How to Fix a Severely Clogged i1600 Printhead: Causes and Solutions for DTF and XL Cartridge Printers

Question: Do you have any tips for unclogging a severely clogged i1600 printhead? I set up the printer on Friday night, printed a few items on Saturday, then wet-capped the head. By Sunday morning, both printheads were already severely clogged. The room temperature was around 33°C. Could this have caused the clogging issue?

Answer:
At BCH Technologies, we are especially grateful for your support, including your engagement on our YouTube channel (https://youtube.com/@bchtechnologies). Your questions and feedback help us dig deeper into printer behaviors and improve our guidance for all users.

Now, regarding the clogged i1600 printhead:
What you’re experiencing is unfortunately familiar with Epson i1600 heads, especially in converted printers or when using third-party inks. Let’s break down the possible causes and some steps to resolve the issue.

Possible Causes of Sudden i1600 Printhead Clogging

1. Capping Station Seal Issues
   The most likely cause is air exposure due to poor sealing at the capping station. Even if you wet-capped the head, if the cap doesn’t form an airtight seal, it allows air to dry out the nozzles—especially for volatile inks like DTF or pigment inks.

   • Check the rubber seals on your capping station. If they’re warped, cracked, or too stiff, they won’t form a proper vacuum seal.

   • Inspect the height and alignment of the cap relative to the printhead. If it's too low or misaligned, even a fresh cap pad won't seal properly.

2. Firmware or Auto-Maintenance Errors
   Some printers are configured to perform automated cleaning or maintenance cycles. If the printer encountered an error (such as a paper jam, ink supply interruption, or firmware hiccup) mid-cycle, it may have left the printhead exposed for an extended period.

   • Review your printer logs or display to check for any errors that may have occurred during maintenance.

   • If this is a common issue, consider disabling or manually managing maintenance intervals.

3. Temperature and Humidity
   While 33°C (91°F) is warm, it’s not necessarily too hot—but high temps combined with low humidity can dramatically increase ink evaporation at the nozzles.

   • Ideal humidity for inkjet environments is around 40–60%.

   • If your workspace is too dry, consider running a humidifier nearby, especially overnight.

4. Improper Wet Capping Technique
   Simply adding a cleaning solution or leaving a soaked pad under the printhead isn’t always effective if it isn't sealed correctly.

   • Try using a specialized printhead flushing fluid and apply it directly to the cap station pad, ensuring the head rests entirely within it and seals tightly.

Solutions for Recovering the i1600 Printhead

1. Flush Through the Capping Station

   • Fill the cap station with printhead cleaning solution (specific to your ink type).

   • Park the printhead over it for several hours.

   • Perform multiple cleanings, followed by nozzle checks.

2. Manual Soaking Method (With or Without Vacuum)

   • Soak a lint-free pad with cleaner.

   • Place it on the capping station, then carefully move the printhead over it.

   • Let it sit overnight.

   • You may also consider using a vacuum purge tool to gently pull solution through the head (if your model allows).

3. Backflush via Dampers (Advanced)

   • Disconnect the damper and use a syringe with cleaner to gently backflush.

   • This should be done carefully to avoid damaging internal membranes or clogging further.

4. Avoiding Future Clogs

   • Ensure good capping pressure and no air leaks.

   • Use a humidity monitor in your room.

   • If your printer supports it, set scheduled purges to occur every few hours to keep the ink flowing.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. Therefore, we're unable to provide remote troubleshooting, suggestions, or support for printer repairs. We offer an in-person evaluation and repair service via our local diagnostic facility (https://bchtechnologies.com/printer-repair-service). Due to high demand, service is on a first-come, first-served basis, so it may take a few weeks after drop-off. Our repair service covers both full units and individual components. However, since our rates may not fit every budget, we strongly encourage self-help through online resources. A good starting point is our YouTube homepage (https://youtube.com/@bchtechnologies). Use the search icon near the “About” tab to look up specific issues—it's the fastest way to find tutorials we've created over the past nine years. YouTube’s suggestions can also help by pointing to useful content from other creators.

Thank you again for your detailed question and for being an engaged member of our community. We truly hope your i1600 gets back to printing smoothly soon!