Colors are pale or missing - Troubleshooting

  • Updated

Correct color on the thread is of significant importance. This article describes how to check and troubleshoot if the colors appear pale or missing.

For correct coloring of the Coloreel thread, two things are critical:

  • The print heads are jetting out ink
  • The ink is hitting the thread

Should you experience a problem with pale or missing colors, follow the steps below. Run a sample embroidery after each completed step until the problem is solved.

1. Check the start marker for missing color.

This is standard procedure. Always check the start marker for every embroidery. The first four fields of the Start Marker come from each of the four printer heads: Black - Cyan - Magenta, and Yellow, in that order. A piece of white thread follows each color, and after the last white part, a short piece of black is printed right before the first design color is printed. That short black part is the actual start marker. Missing or pale coloring indicates a problem that should be resolved before producing commercial embroidery.

2. Check the threading

The three thread guides in the Print engine ensure the thread is correctly positioned for the ink to hit the thread. The three thread guides, most important for thread coloring, to check for correct threading is:

  • The first thread guide is at the left side of the print engine, right after the entry encoder wheel.
  • The vibration damper is located in the middle of the thread path of the Print Engine.
  • The exit thread guide is at the rightmost part of the Print Engine.

3. Check the thread tensioner on the Entry Feeder module

  • Should the tension be too loose, it might cause the thread to move out of its path, and the ink will miss the thread.

See instructions for threading here:

4. Clean the thread guides.

Even tiny residues on the guide pins can shift the thread from the correct position. See the close-up image below.

thread_guide_1.png

Residue buildup on thread guide pins can dry and form a hard deposit. Loosening the residue buildup might require using your fingernails or some wooden or plastic knife.

Regular cleaning of the thread guides is part of the weekly maintenance. See the video instructions below.

 

5. Check for mottling or gradient transitions

Mottling and non-smooth transitions can be symptoms of an issue that can also cause pale colors.

There is a separate article describing how to check for those issues here...

 

NOTE!

We strongly advise you to contact a Coloreel support agent or a trained technician before proceeding with the next steps in this troubleshooting guide.

 

The following troubleshooting steps require a Computer or Tablet to log in to the unit's Operator panel as an Advanced User in a web browser.

 

6. Check the print heads

This step will determine if the issue is ink missing the thread or if the print head nozzles are clogged. Follow these instructions to perform the check. 

If the test results indicate that the print heads are jetting ink without hitting the thread, and you have confirmed that the thread guides are adequately cleaned, a print head position calibration is needed. See the auto-calibration instructions in the installation manual.

If the above test indicates that the print heads are partially or entirely clogged, proceed with section 6 below.

 

6. Actions for clogged print heads

One reason for print head nozzle clogging is not using the unit for an extended time. Follow the maintenance schedule prompting you to power on the unit every second week. This is essential when the unit has not been used for several weeks. When the unit is started, an auto-cleaning sequence is executed. Please let the maintenance cycle finish before powering off the unit again.

  • First, run any Coloreel-colored embroidery of about 10,000 stitches. This will "exercise" the Print Heads and is often enough to make them work properly again.

If the issue is still present, please check the print head nozzles by performing a nozzle check. Take a photo of the papers from the test to document the number of missing nozzles. Save the photo for reference if you need to contact Coloreel Support.

If any printer head shows that more than eight nozzles are failing, continue with those actions:

  • Perform a Manual Clean:
    • Go to the Maintenance tab in the left sidebar of the Operator panel.
    • Choose cleaning of one or several colors, giving you problems. By selecting "All," you can clean all four Print Heads.
    • Tap the "START CLEANING" button to begin cleaning. A pop-up will notify you when the cleaning process is finished.
    • Run a test embroidery with about 10,000 stitches.
    • Check the result by doing another Nozzle check—Take a photo of the papers for documentation.
    • If the new Nozzle check still shows more than eight nozzles missing:

 

  • Perform a Deep Cleaning cycle:
    • Click the Maintenance tab in the left sidebar.
    • Choose the extra option to perform a Deep Cleaning.
    • Select the print head with nozzle problems or "All."
    • Click the "START DEEP CLEANING"-button to begin. Warning: This process will use a lot of ink.
    • The Deep Cleaning process will take more than one minute to complete, and you will see a Notification when the cleaning is finished.
    • Run a test embroidery with about 10,000 stitches.
    • Check the result by doing another Nozzle check—Take a photo as documentation.

If those troubleshooting actions fail to solve your color issue, please file a support request. A Coloreel support technician will contact you to find a solution to your problem.

 

At our e-learning site, Coloreel Academy, you can find complete courses with video lessons learning how to use and maintain the Coloreel ITCU.

Coloreel Academy can be found at https://academy.coloreel.com