How to Fix Epson XP-440 Stuck in Printer Mode, Firmware Update Failure, and Ink Out Error

Customer Question:

I have an Epson XP-440 that’s stuck in Printer Mode. The firmware update failed, and I followed your YouTube method, but the menu screen didn’t appear. While connected via USB, I entered Program Update Mode by pressing the Stop, Left, Down, and Power buttons. I downloaded and installed the firmware successfully, but the printer never powered off automatically—it flashed for 40 minutes. I finally unplugged it, and now I'm back to square one. Also, I’m getting an “Ink Out” error. Any suggestions? I’m losing confidence in Epson. Do you have any recommendations for alternatives?

Answer:

Understanding "Printer Mode" and Firmware Update Failures

When your printer gets stuck in Printer Mode, it’s typically because the firmware update process didn’t complete successfully. You did a great job navigating into Program Update Mode using the key combination—many users aren’t aware of that trick. However, if the printer firmware installation doesn’t auto-complete or restart the machine, it’s often because of a deeper issue with the EEPROM (Electrically Erasable Programmable Read-Only Memory).

Here are the most likely reasons for the symptoms you're seeing:

1. EEPROM Data Corruption

• Cause: Interrupting power (e.g., unplugging the printer or a failed firmware flash) during writing to EEPROM.

• Effect: The printer fails to boot, freezes in “Printer Mode,” or the firmware doesn't fully load.

• Fix: Sometimes re-flashing using official or modified firmware can help, but in severe cases, you may need to reprogram the EEPROM externally using a chip programmer like CH341A and a SOIC clip.

2. Electrostatic Discharge (ESD) Damage

• Cause: Handling the mainboard or chip without grounding yourself can cause static to short the chip.

• Effect: The EEPROM becomes unreadable or permanently damaged.

• Fix: Usually permanent—replacement of the EEPROM chip or the entire mainboard is necessary.

3. Firmware Mismatch or Incompatibility

• Cause: Installing firmware for a different version/model or downgrading firmware.

• Effect: Locks the EEPROM or renders it unreadable.

• Fix: Requires external re-flashing. Make sure to download the exact firmware version specific to the Epson XP-440 (check for compatibility with your region too).

4. Physical EEPROM or Board Failure

• Cause: Heat damage, aging solder joints, or mechanical stress.

• Effect: Flashing light indefinitely, won’t shut off, stuck in a loop.

• Fix: If you’re skilled, you can try reflowing the solder joints, but often this requires replacing the board.

5. Ink Out Error After Firmware Recovery

• Explanation: This typically shows up after a failed or interrupted firmware update. The EEPROM may be stuck reporting low ink or unable to read the ink level sensors correctly due to data corruption.

• Fix:

  • Reset the Ink Counter using a WIC reset tool (if available for XP-440).

  • As a diagnostic step, try installing a different cartridge set—preferably original Epson cartridges, not third-party ones.

  • If it persists, it's likely an EEPROM reading error, not just the cartridge.

Recommendations if You're Considering a Replacement

If you're leaning away from Epson, here are some alternatives to consider:

• Brother: Known for reliability and easier maintenance, especially for monochrome laser models.

• Canon: Has decent photo quality but may involve similar chip-locking mechanisms.

• HP: Reliable hardware but increasingly uses DRM-style chip authentication.

We recommend sticking with Epson if you're involved in any ink-related DIY like sublimation or DTF printing, but go with Brother for less maintenance and fewer firmware headaches.

Important Note

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. So, we cannot 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). Given the high demand, we operate on a first-come, first-served basis. So, it might take a few weeks to get your printer to drop it off. Our services are structured to repair 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 (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 supporting our content. We hope this helps clarify the situation and provides a path forward for restoring your printer or moving on to a more reliable alternative.