I had to pause an ongoing print (because of complicated reasons) and that caused the printer to reboot (I don't know why).
When it rebooted, the Z extents were screwed up. I know this because when I gave the print again, the nozzle hit the print bed and started grinding.
The printer has an auto bed levelling function that runs before every print.
It takes three points on the bed where the sensor needle comes down to contact in a vertical to-and-fro motion. When that runs now, the head starts its vertical to-and-fro motion from a point considerably higher than where it used to start from earlier. The sensor needle does come down to touch the bed but it takes a longer time per point since the distance travelled is more now. (Hope this is clear)
To print again, I compensated for the Z-direction by giving a global offset (2.65 mm) while generating G-code. But I realised later that X and Y dimensions were incorrect (larger by 4.6% to be precise). I tested this by printing cubes of 10, 20, 30 and 100 mm. The Z dimensions are perfect though.
Also, there have been weird "lags" while printing larger objects. The print head stutters and this is causing sharp vertexes in between curves and some little blotching of material.
The printer runs on Repetier 0.92.6 and I've been reading about it but its honestly intimidating to me. Please let me know how to figure out what to change and by how much.
Edit: I agree this is quite similar to scaling issues thread here: Scaling/size issues in delta printers
I just want to know what could've caused this problem, whether there are any other possible solutions, and how to get started with Repetier framework.
Edit2: Attached image is the bottom surface of the 100 mm cube. You might notice slight charring on the bottom right corner. The masking sheet I pasted on the print bed was charred underneath. Also, it's evident that the bottom surface is not as compact at the corners as it is in the center.
What could be the possible reasons for that?