Not sure what the problem is, and nothing on the net about it I could find. I did get Datacard's support web page, and if this is a normal problem, someone in the tech division should have the answer. Be persistent, as this is an often frustrating, time-consuming task. Not sure about the ink delivery system, but seems to be delivering too much from faulty signals due to a slightly loose ribbon connector (they usually deliver the electrical signals to the ink delivery system). It's possible for them to jar, and shake a bit loose from time to time. Be careful about their plastic tabs that hold them, and disassemble them, then reseat and clamp them. Have it serviced, if still in warranty, otherwise, you might take a shot at this. Other possibility is a clogged ink system, to a degree, and defective cartridge, I guess they have. All I can think of, so good luck! Here's the support site:
http://www.datacard.com/contact-datacard-group