Z-Axis Issue After Klipper Upgrade on Ender 5 Pro – Layers Stacking at Same Height

3D Printing
1

Hi all,

I’m fairly new to the world of custom 3D printers and could use a bit of help. I’ve had an Ender 5 Pro for years and recently decided to upgrade it to improve print quality. Unfortunately, I’ve run into an issue I can’t figure out.

Here’s my current setup:

  • Mainboard: BTT Manta M4P with CB1
  • Drivers: TMC2209
  • Extruder: Micro Swiss NG Direct Drive
  • Firmware: Klipper (installed via the BTT GitHub)

The printer powers on and starts printing fine, but after around 10 layers (not exactly sure), it looks like all the following layers are being printed at the same Z height. So the nozzle just dumps filament on top of the same layer, and the print fails.

I’ve tried slicing with both Cura and OctoPrint (using the Klipper plugin), but the issue happens in both.

BTW, I’ll attach my printer.cfg file here as well for anyone to take a look at.
I created the config myself and even asked ChatGPT to review it—no obvious issues were found.

Has anyone experienced something like this or know what could be causing it? Any help would be greatly appreciated!

Thanks in advance!

# Host MCU service for BIGTREETECH CB1
[mcu CB1]
serial: /tmp/klipper_host_mcu

# Main MCU for BIGTREETECH Manta M4P
[mcu]
serial: ---

[printer]
kinematics: cartesian
max_velocity: 120          # Max speed mm/s
max_accel: 1500            # Max acceleration mm/s^2
max_z_velocity: 3          # Max Z speed mm/s
max_z_accel: 50            # Max Z acceleration mm/s^2

[stepper_x]
step_pin: PC6
dir_pin: !PA14
enable_pin: !PC7
microsteps: 16
rotation_distance: 40
endstop_pin: ^PC0
position_endstop: 0
position_max: 220
homing_speed: 50

[tmc2209 stepper_x]
uart_pin: PB12
run_current: 0.800
hold_current: 0.500
stealthchop_threshold: 999999

[stepper_y]
step_pin: PB10
dir_pin: !PB2
enable_pin: !PB11
microsteps: 16
rotation_distance: 40
endstop_pin: ^PC1
position_endstop: 0
position_max: 220
homing_speed: 50

[tmc2209 stepper_y]
uart_pin: PC10
run_current: 0.800
hold_current: 0.500
stealthchop_threshold: 999999

[stepper_z]
step_pin: PB0
dir_pin: PC5
enable_pin: !PB1
microsteps: 16
rotation_distance: 8
endstop_pin: ^PC2
position_endstop: 0
position_max: 250
position_min: -5
homing_speed: 8
second_homing_speed: 3
homing_retract_dist: 3

[tmc2209 stepper_z]
uart_pin: PC9
run_current: 0.800
hold_current: 0.500
stealthchop_threshold: 999999

[extruder]
step_pin: PB3
dir_pin: PB4                      # Add '!' if direction is reversed
enable_pin: !PD5
microsteps: 16
rotation_distance: 33.5          # Adjusted for Micro Swiss NG Direct Drive
nozzle_diameter: 0.400
filament_diameter: 1.750
heater_pin: PC8
sensor_type: EPCOS 100K B57560G104F
sensor_pin: PA0
control: pid
pid_Kp: 22.2
pid_Ki: 1.08
pid_Kd: 114
min_temp: 0
max_temp: 275
max_extrude_only_distance: 120

[tmc2209 extruder]
uart_pin: PA13
run_current: 0.800
hold_current: 0.500
stealthchop_threshold: 999999

[heater_bed]
heater_pin: PD8
sensor_type: Generic 3950
sensor_pin: PC4
control: pid
pid_Kp: 62.901
pid_Ki: 1.808
pid_Kd: 547.241
min_temp: 0
max_temp: 120

# Part cooling fan (duct fan), controlled by slicer via FAN0
[fan_generic part_cooling_fan]
pin: PD2
shutdown_speed: 0
kick_start_time: 0.5

# Hotend heatsink fan (FAN1), auto on above 50°C
[heater_fan hotend_fan]
pin: PD3
heater: extruder
heater_temp: 50
shutdown_speed: 0
kick_start_time: 0.5

[board_pins]
aliases:
    # EXP1 header
    EXP1_1=PD6,  EXP1_3=PB9,  EXP1_5=PA15, EXP1_7=PA9,   EXP1_9=<GND>,
    EXP1_2=PB8,  EXP1_4=PC3,  EXP1_6=PA10, EXP1_8=PB5,   EXP1_10=<5V>,
    # EXP2 header
    EXP2_1=PB14, EXP2_3=PC11, EXP2_5=PC12, EXP2_7=PC13,  EXP2_9=<GND>,
    EXP2_2=PB13, EXP2_4=PA8,  EXP2_6=PB15, EXP2_8=<RST>, EXP2_10=<NC>
2

I don’t see the problem either.

When you aren’t printing, can you successfully move the bed further in Z when you aren’t printing, to rule out a mechanical problem?

Have you looked for errors in your klippy.log?

Have you asked on the Klipper forum?

3

Besides what Michael mentioned, have you looked at the stepper drivers power settings to see they match the previous configuration? Z motors might be stalling.

4

Hi, Yes I am able to move the bed further down.

I am not sure how to look at the previous installation since it’s a new install. Before I was working with the standard creality board for the ender 5 pro(2019). I think I will flash the board and start from scratch once again, maybe I made a mistake with the instal of klipper and mainsail.
Will let you know how it goes.

5

It might be a new install of Klipper but you were running some other firmware on there and that firmware had settings for steps-per-mm, end stops, and current settings for the drivers that board had. Or you can get the specs off the motors, determine the proper current settings for the voltage you are using and be sure that your 2209 driver settings have the currents set appropriately.
Or you can just keep increasing the power and see when your motors either stop stalling or starat getting hot.