Fix unstable drop formation and charge timing faults by diagnosing breakoff sensor issues and restoring proper stream alignment.
What is stream breakoff?
CIJ printers generate a continuous ink stream that breaks into individual droplets. The breakoff point is critical—if the printer can’t detect it, the ink stream can’t be charged or deflected accurately.
Symptoms of stream breakoff problems
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Blurred or smudged prints
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Charge/EHT fault
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Ink stream visibly unstable
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Printhead cleaning has no effect
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Warning: Breakoff Undetected
Common causes
| Cause | Fix |
|---|---|
| Dirty or blocked nozzle | Clean head with approved solvent |
| Deflector plates misaligned | Realign with service spec tools |
| Faulty breakoff sensor | Inspect and test sensor with diagnostics |
| Incorrect viscosity | Check VMS status and solvent usage |
| Stream out of alignment | Adjust restrictor and test stream with light |
Fix the issue in 5 steps
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Run a head clean and inspect for dried ink
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Inspect stream with strobe or light—should break cleanly, consistently
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Run Clean Ink System if ink appears contaminated or thick
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Replace restrictor or nozzle filter if clog is suspected
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Use diagnostic tools to test breakoff sensor voltage and output
Still stuck?
Breakoff issues can lead to permanent nozzle damage if not addressed quickly. Contact Needham technical support