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How did you end up figuring "trailing cable or the PCA" when it's pointing to the ISS??
Could be loose connection from the previous repairs or ink leakage etc.
Well most logical thing is to go trough the cabling or replace it next. Then the junction pca and eventually power box
You could try to really spend some time in front of it running the curing diagnostic and wiggling wires or something.
But clearly it's not the heaters it's something else...
There's bunch of threads about it. You can try to calibrate the material, scotchs tape or yellow filter on the OPOS.
Bottom line tho, don't use the barcode. Send the file and only, only use the square marks. You might keep your sanity...
Yes encoder strip and sensor. Don't need no replacing just proper cleaning.
I guess you could have issues with the trailing cable as well but lets not go so far yet. First calibrate that line sensor if you haven't.
Two things. First you must calibrate the line sensor or it's not reliable.
There's really never any issues with it unless it gets wet.
2ndly I think your real issue is the encoder/sensor that needs proper cleaning.
Last possibility is the carriage motor malfunctioning.
Best would be a backup and off-site backup so even if your building burns you can still get the data.
Other than that I personally think you are pretty good with offline backup as you still have your original data even if the external drive fails.
(There's more scenarios like encryption...
Im telling you to print something small you can see the advance like my attached test image and adjust it on the fly. Shouldn't take more than 5 feet.
Let it print 5", adjust, let it print 5", adjust etc. Should be fairly quick process.
Just start printing something you can clearly see the movement and adjust the advance on the fly. Just copies for 50 feet ex. you can cancel the job when you find the correct value. RIP without color correction so it's pure black (or use something of your own).
You probably want to start at 0...
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