Heater Faults

Heater faults are protective mechanisms built into the printer's firmware to prevent damage or fire hazards. When the control system detects abnormal temperature behavior - such as a spike, drop, or slow heat-up - it triggers a fault and shuts off the heater.

This guide covers what causes heater faults, how temperature sensors work, common fault scenarios with their symptoms, and step-by-step troubleshooting to diagnose, fix, and prevent these issues.

Tools & Materials

Before starting troubleshooting or maintenance, gather the following:

• Replacement Temperature Sensor - for hotend, bed, chamber heater, or chamber
• Thermal Conductive Paste - ensures optimal thermal contact when installing a new sensor (e.g., Boron Nitride paste)
• 2 mm Hex Screwdriver or Allen Key - for accessing panels or sensor mounts
• Protective Gloves - for handling hot components

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How Temperature Sensors Work

1. Basic Principle - The temperature sensor changes its electrical resistance in response to temperature changes. The printer's firmware measures this resistance and converts it into a temperature reading in Celsius.

2. Firmware Monitoring - The control system continuously checks if temperature increase or decrease matches predicted values. If the system detects a sudden spike, drop, or slow rise during heat-up, it triggers a heater fault to protect the machine.

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Common Heater Fault Scenarios

Below are the main scenarios that trigger heater faults, along with typical symptoms, possible causes, and recommended fixes.

1. Temperature Spikes Up

Symptom: The temperature graph shows abrupt upward spikes (potentially reading up to 2000°C).

Possible Cause:

• Poor connectivity or loose/disconnected wire in the temperature sensor circuit
• Damaged or improperly seated wiring inside the distribution block

Diagnostic Steps:

1. Power off the printer.
2. Check and reseat wiring connections in the distribution block:
   • Press the orange tab to release the wire
   • Inspect the wire ends and crimps for damage
   • Reinsert securely

3. If spikes persist, replace the temperature sensor.

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2. Temperature Spikes Down

Symptom: The temperature suddenly drops on the graph (potentially down to -273°C).

Possible Cause:

• Short circuit in the sensor wiring (worn insulation causing wire-to-wire contact)
• Severely damaged or frayed sensor cables

Diagnostic Steps:

1. Power off the printer.
2. Inspect the temperature sensor wire thoroughly for cuts or exposed metal.

3. If damaged, replace the temperature sensor.
4. Check the heater wires on the tool head as well - any fraying must be addressed.

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3. Inadequate Heating Rate (Slow Heat-Up or Sudden Cooling)

Symptom:

• The printer stops heating and displays a "temperature lower than expected" error
• Temperature fails to rise fast enough or drops suddenly during printing

Possible Causes:

1. Cold surface on a hot bed - Placing a cold build surface on a hot bed can rapidly cool the plate
2. Open chamber - Leaving the door open while heating to high temperatures (200°C or more) causes heat loss
3. Excessive cooling fan - High airflow on the nozzle or build plate drops the temperature below target

Fixes:

1. Close the printer door/lid when heating to maintain a stable chamber.
2. Preheat or at least allow the build plate to partially reach its set temperature before placing a cold build surface.
3. Reduce part cooling fan speed in your slicer or use a silicone sock to insulate the hotend.

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4. Temperature Oscillation (Wavy Line on the Graph)

Symptom: Instead of staying near the setpoint, the temperature line oscillates up and down in a wavelike pattern.

Possible Cause: PID (Proportional-Integral-Derivative) control settings are off, causing the system to over- and under-shoot the target temperature.

Fixes:

1. Perform PID Tuning:
   • Open the Web Interface
   • Go to Dashboard > Macros tab
   • Navigate to System > Calibration > Temperature Tuning
   • Choose the appropriate macro for the affected heater

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5. Inaccurate Temperature Readings at Ambient

Symptom: After the machine is completely cooled to room temperature, most temperature sensors read a similar ambient value, but one sensor reads significantly higher or lower than the others.

Possible Cause:

• Higher-than-ambient reading (while physically cold to the touch): often indicates a loose contact or partially disconnected sensor
• Lower-than-ambient or negative reading (while physically cold to the touch): often indicates a short circuit or frayed/damaged wires

Diagnostic Steps:

1. Confirm the machine is cold:

   • Use an IR temperature gun to verify temperature
   • If safe, carefully touch the component (bed or tool head)

2. Check the suspect sensor:

   • If it reads higher than ambient but is cold to the touch, inspect all wire connection points (distribution block, mainboard, tool head wiring) for looseness. Reseat if necessary.
   • If it reads noticeably lower or negative, look for wire damage or frayed insulation that could cause a short.

3. Replace the sensor if wiring is damaged:

   • A sensor that continues to read incorrectly after reseating or repairing connections may need to be replaced.

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General Step-by-Step Troubleshooting

1. Check for External Factors
   • Ensure the printer door is closed and fans are set appropriately.
   • Remove any cold surface from a hot bed to prevent sudden temperature drops.
2. Inspect All Connections
   • Power off the printer.
   • Locate the distribution block for your tool head or build plate.
   • Press the orange tab(s) to release each wire, inspect, and re-seat them firmly.
3. Replace the Temperature Sensor (If Needed)
   1. Power Off and unplug the printer.
   2. Disconnect the old sensor from the distribution block.
   3. Apply thermal conductive paste to the new sensor if required.
   4. Insert and secure the new sensor wires.
   5. Power on the printer and test for stable temperature readings.
   • The replacement procedure for the Head Temperature Sensor is detailed separately here.
4. Perform a Test Heat-Up
   • Heat the nozzle or build plate to a moderate temperature (e.g., 150-200°C).
   • Observe the temperature graph for any unusual spikes or drops.
5. Run PID Calibration (Optional but Recommended)
   • Use the printer's built-in macro to recalibrate temperature control parameters.
   • Ensure the hotend/bed is at ambient temperature before starting.
   • PID Tuning Guide

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Support

If you could not find an answer here, reach out to our support team.

If you encounter persistent errors after reseating wires and checking for damaged sensors, reach out to our support team.