Troubleshooting Print Alignment and Ghosting Issues – Version CVersion DVersion E

Full Process (3 Main Tasks):

1.1 Check and Turn ON Vacuum Suction

1.2 Check the Paper Feeder Switch — set to Forward

1.3 Perform Two Calibrations:

• 1.3.1 Step Calibration (adjusts feed distance for accurate scaling)
• 1.3.2 Vertical Alignment Calibration (aligns white and color layers vertically)

Full Process (4 Main Tasks):

1.1 Check and Turn ON Vacuum Suction

1.2 Check the Paper Feeder Switch — set to Forward

1.3 Check the Feed motor damping system — Left and right sides are in relaxed state.

1.4 Perform Two Calibrations:

• 1.4.1 Step Calibration (adjusts feed distance for accurate scaling)
• 1.4.2 Vertical Alignment Calibration (aligns white and color layers vertically)

1.2 Paper feeder switch — set to ‘Forward’

• Is vacuum suction turned on?
• Is the paper feeder set to Forward?
• Is the DTF film slipping or not properly loaded?

• Is the suction working properly?
• Is the DTF film flat and parallel to the feed path?
• Is the paper feeder switch in Forward?
• Is the DTF film slipping or skewed?

1.3 Feed motor damping system — Left and right sides are in relaxed state.

1.3-1 Feed motor damping system

❌ Incorrect

1.3-2-Feed-motor-damping-relaxed

✅ Correct

1.3-3-Feed-motor-damping-tightened

✅ Relaxed State: The screw is almost fully tightened inward, with little to no thread visible.
❌ Tightened State: Multiple threads are visibly exposed, indicating the screw is not fully tightened.

1.4 Check the calibration settings (this involves two steps: step calibration first, followed by vertical alignment calibration).

1.4.1 Step Calibration: Adjusts the feed distance to ensure accurate image scaling.

Step-by-Step Instructions:

Step 1 Access the Calibration Menu
Open the printer control software and click the “Calibrate” tab.

1.4.1-1-Access-the-Step-Calibration-Menu

Step 2 Access and Print the Calibration Chart
A dialog box pops up. Click “Base Step”, then click “Print” to start printing the step calibration chart.（Ensure the media is loaded and the printer is ready.）

1.4.1-2-Print-the-Step-Calibration-Chart

Step 3 Find the group of lines that overlaps perfectly between the left and right columns, and record the number.
Look at the printed chart. In the first row, find the group of lines from the left and right columns that overlap perfectly, and record the number.

1.4.1-3-Find-the-Lines-that-Overlaps-Perfectly

Step 4 Adjust the Calibration value
Enter the number in “Revise” and click “=>”

• Rough Adjustment (Initial Calibration)

Use the value that gives the best overlap — for example, if -3 looks best, enter -3 as the Calibration number.

• Fine Adjustment (Precise Calibration)

If the result is still not ideal, make fine adjustments using decimal number, such as -2.1, -2.2… up to -2.9, until the best result is achieved.

1.4.1-4-Adjust-the-Calibration-Value

Step 5 Save the Calibration value
Click “Save” to apply it.

1.4.1-5-Save-the-Calibration-Value-K602-K603-K604

Step 6 Check if Calibration is Complete
If the value of the overlapping line group is “0”, calibration is complete. If not, repeat the above steps until it is.

⚠ If the value is still not “0” after several attempts, stop and check:

• Is vacuum suction turned on?
• Is the paper feeder set to Forward?
• Is the feed motor damping system on left and right sides are in relaxed state?
• Is the DTF film slipping or not properly loaded?

Fix these issues before repeating calibration.

1.4.1-6-Step-Calibration-Completed

1.4.2 Vertical Alignment Calibration: Ensures white and color layers align correctly in the vertical direction.

Step-by-Step Instructions:

Step 1 Access the Vertical Calibration Menu
Open the printer control software and click the “Calibrate” tab.

1.4.2-1-Access-the-Vertical-Calibration-Menu

Step 2 Access and Print the Vertical Calibration Chart
A dialog box pops up. Click “Vertical/Overlap”→Click “VertCal Calibration”→Click “Print ” to print the vertical calibration chart （Ensure the media is loaded and the printer is ready.）

1.4.2-2-Print-the-Vertical-Calibration-Chart

Step 3 Find the group of lines That Overlaps Perfectly between the left and right columns, and record the number below.

• First, look at the printed chart. Each row of calibration lines has its name indicated on the left side of the line. For example, the calibration line in the first row is labeled “G1, 1 (C, M, Y, K, G, R, O, B)”, the second row is labeled “G2，1（W1, W2, W3, W4, W5, W6, W7, W8）”, and so on.
• Then, for each row, find the group of lines from the left and right columns that are perfectly overlapping, and check the number displayed directly below that group.
  If the value is not “0”, you need to adjust that row accordingly.
• For example, in the second row, the value below the group of lines that overlap perfectly on the left and right columns is “-5“, indicating that this row needs adjustment.
• If all other rows have an overlapping group with a value of “0”, then those rows do not need adjustment.
• Finally, record the name and value of the row that requires adjustment: “G2, 1 (W1, W2, W3, W4, W5, W6, W7, W8)” and “-5”.

