Continuous Printer Settings and the Carriage Position Error Videojet Dataflex 6530 6330
Troubleshooting Printhead Carriage Position Errors in Continuous Application Printers
At TTOParts.com, our service department has recently seen an uptick in printhead carriage position errors, particularly on continuous application printers. If you're using one of these systems, you may have encountered this issue too. Today, we want to discuss what continuous printing means, the common causes of carriage position errors, and how we found an unexpected solution through a thorough inspection of our units.
What is Continuous Printing?
Continuous printing refers to a setup where the substrate or film moves continuously without stopping, and the printhead does not traverse across the carriage. Instead, the printhead only moves up and down to make contact with the substrate when a print signal is received. This type of printing is highly efficient, as it minimizes the time needed for the printhead to move horizontally, focusing only on the necessary vertical movement to create imprints.
Understanding Printhead Carriage Position Error
A printhead carriage position error occurs when the printer detects unexpected movement or lack thereof. This is crucial for maintaining print quality and avoiding damage to the equipment. The error typically means the printhead has hit an obstacle or has been obstructed in some way, preventing it from moving correctly. Think of it as the printhead hitting the peel arm; the printer's feedback loop, through the motor encoder, detects this impact and triggers the error.
Our Investigation into Printhead Carriage Position Errors
To get to the bottom of this issue, we started with our standard troubleshooting checklist:
- Head Cycle Test: All units passed, making it unlikely that there was a motor problem.
- Printhead Movement Check: We confirmed that the printhead was moving up and down correctly, without any signs of smacking or bending—eliminating the most common cause of this error.
However, these checks did not identify the root cause of the issue. So, we went further by disassembling the unit for a closer inspection.
The Discovery: The Importance of a Clean and Secure Linear Slide
In speaking with one of our customers who reported the error, they mentioned that the printhead appeared to be moving while printing. This observation made sense and could certainly cause the printhead carriage position error. Knowing that this printer had been in the field for a long time and that the environment was particularly dusty and dirty, we had a hunch that the problem might be with the linear slide.
Upon fully disassembling the unit, we discovered that the slide was slipping more than it should, likely due to the accumulation of dust and debris over time. This subtle movement during printing was causing the printhead carriage position error. It turns out that the printhead wasn’t faulty, nor was the motor—it was the compromised linear slide that was the culprit.
Watch Our Troubleshooting Process
If you're skeptical or want to see how we diagnosed this issue, check out our YouTube video, where we walk through the disassembly and inspection process step-by-step. It's a great resource for anyone looking to understand more about maintaining continuous application printers and preventing common errors.
Takeaway for Our Customers
This experience underscores the importance of regular maintenance and inspections, especially in environments that are prone to dust and debris. Even when all standard tests are passed, a closer inspection might reveal underlying issues that could impact your printer’s performance. At TTOParts.com, we are committed to helping our customers maintain optimal printer performance. If you're experiencing printhead carriage position errors or have any other concerns, don't hesitate to reach out to our service department for assistance.
Maintaining your equipment isn’t just about keeping it running—it's about ensuring it runs efficiently and accurately for as long as possible.
