COMPLETE How to rescue a thermal runaway print

Discussion in 'Guides, Mods, and Upgrades' started by Stefan, May 5, 2016.

  1. Stefan

    Stefan Well-Known Member

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    Little guide how to rescue a thermal runaway print:
    If it is still stuck to the bed

    So your print stopped because of ... the fan argh!!11!!1.

    OK Steps:
    - Find your stating point
    E.g. go to Octoprint > Terminal tab or S3D terminal output or, or, or, or else you could try a caliper... good luck :)
    Right before the "thermal runaway System Halt" line you find the last position it tried to print like this one:

    Code:
    Send: N71694 G1 X199.057 Y155.076 E49.77390*91
    The important part is G1 X199.057 Y155.076, the end / start point​

    - Open the g-code file in a text editor
    I use notepad++, it has line numbering and bookmarks (line marking)​
    - Search for this point
    you should only find one instance... if you find more... it's harder :) to find the correct layer... caliper ?!?​
    - Bookmark the line or note the line number.
    - Search back/upwards for "G1 Z"
    this is the start of the current layer, bookmark it too.​
    - have a look on the lines around the layer change

    ; end of last layer
    G1 X38.333 Y154.092 E98.72381
    G1 E97.52381 F4200.00000 ; retract
    G92 E0 ; reset extrusion distance
    ; Our Layer change
    ; Note the Z height we need to know it so we do not crash into the print on restart

    G1 Z2.750 F7200.000 ; BOOKMARK2,
    G1 X78.260 Y150.640 F7200.000 ; move to first perimeter point
    G1 E1.20000 F4200.00000 ; unretract
    ; F1200 is important here, this is the print speed we need that.
    G1 X78.260 Y47.160 E5.83846 F1200.000 ; perimeter​
    ... Lot's of lines in between...
    G1 X199.057 Y155.076 E... ; BOOKMARK1

    - Change it like this

    G1 Z2.750 F7200.000 ; BOOKMARK2
    ... delete all line between the bookmarks and replace E.... with the F1200.000
    G1 X199.057 Y155.076 F1200.000 ; BOOKMARK1

    - Go all the way up to the top, you should find a lot of comments (lines starting with ";")
    and your start g-code like this:

    M107
    ;BigBox Printer Start Script Begin
    ;relies on M83 (use relative extrusion distances)
    M117 Preparing
    M140 S70 ;set bed temperature
    T0 ; select extruder 0
    M104 S190 ;set extruder temperature
    ;home
    T0 ; select extruder 0
    G28
    ;move to dock
    T0 ; select extruder 0
    G1 X70 Y200 F3000 ; move to position in front of dock
    G1 X70 Y240 F3000 ; move into dock
    ;heat bed
    M190 S70 ;wait for bed temperature
    ;heat extruder 0
    T0 ; select extruder 0
    M109 S190 ;wait for extruder temperature
    ;prime extruder 0
    T0 ; select extruder 0
    G1 E15 F200 ; reverse end of print retraction
    G1 E10 F50 ; extrude 10mm
    G92 E0 ;Reset E

    ;move out of dock
    T0 ; select extruder 0
    G1 X80 Y240 F3000 ; move to position in dock
    G1 X80 Y200 F3000 ; move out of dock

    M117 Print starting

    ;BigBox Printer Start Script End
    G21 ; set units to millimeters
    G90 ; use absolute coordinates
    M82 ; use absolute distances for extrusion
    G92 E0
    G1 E-1.40000 F4200.00000
    G92 E0
    G1 Z0.320 F6000.000
    G1 X118.604 Y91.248 F6000.000

    - Change it like this

    ; lift nozzle above the print... remember the Z2.750 from bookmark2 ? add some safety to it.
    G1 Z25 F5000
    T0 ; I have dual and I'm printing with the left extruder
    M107 ; disable fan
    M190 S70 ; set YOUR bed temperature
    M104 S220 ; set YOUR extruder temperature
    G28 ; home all axes
    ; again lift nozzle above the print...
    G1 Z25 F5000

    M109 S220 ; wait for temperature to be reached
    G21 ; set units to millimeters
    G90 ; use absolute coordinates
    M82 ; use absolute distances for extrusion
    T0 ; select extruder 0
    G92 E0 ;Reset E
    G1 E15 F200 ; extrude some plastic to be sure it's working
    G1 E1 ; retract some
    G92 E0 ;Reset E
    ; move to start position
    G1 X199.057 Y155.076 F1200
    ; Lower the nozzel to start height, remove the feedrate so the last (1200) is used from now on.
    G1 Z2.750 ; same as BOOKMARK2
    ... delete all lines down and including bookmark2
    G1 X199.057 Y155.076 F1200.000 ; BOOKMARK1
    ....A lot more lines to print...
    - Search and replace all "M106 S255;" with "M106 S0;"
    To disable the fan completely or set it lower if you like.​
    - Save the file and print the file.
    - Remove the test extruded plastic and what the magic happen :D


     
    #1 Stefan, May 5, 2016
    Last edited: May 5, 2016
    Mike Kelly and Colin like this.
  2. Stefan

    Stefan Well-Known Member

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    Btw this helped me to times now :D
     
  3. Michael Meixner

    Michael Meixner New Member

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  4. Stefan

    Stefan Well-Known Member

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    This maybe true, but I did not have any luck with S3D it always does strange stuff, crashing into the bed.... "When I have time" TM I wil give it a try again.
     
    Colin likes this.
  5. Stefan

    Stefan Well-Known Member

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    Now I use S3D most of the time with success :) and @Michael Meixner is right, it is simpler with S3D and "Start printing at height"
     

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