Managing a Partially Clogged Printhead on an Epson Printer with DX7 Printheads

Question: How can I address a partially clogged Epson DX7 printhead for an Epson P800 printer, and what are my options for unclogging it?

Answer:

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Firstly, it’s important to note that at BCH Technologies, we do not work directly on printheads due to the extensive time required and the high costs associated, which often do not justify the repair. However, based on the nozzle check you provided, it seems your Epson DX7 printhead is not severely clogged, as only a few pixels are missing. This issue might not necessarily be a clog but could be caused by air bubbles, which should resolve themselves after a few hours of operation. Alternatively, the issue could be due to dried ink or debris. In the case of dried ink, extensive cleaning might be required, which could risk further damage to other functioning nozzles. If debris is the cause, it may result in a permanent blockage where little can be done to rectify the issue.

Given these possibilities, it might be better to continue using the printer as is without further intervention. Over-cleaning is a common mistake; many users refer to the nozzle check for clarity on whether to continue cleaning. However, this can lead to overzealous cleaning practices that might ultimately damage the printhead. Instead, I recommend printing a CMYK block to see if the printer can produce good quality prints despite the nozzle check pattern. This approach often reveals that the printer performs adequately even if the nozzle check suggests otherwise.

Example of CMYK block that we use:

We use a common CMYK block, resize it to 30x30, and repeat 10 times. This can tell us 1) if color comes out alright, 2) if the left margin is good and 3) if the width (300 mm) is good. We only use nozzle check when we need to fix a printer related problem, not production problem.

If print quality is still below your expectations, consider using high-resolution settings on your printer. With a Raster Image Processor (RIP) software, adjust your printer’s settings to produce less ink per dot but increase the resolution, allowing multiple nozzles to cover the same area, thus compensating for any missing nozzles. The 'boost' setting in many printers maximizes ink output, which could expose missing nozzles more prominently. Adjusting this setting can help blend in the color output more seamlessly. 

If your RIP software includes a "boost" setting, consider using your printer's standard driver instead. Typically, the standard driver emits less ink but at a higher resolution, allowing each area to be covered multiple times by different nozzles. This technique enables you to increase the color ink percentage, achieving a color output comparable to the "boost" setting. The "boost" mode is designed to maximize ink output from the nozzles, which can make missing pixels more noticeable. By using the standard driver, you can more effectively conceal these imperfections.

Another practical tip is to swap the damper from a color channel that is less critical. For example, if white channels are not as crucial and are performing well, you might swap a black damper with a white one. This is because a few missing nozzles in the white channels are usually less noticeable. After this swap, redefine your color sequence in the RIP software to accommodate the change.

Addressing printer issues such as a partially clogged printhead can indeed be complex. While we do not provide remote troubleshooting, our local diagnostic facilities are available to offer in-person evaluations and repairs. You can find more information and schedule a service at BCH Technologies Printer Repair Service. We operate on a first-come, first-served basis, and while our rates may not be the lowest, we ensure detailed and effective solutions. Alternatively, exploring self-help options through our YouTube channel and other online resources can also provide beneficial insights.

Thank you again for your query. Should you have further questions or require additional assistance, please feel free to contact us. Your inquiries help us improve our service and provide valuable information to our community.