I've been trying to print anything for the past few days. Every time I go to print something the printer stops pushing plastic out and usually the motor makes a knocking sound.
My original thought was that my E-steps were off (because they were) but I solved that and I still have a problem. Then I noticed that I was struggling with getting the PLA filament to feed into the nozzle. I assumed it was a clogged nozzle and possibly heat creep (because I was a dummy and used my old, bowden retraction settings on my new, direct extruder). I cleared out the clog and I'm able to feed plastic through after disengaging the idler arm. Though, I do struggle getting the filament into the nozzle. Maybe it's due to the Hemera's tight tolerances or due to a misalignment in the hot end, I'm not sure yet. Once I do get the plastic in, it quickly and easily pushes through and spits out of the nozzle so I think that my nozzle isn't clogged. I did do a cold pull the other day.
But I've noticed that my extruder is making a knocking sound, as if someone was gently rapping on my chamber door. I also see that the gears move one step back and forth. It looks to me that the motor is stuck or frozen. I'm pretty sure that it's not skipping steps. The sound happens at varying heights and not just the first layer. The first time I noticed it, it was printing the cabin of Benchy. Z > 1 mm when I finally decided to ask this question. The sound is kind of loud, but that's most likely the resonance in the machine than a symptom, stating it nonetheless.
- Printer: Creality CR-10S
- Extruder: E3D Hemera
- Nozzle temp: 205-220 °C
- Retraction: Initially 5 mm at 40 mm/s, then 0.3 mm, then most recently none
- Motor Vref: just north of 800 mA. (I've read somewhere that the Hemera motor wants 800 to 1000 mA)
I'm just not sure what could be wrong here. I feel like I checked all the steps and I'm just missing something.