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HP Designjet H-Series (ColorSpan Legacy 5400uv series) - Error Message "0220E002 Carriage encoder position not detected. Unable to detect carriage encoder ticks"

Issue
An event occurs during printing that causes the message 0220E002 Carriage encoder position not detected. Unable to detect carriage encoder ticks to appear on the control panel. When the printer is restarted, this message occurs and printer initialization cannot complete.
Solution
The carriage encoder system refers primarily to two components: the main carriage encoder strip and the carriage encoder reader. The encoder strip is a plastic strip located in the rail, just above the blue main carriage drive belt.
    Figure : Encoder strip
  1. Encoder strip
The encoder reader is a sensor located on the back side of the carriage, not normally visible.
Figure : Carriage encoder reader
The Carriage encoder reader, identified by arrows. This carriage has been removed from the printer for visibility.
When operating normally the encoder strip passes through the encoder reader, allowing the reader to detect the individual "tick" marks on the strip. As the carriage is moved by the printer controls, the encoder reader passes over the strip and the printer counts the tick marks to determine the location from left to right.
The error 0220E002 Carriage encoder position not detected indicates that, fundamentally, one of two things is happening:
1. The printer is attempting to move the carriage, and the carriage is not moving; therefore, no tick marks are being read because reader is remaining in one place.
2. The printer is successfully moving the carriage, but the encoder reader/strip system is not working as expected.
To test which of these is the case, shut down the printer. Open the front cover door and move the carriage by hand so that it is approximately at the center of the print zone. Close the cover and turn on the printer. Observe the carriage during startup. If the carriage does not move even the slightest bit before the error occurs, then it indicates there is a problem with the electrical or mechanical carriage drive components. These include the carriage drive belt, the carriage drive motor, the drive circuits in the printer’s electronics, and other related parts. Troubleshooting these components is outside the scope of this document. Contact the local HP authorized service provider or contact HP Customer Care for further assistance.
If the carriage does move before the error occurs, then it indicates that the carriage drive system is trying to work, but the expected feedback from the encoder strip/reader system is not working.
In this situation there are three primary possibilities:
  1. The condition of the strip is such that the reader cannot read the tick marks. The strip may be dirty; the tick marks may be worn off the bottom surface of the strip; or the strip may be mangled and physical damaged in some way. Inspect the strip for any obvious physical damage. If damage is found, the strip likely will need to be replaced. A replacement encoder strip may be obtained via HP spare part listed below (FRM,RLD_E_STRP&FM,ABCDHIJ):
    If no damage is seen, then clean the strip using a lint-free cloth moistened with 50-70% isopropyl alcohol solution, such as rubbing alcohol.
    Figure : Cleaning the encoder strip
    Wipe the top of the encoder strip, cleaning the entire length of strip. After cleaning most of the encoder strip, move the carriage to clean the section of the encoder strip that was behind the carriage. This enables the user to clean the entire encoder strip from end to end. After cleaning, restart the printer to see if the error code appears or not.
  2. The reader may be dirty or not working and therefore not seeing the tick marks. Cleaning the encoder reader is not easy due to the location. Canned compressed air can be used to blow out the sensor error to remove any large particles. A thin cleaning swab with a long handle can be used to clean the sensor itself, if available. After cleaning, restart the printer to see if the error code appears or not.
  3. Both the reader and the strip may be fine, but something caused the strip to become dislodged from the normal position in the reader, and so the reader is not seeing the strip at all. This condition is more likely if the first appearance of the error was after a head strike on media, cleaning of the encoder strip or reader, or some other event that could have disturbed the carriage placement on the rail. To check for this, one will have to remove at least the upper service-end enclosure to look in toward the back of the carriage from the side.
    See Figure 4, items A and G, for the fasteners to remove to remove this enclosure.
      Figure : Fastener locations for printer enclosures
    1. Output side Service end
    2. Output side User end
    3. Input side Service end
    4. Input side User end
The figure 5 listed below, shows the correct appearance of the strip passing through the reader. If the strip has been dislodged, it will slope down and pass underneath the reader instead.
Figure : Encoder strip passing through the reader
Numerous components have been removed for this photo; in a normal, fully assembled printer, the reader is not this easily seen.
If the encoder strip appears not to be passing through the sensor as it should, then the user will have to reseat it. To do this, carefully tilt the carriage slightly away from the rail so that the strip can get past the reader. Using the fingers or a long object as a lever, lift the strip up and lower the carriage back into place, as shown in Figure 6. Be careful not to scratch the bottom of the strip. The strip should nestle into the reader as shown in Figure 5. Lower the carriage back into position and ensure that it rolls freely.
Figure : Reseating the strip into the reader
Numerous components have been removed for this photo; in a normal, fully assembled printer, the reader is not this easily seen.
Once the strip is back in place, restart the printer and confirm that the error code does not appear. If the problem continues after reseating the strip and cleaning both the strip and reader, then please contact the local HP authorized service provider or contact HP Customer Care for further assistance.

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