Precision and Patience: Replacing an i3200 / i1600 Printhead

Replacing an Epson i3200 or i1600 printhead is the most “high-stakes” job in a DTF workshop. It is an expensive component, and the margin for error is razor-thin. One skewed cable or a single drop of stray ink can instantly “pop” the head and take the mainboard down with it.

If you are a technical user ready to perform a swap on your 42cm or 60cm machine, follow this “anti-short” protocol to ensure your new head survives its first power-up.

1. The “Golden Rule”: Power and Patience

Before you even touch a screwdriver, you must eliminate all residual electricity in the system.

1. Power Down: Turn the printer off at the control panel, then flip the main switch at the back.

2. Pull the Plug: Physically remove the power lead from the UK mains socket.

3. The Wait: Wait at least 20 minutes. The capacitors on the mainboard hold enough charge to “fritz” a new head even when the machine is switched off. Use this time to clear your workspace and put on a fresh pair of nitrile gloves.

2. Labelling and Removal

On an i3200 and i1600, the four ribbon cables plug into the sides of the head. Because the carriage is a tight fit, you won’t be able to unplug them while the head is still screwed down.

Mark Your Cables First

Before you loosen anything, take a marker pen or some small sticky labels and mark every single cable. If you mix these up during re-installation, the printer won’t know which signals to send where, and you have a high chance of damaging your machine.

• Which Head: (e.g., Head A / Head B)

• Which Side: (Left / Right)

• Position: (Top / Bottom)

The Removal Process

1. Dampers First: Carefully pull the dampers off the manifold. Use a 1ClickPrint Isopropanol wipe to clean any ink that drips onto the carriage frame. If ink gets into those side-mounted connectors, the head will likely be damaged.

2. Unscrew the Head: Loosen the three mounting screws. Only once the head is free can you carefully lift it slightly to gain access to the side ribbon cables.

3. Disconnect: Gently unplug the cables one by one, keeping them in their relative positions.

3. Connecting the New Head (The Critical Point)

The most common cause of printhead damage during replacement is a short circuit caused by poorly seated cables or debris on the pins.

1. Inspect the Tips: Look at the silver pins on the ends of your ribbon cables. If they are folded, burnt, or have ink on them, replace the cables immediately. Do not risk a £1,000 head on a £5 cable.

2. The 1ClickPrint Clean: Even if they look clean, give the cable tips a quick, gentle wipe with a 1ClickPrint Isopropanol wipe to remove any finger oils. Ensure they are bone-dry before connecting.

3. Seating the Cables: Connect the cables while the head is still loose. They must go in perfectly straight. If a cable enters at an angle, the pins can bridge. You should feel a firm “seat”.

4. Mount the Head: Carefully lower the head into the carriage, ensuring the cables aren’t being pinched or stressed. Tighten the three screws until they are “finger-tight”—do not over-torque them.

4. Initialisation via BYHX

Once the head is physically installed and the cables are verified, you need to “introduce” the new hardware to the software.

1. The Head ID: Every i3200 and i1600 has a unique “Head ID” or “Voltage Code” printed on a sticker on the side of the head.

2. Enter the Code: Open your BYHX software, navigate to the Realtime Settings, and enter the new ID. This ensures the board sends the correct voltage pulses to this specific piezo array.

3. Ink Charge: On the BYHX clean screen, do an ink fill and then a head clean to pull ink into the new head.

4. Nozzle Check: Run a nozzle check. If it’s clear, proceed to your “Head-to-Head” alignment. If not, repeat step 3.

Summary Checklist