The material failed to load wizard

This wizard has shown up because your Pro Bundle detected a problem when loading the material. This happened during a end of filament scenario.

Note: This wizard only exists on firmware 5.8.2 and newer.

The loading wizard has a few troubleshooting screens. While in the Remove filament from extrusion train screen, the stepper motor of the bay where the loading error happened is disabled. That means it is possible to manually remove the filament, by pulling it backward from the Material Station entry port. If needed, you can then feed a different piece of filament in to remove broken pieces that may have been left in the system.

Follow the troubleshooting steps below to make sure that your Pro Bundle is up and running again. These troubleshooting steps should be done while the Remove filament from extrusion train screen is active:

Identify why loading failed

The first thing to do is identify where in the extrusion train the loading failed. Identify whether the filament is:

load_material_issue_wizard3.jpg

1. Visible past the Ultimaker S5 feeder

2. Visible in the Ultimaker S5 feeder, but not past it
3. Visible past the decoupler, but before the Ultimaker S5 feeder
4. Visible in the decoupler with the decoupler extended
5. Visible in the decoupler with the decoupler not extended
6. Not visible in the back of the Pro Bundle

 

1. Visible past the Ultimaker S5 feeder

If the filament is past the Ultimaker S5 feeder, but loading still failed:

  • Check that the decoupler is fully retracted. The decoupler should be in a fully retracted state
  • Manually unload the material and check for grinds. If there is a ground down part, please cut it off according to the instructions and make sure the Ultimaker S5 feeder is clean
  • Recover the Material Station bay and re-load your filament. Wait until the wizard bay recovery step is complete before pre-loading your filament again

To prevent this issue from happening in the future, please refer to our general printing guidelines.

2. Visible in the Ultimaker S5 feeder, but not past it

  • Ensure that there is no obstruction of the decoupler. Remove any external objects that may be interfering with the decoupler or cables that may be tangled to the Bowden tubes.
  • Check if the decoupler is fully extended. If the decoupler is fully extended, and the filament gets stuck at the Ultimaker S5 feeder - you may need to clean the Ultimaker S5 feeder
  • Manually unload the material and check for grinds. If there is a ground down part, please cut it off according to the instructions
  • Recover the Material Station bay and re-load your filament. Wait until the wizard bay recovery step is complete before pre-loading your filament again

To prevent this issue from happening in the future, please refer to our general printing guidelines.

3. Visible past the decoupler, but before the Ultimaker S5 feeder

  • Check the state of the Bowden tubes. There may be internal damage or bend marks inside the Bowden tubes. This could lead to excessive friction on the filament or preventing correct loading. If that seems to be the case, please raise a support ticket for assistance
  • Check if broken pieces of filament are present. If there is broken filament present, clean the Bowden tubes by disassembling and pushing filament through

Note: Never disassemble the Bowden tubes at the decoupler end. Always disassemble the Bowden connected to the Ultimaker S5 feeder.

Warning: Unlike the broken filament instructions. It is not necessary to power off the Material Station while executing the wizard. 

  • Manually unload the material and check for grinds. If there is a ground down part, please cut it off according to the instructions
  • Recover the Material Station bay and re-load your filament. Wait until the wizard bay recovery step is complete before pre-loading your filament again

4. Visible in the decoupler - decoupler extended

  • Ensure that there is no obstruction of the decoupler. Remove any external objects that may be interfering with the decoupler or cables that may be tangled to the Bowden tubes
  • Check if the Bowden tube is fully inserted. If the Bowden on the upper side of the decoupler is not fully inserted it can create a gap where the filament can get stuck
  • Manually unload the material and check for grinds. If there is a ground down part, please cut it off according to the instructions
  • Recover the Material Station bay and re-load your filament. Wait until the wizard bay recovery step is complete before pre-loading your filament again

To prevent this issue from happening in the future, please refer to our general printing guidelines.

5. Visible in the decoupler - decoupler not extended

  • Ensure that there is no obstruction of the decoupler. Remove any external objects that may be interfering with the decoupler or cables that may be tangled to the Bowden tubes
  • Check for broken filament in the system. Check if there are broken pieces of filament in the system that could cause a collision

Warning: Unlike the broken filament instructions. It is not necessary to power off the Material Station while executing the wizard. 

  • Manually unload the material and check for grinds. If there is a ground down part, please cut it off according to the instructions
  • Recover the Material Station bay and re-load your filament. Wait until the wizard bay recovery step is complete before pre-loading your filament again

To prevent this issue from happening in the future, please refer to our general printing guidelines.

6. Material is not visible at the back of the machine

If the filament is not visible at the back of the machine, then the filament is getting stuck and not finding its way outside of the Material Station. To successfully troubleshoot:

  • Ensure that there is no obstruction of the decoupler. Remove any external objects that may be interfering with the decoupler or cables that may be tangled to the Bowden tubes
  • Manually unload the material and check for grinds. If there is a ground down part, please cut it off according to the instructions
  • Manually push filament into the system. The filament should be making its way to the back of the Pro Bundle. If this is not the case there may be:

6.a If there is no grind on the filament:

An open merger, leading to never ending filament loading. An open merger does not guide the filament to the back of the Pro Bundle. This simple repair requires opening the bottom cover of the Material Station, please raise a support ticket.

6.b An obstruction in the extrusion train, preventing the filament from continuing its path

There is likely an obstruction in the merger. The filament path was obstructed, and the prefeeder motor ground the filament down as it was unable to push it forward.

  • Obstruction, caused by broken filament in the merger. There is likely broken filament in the system which must be cleared out
  • Obstruction, caused by another bay still having filament in the merger. Check if other bays have filament fed in the merger. Try to manually pull that filament out of the system. If this is not possible, it may be necessary to turn off your Material Station
  • Recover the Material Station bay and re-load your filament. Wait until the wizard bay recovery step is complete before pre-loading your filament again

To prevent this issue from happening in the future, please refer to our general printing guidelines.

General Guidelines

  • Pro Bundle should be mounted with enough clearance in the back
  • Decouplers should at all times be free to move and not entangled by any cables
  • Bowden tubes are fully inserted above the decoupler and below the S5 feeder
  • Filament tip needs to be pre-cut in a pointy shape to avoid getting stuck
    filament-cutting-conical__1_.jpg
  • There should be no broken pieces of filament or strings in the system
  • S5 lever should be down and feeder tension properly set (about mid-range)

If the instructions above consistently fail to improve load behaviour, consider re-calibrating the decouplers following the instructions in this document.

 

 

 

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