Doing a Nozzle Check on the Melco G2

A Nozzle Check is a self test print to verify that the Ink Delivery System of the printer is producing adequate ink output. If the Nozzle Check meets specification the ink delivery system is typically in good working order. To command the machine to perform a Nozzle Check use the following steps:

Required Supplies or Tools:

• 8.5 x 11" Transparency Film

Test Print (Nozzle Check)

1. With the machine in the READY state move the table to the "load" position by pressing the Auto Out Button on the machine control panel.
2. Place a sheet of 8.5" x 11" Transparency Film on the platen in the most forward right corner.

Note: Image shows an 8.5" x 11" sheet of white paper instead the transparency film for clarity, be sure that you use a transparency and not a plain white sheet of paper.

3. Move the platen/table to the "print ready" position using the "manual in" button from the machine control panel until the Transparency Film is just below the Table Height Sensors.

4. Set the Table Height for printing.

5. Press the Auto In button on the machine control panel to move the table to the print ready position.
6. The display will read READY at this point.
7. Press the menu button on the printer control panel 1 time until the display reads PRINTER SETUP.
8. Press the down arrow (1) one time until the display reads TEST PRINT.
9. Press the Menu button to accept.
10. The display will read NOZZLE CHECK press the Menu button (1) one time to accept.
11. The display will read NOZZLE CHECK on the top line and PRINT below.
12. Press the Menu button to accept the PRINT option.
13. The display will read PRINTING as the machine performs the Nozzle Check test print.
14. When the Nozzle Check test print is complete the display will read READY.
15. Move the table to the load position by pressing the Auto Out Button on the table control panel.
16. Inspect the Nozzle Check test print to verify that adequate the ink output appears on the test print by comparing to image of good Nozzle Check test print below.

18. If the Nozzle Check test print results do not show adequate ink output refer to the troubleshooting information below to match the test results and how to proceed.

All 8 channels completely missing

If the Print Head Carriage is moving and there is no ink output from any channel the pump may not be working properly or may not be working at all. To verify proper pump function empty Waste Ink Tank and perform a Power Cleaning cycle. Remove the Waste Ink Tank and inspect for ink output in the tank. If there is no ink at all in the Waste Ink Tank the pump is not working.

• Inspect for loose or damaged cables.
• Replace Pump Station
• Replace the Epson Main Board

All 4 white channels are completely missing

• Check the white ink cartridges to be sure they are not empty.
• Inspect the white ink lines for heavy sediment or air in the lines.
• Install Cleaning Solution Cartridges in the white ink bays and draw solution into the lines with a syringe (see Charging Ink Delivery System)
• Perform the daily use maintenance from the Maintenance Schedule.
• Command (2) two Power Cleaning cycles to charge the white ink Dampers and the Print Head Nozzles with cleaning solution.
• Allow the solution to remain in the entire white ink delivery system over night before recharging the lines with ink.
• Print a Nozzle Check test and inspect for white ink output.

All 4 color channels completely missing

• Check the color ink cartridges to be sure they are not empty.
• Inspect the color ink lines to be sure there is no foam or air in the lines.
• Install Cleaning Solution Cartridges in the color ink bays and draw solution into the lines with a syringe (see Charging Ink Delivery System)
• Perform the daily use maintenance from the Maintenance Schedule.
• Command (2) two Power Cleaning cycles to charge the white ink Dampers and the Print Head Nozzles with cleaning solution.
• Allow the solution to remain in the entire color ink delivery system over night before recharging the lines with ink.
• Print a Nozzle Check test and inspect for white ink output.

Any (1) one channel is completely missing.

• Check the ink cartridge of the missing channel to be sure it is not empty or near empty.
• Check the ink line of the missing channel for air, foam or sediment in the line.
• Attempt to draw ink through the line of the missing channel where the ink line meets the damper using a syringe (see Charging Ink Delivery System)..
• Inspect the Damper and related fitting to be sure there is no loose fittings allowing air in the line.
• Replace the related damper

Any channel is partially missing.

• Check the ink cartridge of the partially missing channel to be sure it is not empty or near empty.
• Perform a normal cleaning and then retest by printing a Nozzle Check.
• Perform a Power Cleaning and retest with a Nozzle Check test print.
• Check the ink line of the partially missing channel for air in the line.
• Attempt to draw ink through the line of the partially missing channel at the Damper
• Inspect the Damper and related fitting to be sure there is no loose fittings allowing air in the line.
• Replace the related Damper

Nozzle Check using cleaning solution

• Check that ink cartridges with ink are installed in the printer
• Verify that the ink lines and dampers are fully charged with ink
• Perform a Nozzle Check

Note: you may choose to test with cleaning solution to reduce ink costs.