How to Prevent and Fix Cartridge Errors After Refilling HP 901XL Ink Cartridges

Question:

After refilling several HP 901XL cartridges, I started receiving cartridge errors. I plan to convert one of my empty but functional 901XL cartridges using the refill kit I bought from BCH Technologies. However, I’m worried I might reencounter the same error, especially after installing the kit permanently. I’d like to understand why these errors occur and what I can do to prevent or fix them if they happen.

Answer:

Why Refilling HP 901XL Cartridges Sometimes Triggers Errors

Refilling HP 901XL cartridges is a smart way to save money and reduce waste—but it doesn’t come without challenges. The error messages you’re encountering are often the result of HP’s chip-based ink monitoring system. Here are the main reasons why this happens:

🔧 Common Error Messages:

• “Cartridge damaged”

• “Used or counterfeit cartridge”

• “Cartridge cannot be recognized”

• “Incompatible or empty cartridge”

These errors usually occur because:

1. Ink Tracking Chips Don’t Reset Automatically: HP’s chips estimate ink levels based on usage rather than actual ink volume. Once the chip reads “empty,” it often stays that way—even after refilling.

2. Firmware Updates Can Block Refilled Cartridges: HP regularly updates printer firmware to enhance chip validation, which can disable previously working refilled cartridges.

3. Cartridges Can Become Electronically Locked: If a cartridge has been removed, inserted multiple times, or used across different HP printers, the chip may become “killed” by the printer.

⚠️ Beware of the HP+ Program

An important factor to consider is whether your printer is enrolled in HP+, a program that imposes strict limitations on cartridge usage. Once HP+ is activated (even unintentionally), your printer may permanently block all refilled or third-party cartridges—even if they're genuine HP OEMs that have simply been refilled.

Unfortunately, once HP+ is enabled, there is no way to disable it, and no workaround currently exists. This is often the biggest hurdle for refillers and can render even a properly refilled cartridge useless.

✅ How to Reduce the Risk of Cartridge Errors

Here are some practical tips to help prevent cartridge errors and protect your refill investment:

✔️ Use an Original OEM Cartridge That’s in Good Condition

You're on the right path—starting with an empty OEM cartridge that hasn’t yet triggered an error is key. These have the highest chance of working after refill and conversion.

🔄 Disable HP Cartridge Protection

If your printer model allows, disable "HP Cartridge Protection" through the printer settings or HP software. This prevents the cartridge from being permanently associated with a specific printer.

⏸️ Ignore Low-Ink Warnings

After refilling, the printer may still report low or empty ink. In most cases, you can press OK, Continue, or Resume to bypass the message and continue printing.

🧪 Test the Cartridge Before Gluing

You’re absolutely right to hesitate before gluing the refill kit in place. Always insert the cartridge and run a test print first. If the printer accepts it without error, then you can move forward with the conversion confidently. If it throws an error, you’ve saved yourself from committing to a non-functional setup.

🗃️ Keep Spare Cartridges On Hand

We highly recommend keeping one or two extra OEM cartridges on hand. Once a cartridge is electronically “killed” by the printer, no amount of refilling will bring it back—so it’s good to have backups ready to go.

🧰 Summary & Best Practices

The cartridge errors you’re experiencing are largely due to HP’s chip technology, printer firmware restrictions, and increasingly, the HP+ program. These factors are outside the user’s control, and unfortunately, there is no universal fix. However, careful testing, avoiding firmware updates, and sticking with known-good OEM cartridges can significantly reduce the likelihood of errors.

Dealing with printer problems can be particularly tricky because they often require hands-on diagnosis. As such, we’re unable to offer remote support for cartridge or printer repair. If you're local to our area, you can visit our printer repair facility [https://bchtechnologies.com/printer-repair-service], where we offer diagnostic and repair services on a first-come, first-served basis. Due to high demand, it may take several weeks for an appointment, and while our repair rates are not the lowest, we strive to offer honest assessments and thorough service. For DIY help, we highly encourage browsing our YouTube channel [https://youtube.com/@bchtechnologies]. Use the search icon on the channel's menu bar to find videos on specific cartridge models or refill techniques. With over nine years of content, this is the fastest way to find relevant tutorials—even ones I may not immediately recall.

Thank you again for your thoughtful message and for choosing BCH Technologies. We’re here when you’re ready to move forward with your refill project, and we’ll continue to do our best to help wherever we can.