How to Troubleshoot Poor Nozzle Check on Prestige R1

SECTION (00:00:01) Standard Deep Cleaning Procedure

1. On the control panel, press Menu
2. Go to Head Maintenance, then press Enter
3. Select Fill Ink, then press Enter
4. Select One Head, then press Enter
5. Run Fill Ink for 30 seconds
6. Press Cancel to stop Fill Ink
7. Press Menu to reset
8. Press Cleaning to run a head cleaning
9. After it completes, press Cleaning again for a second head cleaning
10. Print a nozzle check: Menu > Head Maintenance > Head Status SECTION (00:01:21) If Nozzle Check Is Still Bad – Record Capping Station Alignment
11. Turn the printer power off
12. Open the front cover
13. Open the bottom panel to access the knob
14. Rotate and hold the knob counterclockwise
15. With your free hand, move the carriage to the center of the bed
16. Remove the capping station cover by removing: Two top screws
17. Move the carriage back onto the capping station: Rotate and hold the knob counterclockwise
18. Turn the printer back on
19. Record video of the contact point between the capping station and print head
20. Press Enter repeatedly to raise/lower the capping station while recording
21. Confirm the cap aligns centered to the print head surface
22. Send the footage to your technician for review SECTION (00:02:39) Deep Clean the Capping Station and Around the Print Head
23. Prepare a cleaning swab and isopropyl alcohol
24. Disengage the capping station: Press the Left Arrow once
25. Move the carriage to the center: Press and hold the Left Arrow
26. Thoroughly clean the capping station: Around the cap
27. Record your cleaning process for technician review
28. Move the carriage back toward the capping station using the Right Arrow
29. Clean around the print head: Do not touch the print head face
30. Press Enter to cap the print head SECTION (00:04:41) Understand the 5 Steps of a Head Cleaning (For Diagnosis)
31. Open DTF Station Pilot
32. Go to Advance
33. Enter password 1111, then click Confirm
34. Go to the Ink Stack tab and monitor Ink Parameters while you run a head cleaning
35. Press Cleaning on the printer and observe: Step 1 (Pump): Cap rises and seals to pull ink (inner cap layer presses in) SECTION (00:05:51) Ink Stack Height Controls (What Each One Does) SECTION (00:08:00) Set Correct Ink Stack Heights (Example Values From Video)
36. In Pilot, adjust Wetting height until the inner cap layer presses in without lifting the carriage
37. Example tuning shown: Wetting: test 650 (not enough), then 150 (inner layer presses)
38. Copy the final Wetting value into Pump (they should match)
39. Set Flash height to leave a small gap (no contact): Example tuning shown: 500 (still too high), then 400 (correct gap)
40. Set Scarp (wiper) height so it contacts without bending: Example tuning shown: initial bends, then 450 (barely contacts) SECTION (00:11:11) Save and Initialize After Adjustments
41. Click File > Save, then click OK
42. Go to Operation > Initialize SECTION (00:12:00) Increase Flash Volume (Recommended Settings)
43. In the same window, go to the Clean tab
44. Under Print Before Flash: Set Flash Frequency to 3000
45. Go to the Manual Clean tab
46. Under Flash Parameters: Set Flash Frequency to 3000
47. Click File > Save, then click OK SECTION (00:12:52) Export Firmware After Finalizing Settings
48. Go to Firmware
49. Click Export Firmware
50. Save the file somewhere safe
51. Name it with the current date SECTION (00:12:58) Run Nozzle Check After Changes
52. Load media and position media guides
53. Bypass the cover sensor with a metal object if the lid is open
54. Print nozzle check: Menu > Head Maintenance > Head Status SECTION (00:14:19) If No Pattern Prints – Verify Boards, Then Inspect Dampers
55. Check the motherboard area for red lights (red indicates an error)
56. Remove media and lower pinch rollers after removal
57. Loosen carriage cover screws and move the carriage to center
58. Turn power off and remove carriage cover
59. Confirm all dampers are seated firmly
60. Look for contamination (ex: a white damper showing another color)
61. Leak test: Pull each damper out and let them hang
62. Syringe ink pull test (each damper): Hold damper by outer plastic frame only
63. If a damper shows no resistance and no ink flow, replace it SECTION (00:18:56) Replace a Bad Damper
64. Prepare a new damper and scissors
65. Control the tube while removing it to avoid ink flicking onto the printer
66. If ink splatters, clean immediately with lint-free cloth and 99% isopropyl alcohol
67. Inspect and clean the encoder strip if any ink got on it
68. If tube end is stretched or damaged: Cut a small amount off with a straight cut
69. Push the tube fully onto the new damper nozzle
70. Prime the new damper: Hold damper upside down
71. Seat the damper back into the carriage with firm, even pressure (do not over-press) SECTION (00:21:04) Reassemble and Re-Test
72. Reinstall the carriage cover and organize ribbon cables so they do not get pinched
73. Turn printer on and wait for Idle
74. Run Cleaning twice (back to back)
75. Reload media correctly: Raise pinch rollers
76. Print nozzle check: Menu > Head Maintenance > Head Status SECTION (00:22:09) If Nozzles Fire but You’re Under 90% – Print a Multicolor Test
77. Send a 10x10 multicolor image from your RIP
78. Check white underbase opacity (should be opaque, not transparent)
79. Print nozzle check again and compare to previous
80. Take photos of every nozzle check for technician review
81. If nozzles get worse after printing, check environment: Excess heat
82. Run Cleaning twice, then re-check nozzle pattern
83. Proceed if you are at 90%+ and regressions are under 10% SECTION (00:27:02) Carriage Board Ribbon Cable Reseating (Technician-Directed Only)
84. Power off, remove carriage cover
85. Inspect ribbon cables one at a time: Pull straight up using two hands and even pressure
86. Check for damaged teeth or residue
87. Re-seat cables: Align teeth to port
88. Reinstall cover carefully (do not pinch cables)
89. Power on, run Cleaning twice, then run a nozzle check SECTION (00:30:48) Additional Ribbon Cable Inspection (Technician-Directed Only)
90. Power off, remove carriage cover again
91. Inspect the 3rd and 4th ribbon cables (more sensitive)
92. If ink residue is present on contacts: Clean gently with 99% isopropyl alcohol and lint-free cloth
93. Re-seat carefully (blue tape provides support)
94. Reinstall cover, power on
95. Run Fill Ink 30 seconds, then Cleaning twice
96. Run nozzle check and proceed if 90%+ with under 10% regression SECTION (00:33:20) Finish

