don't have a clue how to go about it if I did want to try it! I really don't think it is a firmware issue unless somehow the original firmware got corrupted. It has worked for years with the original firmware

Lukas Jakubisin

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Nov 30, 2022, 2:24:10 PM11/30/22
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Hi Bill,

Understood. You can always flash it with the original firmware that was released by makerbot. I think it's worth trying as it could get corrupted, same as it happened to me and it won't do any harm either. I'm happy to guide you through the process, it's pretty straight forward. I believe you can do it via MakerWare software, if not then ReplicatorG would definitely do it in few clicks. Let me know and I can post a quick guide and some pictures if you would like. :)

Just out of curiosity, what slicer are you using?

TobyCWood

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Dec 8, 2022, 5:59:54 PM12/8/22
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Actually it sounds like a bad cable to the stepper motor. Easy to test. First manually from the hi panel jog X and y to see which one is misbehaving… then swap the cables. If the other axis stops working then you know it’s a cable. Cables are relatively easy to replace.

Bill Westheimer

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Dec 8, 2022, 6:00:48 PM12/8/22
to Lukas Jakubisin, Makerbot Users
I finally got a few minutes to work on my makerbot rep2. I updated the firmware as Lukas indicated using the software you so kindly provided. As he said, it was easy. I reset the bot to defaults, switched it off and waited a few minutes, turned it back on, reloaded the filament, ran the stretchlet.x3g file (provided by MB) and same thing. ;-(

But then I noticed that the active cooling fan duct was too close to the build plate and was dragging on the model that was building, so I fixed that.
I also noticed that the metal lever which presses on the button of the x-axis endstop switch was missing, so I have ordered a replacement for the endstop switch!

Then I tried a 3dbenchy file that I sliced in simplify3d and it worked. ;-)

Then I tried the stretchlet.x3g file and it failed as before. ;-(

Then I tried a file that I created and sliced in simplify3d which is just a 15mm x 15mm x 100mm column and it worked.  ;-)

So it appears to be a combination of problems but mostly a corrupted stretchlet.x3g file.  ;-(

I have ordered another set of xyz motor and endstop wiring harnesses again just in case I ever need them.

Thanks for helping out.
=B=
Bill Westheimer


”Art is not what you see, but what you make others see."

-- Edgar Degas



On Wed, Nov 30, 2022 at 3:27 PM Lukas Jakubisin <bish...@gmail.com> wrote:

Hi Bill,

 

I have just checked and you can only flash original firmware with makerware and sailfish with RepG.

Not to worry though, in the link bellow on my google drive you will find the makerware software and couple screenshots on how to flash it. It takes about 4 clicks.

Once you connected your printer, it will show as connected in the MakerWare, then you click on MakerBots tab. Then you click on Upload Firmware and just follow the steps there, it’s straight forward.

The link:

https://drive.google.com/drive/folders/13G2wyaZ9-tBx0MDDTRZQ1eKqFpa15HES?usp=sharing

 

I would suggest you try the sailfish as well, you can always revert back to original with the above instructions. I believe there are improvements in print quality and other bits. I have only recently got my replicator2 and went straight to sailfish firmware so can’t really compare it but I have only read good comments on the sailfish firmware. My prints come out great to be honest. On my drive there is also RepG you can download with some screenshots on how to do it to the latest one. It’s up to you but let me know if you decide to and need help.

 

Thanks

 

 

 

Sent from Mail for Windows

 

From: Bill Westheimer
Sent: 30 November 2022 19:35
To: Lukas Jakubisin
Cc: Makerbot Users
Subject: Re: [makerbot-users] Re: Rep2 x axis malfunction

 

HI Lukas,

I don't have makerware any more, I switched to simplify3d long ago.

Sure, if you can provide instructions for ReplicatorG then I can probably do it.

Thanks,

=B=

Bill Westheimer

 

”Art is not what you see, but what you make others see."

-- Edgar Degas

 

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Andy Cohen

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Dec 9, 2022, 10:52:33 AM12/9/22
to Bill Westheimer, Makerbot Users
Bill
Iirc…
That missing metal lever was per their design. It’s not broken.

Sent from my iPad

On Dec 9, 2022, at 3:24 AM, Bill Westheimer <bi...@billwest.com> wrote:


Hi Toby,
Thanks, but I don't think it is the cable. I replaced it recently. I did test the jog mode and it works fine.

I now think the problem is with the stretchlet.x3g file.

I also noticed that the x axis endstop switch is missing the metal lever which actuates the switch so I will be replacing the x axis endstop assembly as soon as it arrives. But I don't think it is what is causing the problem. I think the stretchlet.x3g file somehow got corrupted.  I was able to successfully print a benchy model and another test file.  I will report back to the group as I learn more.
=B=
Bill Westheimer


”Art is not what you see, but what you make others see."

-- Edgar Degas


On Thu, Dec 8, 2022 at 5:59 PM TobyCWood <andyc...@gmail.com> wrote:
Actually it sounds like a bad cable to the stepper motor. Easy to test. First manually from the hi panel jog X and y to see which one is misbehaving… then swap the cables. If the other axis stops working then you know it’s a cable. Cables are relatively easy to replace.

On Tuesday, November 29, 2022 at 4:59:46 AM UTC-8 bill wrote:
I have a Makerbot Rep2 that has been a wonderful reliable workhorse for years. Occasionally I have to fix or replace something and it works again. I have a problem now that I can't seem to fix. Partway into a build the gantry moves to X min (full left side) makes a grinding noise and the shifts back to the build area but about 75mm to the right of where it was when it shifted to the left. The print fails as the extruder is now printing in the air - not where it left off. It seems to happen about 5 minutes into the build. I have tried different models including some of the x3g files provided by Makerbot as samples. All of them fail after 5-7 minutes of normal printing.

I have replaced the full x-y-z motor wiring harness including the x axis cable extension and the x axis endstop cable extension.

When I go into the jog mode it moves properly.

Anyone know what the problem might be?

(I am certain it is not a slicer issue.)

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