Epson XP-15000 DTF Error During Power-On: Printhead Gets "Locked" on the Capping Station (Gear/Trigger Causes)

Question: I have an Epson XP-15000 that I use for DTF. When it was new, I waterproofed the printhead using supplies from your store and guidance from your videos, and it has printed fine for a couple of months.
Today, during the power-on sequence, the capping station looks like it's locking the printhead, but not correctly. The printhead tries to move away and gets stuck, which triggers an error code on the screen. If I power the printer off and back on, it releases and then repeats the same problem again. I recorded the behavior (it happens around 35 seconds to 1 minute in the video).
Have you seen this before? I thought about reflashing the Inkchip firmware, but I don't think I can get the printer into the right mode while it's stuck-and it would be the same firmware that's already installed anyway.

Answer: 

Yes-this is something we do see, and based on your description, this issue is far more likely to be mechanical (capping station / gear drive / trigger mechanism) than firmware-related. In most cases, reflashing firmware won't resolve a situation where the printer's physical service station can't complete its motion cycle.

What's happening during the power-on sequence (why the head gets "stuck")

During startup, the XP-15000 runs a service routine that typically includes:

• Confirming the carriage can unlock and move freely

• Parking and sealing the printhead on the cap

• Cycling the service station (cap lift/lower, wiper movement, pump/cap engagement depending on the model)

If the printer expects the cap mechanism to move to a certain position and it doesn't (or it overshoots/undershoots due to a jam), the carriage can end up:

• Held in place when it tries to move away, or

• Blocked by the cap assembly, wiper assembly, or gear timing

That mismatch creates a "carriage can't move correctly" condition, which triggers an on-screen error code (you didn't list the exact code, but the code appears as a result of the mechanical stall you're describing).

Most likely root cause: the capping station and its gear-driven mechanism

Your symptoms line up with a capping station that is not returning to its proper home position, or a gear train that has slipped timing. The XP-15000 service station is gear-driven, so even a small obstruction-dried ink, debris, friction, or misalignment-can cause the gears to:

• Bind

• Jump teeth

• Stop mid-travel

When that happens, the printer can "lock" the head at the wrong moment and then the carriage tries to travel away while something is still engaged.

What to check first (most common culprits)

1. Capping station movement

   • Does the cap lift and lower smoothly?

   • Does it look skewed or tilted (one side higher than the other)?

   • Is anything preventing it from fully returning?

2. Wiper area contamination

   • Heavy ink buildup can create drag or physically block movement.

   • DTF usage often accelerates ink sludge around the service station area.

3. Gear train / gear timing

   • Because it's gear-driven, one small slip can offset timing.

   • A timing offset can make the cap "meet" the printhead at the wrong point in the movement cycle.

The white trigger behind the rail (important!)

Yes, you should also check the white trigger/lever on the back of the rail (behind the carriage) because that mechanism often drives or signals the gear movement that controls the capping station sequence. If that trigger is:

• stuck,

• not returning fully,

• mis-seated,

• or obstructed,

...it can cause the printer to behave exactly as you described-repeating the same startup failure every time because it cannot complete the expected mechanical sequence.

Why firmware reflashing likely won't help here

Your logic is sound: even if you could reflash Inkchip firmware, you'd be installing the same package-and more importantly, firmware doesn't fix a service station that:

• can't move due to physical resistance,

• is mistimed mechanically,

• or is stuck in a position the printer can't correct.

When the machine can't pass its mechanical initialization checks, it throws an error and stops-regardless of firmware.

About the error code

You mentioned that an error code appears on the screen, but you didn't include the exact code number. In general, when the printhead carriage is physically blocked by the capping station, the printer may show a carriage/service error because it detects abnormal resistance or incomplete travel. If you capture the exact code text/number in the future, it can help narrow whether the printer is complaining about a carriage lock, service station positioning, or a sensor/state mismatch.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. So, we're not able to provide remote troubleshooting, suggestions, or support for printer repairs. We offer an in-person evaluation and repair service via our local diagnostic facility, Printer Repair Service (https://bchtechnologies.com/printer-repair-service). Given the high demand, we operate on a first-come, first-served basis, so it might take a few weeks before we can get your printer in for drop-off. Our services are structured to repair either a whole printer or specific parts, with clear instructions on how to proceed. However, we acknowledge that our rates aren't the most economical. Thus, we highly recommend that you resort to self-help via online research. You can start by checking out YouTube or visiting our YouTube channel's homepage at BCH Technologies on YouTube (https://youtube.com/@bchtechnologies). Look for specific videos using the search icon next to "About" on the right-hand side of the menu bar. I receive dozens of queries every day asking about videos for specific topics. Having created videos over the past nine years, it's challenging to remember every single one. Therefore, using YouTube's search function would be most efficient. Plus, YouTube might suggest relevant videos from other channels that could assist you.

Thanks again for reaching out and for supporting BCH Technologies-especially for using our waterproofing supplies and learning through our videos. We truly appreciate it, and I hope you're able to get that capping station mechanism back to normal operation quickly.