• Do not perform ribbon cable reseating unless directed by a DTF Station technician
• Two bottom screws
• Push the carriage onto the capping station
• Release the knob
• Around the base of the capping station
• Clean up to the outer edge
• Clean the front side through the front opening
• Clean the back side through the side opening
• Step 2 (Scarp): Carriage shifts left and wiper wipes the head surface
• Step 3 (Flash): Cap rises with a small gap and head spits ink into the cap
• Step 4 (Drain): Cap lowers and drains collected ink
• Step 5 (Wetting): Cap seals again to keep the head capped
• Pump = cap height for suction cleaning
• Scarp = wiper blade height
• Flash = cap height during flashing (gap required)
• Wetting = final capping height (solid seal)
• Pump and Wetting should match
• After finding the correct value, reduce by 100 if possible while still pressing the inner layer in
• Set Flash Times to 6
• Clean initial drips
• Wait to see if ink continues dripping (continued drip can indicate a leak)
• Press syringe firmly against the damper opening (do not insert into the damper)
• Pull slowly and evaluate:
• Excess bubbles inside the damper
• No resistance
• Excess resistance with ink being sucked back in
• Remove syringe by holding plunger, then tilting to release pressure
• Do not cut too short
• Pull with syringe until you see solid ink and good resistance
• Pull media forward to create front tension
• Rotate roll to create back tension
• Lower pinch rollers
• Feed media slightly with Down Arrow
• Set media guides loosely to the edges
• Low humidity
• Excess static
• Too much air/wind
• Do not wiggle
• Do not touch metal contacts with bare hands (wear gloves)
• Press straight down with even pressure
• If the nozzle check is 90%+ and stable, resume production
• If capping station alignment, ink stack heights, or dampers appear abnormal, send photos/videos to your technician