I had this with mind last night, 10 hour print and it happened at hour 9, turned out it was a blocked 0.2mm nozzle, which unfortunately did not make it!
Late reply, but this can happen when you are trying to push more filament through the nozzle than the hotend and extruder can handle reliably.
It is a fairly complex issue, because whether it appears or not can depend on the model, the infill pattern, the infill density, the layer settings, the nozzle size, and the material itself.
I have a PEBA profile for printing solid parts, and if I use circular infill, I occasionally trigger an extruder overload. With that profile at a flow ratio of 1.00, the error can occur from time to time. If I lower the flow ratio to 0.98, the overload no longer occurs, but I then get a slight dimensional inaccuracy in the printed part.
Smaller nozzle sizes make this easier to trigger, because they generally tolerate less volumetric flow.
If you run into this error, you can try adjusting the flow ratio, reducing the volumetric demand, changing the infill pattern or infill density, or checking for partial clogging. In other words, the problem occurs when the system is being asked to extrude more material than it can process cleanly under those conditions.
With my PEBA profile, I can still use a flow ratio of 1.00 without any overload errors as long as I am not printing fully solid parts. I also avoid the issue if I reduce the infill level or change to a less demanding infill pattern.
First of all, don’t lose hope or get frustrated. Been in your exact shoes. First question, when you turned in your ticket, did you include lots of pics? If not, start sending pics, they love pics. It will save you some time. Second question, have you been through the wiki on the extruder? If not, do it. Third question, hopefully during that week of use, you printed the tool you need to remove the front of the extruder?
Mine took about 3 weeks to resolve and a brand new extruder. I feel your pain.
Had this issue early on but haven’t had it since I stopped using custom filament settings. I cannot vouch for if it’s true but there was a Reddit chain talking about how sometimes the printer would go into heating mode instead of cooling at certain filament settings. I watched my custom filament profiles actually do this and stopped the prints and switched to “generic” and have not had it happen since. There is probably some way more complicated reason for this actually happening but right now just keeping watch in whether mine heats or cools (depending on type of print) and not using certain custom filament settings until I hear what actually is happening.
Sorry if already covered, I didn’t read the entire thread.
You can get motor overload errors when running the Maximum Volumetric Flow calibration when you try to flow the filament too fast for the extruder at the given temperature etc.
I would try doing this calibration with the filament and the profile. Use the default start / end points. Then check the settings in the profile to make sure it’s not trying to flow the filament faster than it can.
Max Flow Rate on this page:
Likely not your issue, but I was running into the same problem on my H2D with a particular filament and couldn’t figure why.
Turns out the retraction settings were wayyy off. It was set to something like 3 or 4mm which is way to much for a direct drive extruder. After fixing the retraction settings, no more extruder overloaded error.
Привет. Нужно снять датчик подачи филамента, который находится ниже шестерен экструдера. На нем стоит плата с датчиком Холла. Горячий пластик прилип к стенкам отверстия и не продавливается. У меня такое было.
After 600hours of printing the clicking sound happens here too.
I keep an eye to the vortex hot end #4 , I cold pull a filament and seemed to solve the issue
However after a second print clicking sound (extruded motor overload) happen again.
I removed the current hotend and the other hotends from the vortex seems to work fine will see
My problem sort of cascades from yours. I am unable to remove either PTFE tube from the toolhead. The releases push down like they should, but neither tube will budge.
Not sure if this will help anyone but this has happened to me to my A2L, A1, and now my H2C, and after taking them all apart and troubleshooting, it has ALWAYS been the nozzle for me. I am not sure. I am printing Sunlu PLA black filament at 255 C, so maybe that could be the reason my nozzles are all degrading? But i jsut wanted to come on here and express my frustration and my solution.