So, I had just gotten to the point I was starting to build some confidence in my printer and my ability to set it up and leave it unattended..
(to the point I know I need to change filament providers)
Today, Disaster strikes.
I've recently had weirdness when using Octoprint getting stuck in the middle of prints, but the worst that would happen was an aborted print, maybe with a bit of a plastic blob on top, I basically reverted to using SD card printing as its more reliable.
I'm printing the last few parts for another Hadron I'm working on for a co-worker, I queued up a tiny little print (knob and a button) and couldn't be bothered running out to the shed grabbing the SD card. copying the job to it and going back out. So I sent the job via Octoprint.
The print started fine but got stuck after the first layer or so, I restarted the printer using the reset button on my Reprap Discount Full Graphic LCD controller and resubmitted the print using the SD card method instead. Watched the skirt get laid and went back inside.
When I came back, I found this.
http://www.chibiko.net/wheatley-failure/DSC_7829.JPGhttp://www.chibiko.net/wheatley-failure/DSC_7830.JPGhttp://www.chibiko.net/wheatley-failure/DSC_7831.JPGhttp://www.chibiko.net/wheatley-failure/DSC_7832.JPGhttp://www.chibiko.net/wheatley-failure/DSC_7833.JPGhttp://www.chibiko.net/wheatley-failure/DSC_7835.JPGhttp://www.chibiko.net/wheatley-failure/DSC_7837.JPGThe Hod end had slammed into the HBP and gouged it out in several places (thanks to mis-steps)
Okay I figured, Damage assessment time, I verified the limit switch was active (LED lit) then as I attempted to lift the bed, I find one of the Z steppers has come unplugged. Reattached this and tried to lift the carriage again. Only to find what I can only call weirdness. Telling the Z axis to move up using the LCD would cause the Z axis to move. make buzzing noises and then move down again on the next instruction regardless if the limit switch was active or not.
I tried a soft reset (reset button on LCD) and the issue persisted.
I did a Full power reset (at the PSU) and the printer began behaving normally again, but I can only come up with 2 theories at this point.
1.) The stepper wiring got snagged and unplugged for the first Z stepper. Causing the Stepper driver to get pissed off in some fashion (Silicon bug of some description, they happen. look it up)
2.) The earlier crash when using octoprint caused some weird bug in Marlin/The ATMega where it wasn't setting the direction pin correctly so the stepper driver sent the motor down instead of up.
Moral of the story.. Do a full power reset after any wierdness/failed prints
I havent had time to sus out exactly whats stuffed and start repairing the unit, but so far
- Heated Build Plate damaged beyond repair, I might be able to get it machined but honestly its not worth it. A new HBP or a glass pane will solve that.. $50
- Hotend Nozzle. damaged/missing (cant see it in the blob)
- Potentially a stepper driver (still need to check further)
- Potentially the Merlin hotend Heatblock (depends if the nozzle is just mashed up in the blob or if it was snapped out of the threads)
Time to start picking up the pieces. I guess I'll have that second Hadron running sooner than I expected.