1.4.2-3-Record-the-Number

Step 4 Calculate and Set the Final Calibration Value
Use the following formula:
Final Value = Original Value + Overlap Value
Example: If the original value is 5 and the overlap value is -5, then the final value:
5 + (-5) =0
Enter 0 into the G2, 1(W1,W2,W3,W4,W5,W6,W7,W8) parameter field in the system. (No need to modify the number in other parameter fields)

1.4.2-4-Set-the-Calibration-Value

Step 5 Save the Calibration Settings
Click “Save” to apply the new calibration value.

1.4.2-5-Save the Calibration Settings

Step 6 Check if Calibration is Complete
If the value of the overlapping line group is “0”, calibration is complete. If not, repeat the above steps until it is.
⚠ If the value is still not “0” after several attempts, stop and check:

• Is the suction working properly?
• Is the DTF film flat and parallel to the feed path?
• Is the paper feeder switch in Forward?
• Is the DTF film slipping or skewed?

Correct these issues before redoing calibration.

1.4.2-6-Vertical-Calibration-Completed

Step 2 Print the Left Distance Calibration Chart
Click “Horizontal” → then select “360 dpi, VSD Mode 3, High” under “Horizontal Motion Mode”→ click “Group” and select “Large” under “Dot mode”→ select “Left”→ click the “Print ” button to print the horizontal calibration chart. （Ensure the media is loaded and the printer is ready.）

Step 3 Find the group of top, middle, and bottom lines that Overlaps Perfectly, and Record the number.

• First, look at the printed chart. The name of each row’s calibration line is indicated to the right of the row. For example, the calibration line in the first row is labeled “G1 Col 1”, the second row is labeled “G2 Col 1”, and so on.
• Then, for each row, find the group of top, middle, and Bottom lines that are perfectly overlapping, and check the value displayed below them. If the value is not “0”, it means this row needs adjustment.
• For example: In the second row, The group of lines that overlap perfectly, with a value of “-3” displayed below, indicating that this row needs adjustment. If all other rows have an overlapping line group with a value of “0”, then those rows do not need adjustment.
• Finally, record the name and value of the row that requires adjustment: “G2 Col 1” and “-3”.

Step 4 Calculate and Set the Final Calibration Value

Use the following formula:
Final Value = Original Value + Overlap Value
Example: If the original value is 5 and the overlap value is -3, then final value:
5 + (-3) =2
Enter 2 into the G2 Col 1 parameter field in the system. (No need to modify the number in in other parameter fields)

• Rough Adjustment: Start with the integer value where overlap is most obvious.
• Fine Adjustment: If needed, fine-tune using decimal values (e.g. 2.1, 2.2, etc.) until the overlap is perfect.

Step 2 Print the Right Distance Calibration Chart
A dialog will appear. Click “Horizontal” → then select “360 dpi, VSD Mode 3, High” under “Horizontal Motion Mode”→ click “Group” and select “Large” under “Dot mode”→ select “Right”→ click the “Print ” button to print the horizontal calibration chart. （Ensure the media is loaded and the printer is ready.）

Step 3 Find the group of top, middle, and bottom lines that Overlaps Perfectly, and Record the number.

• First, look at the printed chart. The name of each row’s calibration line is indicated to the right of the row. For example, the calibration line in the first row is labeled “G1 Col 1”, the second row is labeled “G2 Col 1”, and so on.
• Then, for each row, find the group of top, middle, and Bottom lines that are perfectly overlapping, and check the value displayed below them. If the value is not “0”, it means this row needs adjustment.
• For example: In the second row, The group of lines that overlap perfectly, with a value of “-3” displayed below, indicating that this row needs adjustment. If all other rows have an overlapping line group with a value of “0”, then those rows do not need adjustment.
• Finally, record the name and value of the row that requires adjustment: “G2 Col 1” and “-3”.

Step 4 Calculate and Set the Final Calibration Value
Use the following formula:
Final Value = Original Value + Overlap Value
Example: If the original value is 5 and the overlap value is -3, then final value:
5 + (-3) =2
Enter 2 into the G2 Col 1 parameter field in the system. (No need to modify the number in in other parameter fields)

• Rough Adjustment: Start with the integer value where overlap is most obvious.
• Fine Adjustment: If needed, fine-tune using decimal values (e.g. 2.2,2.3,etc.) until the overlap is perfect.

Step 2 Print the Bidirect Adjust Chart
A dialog box will appear. Click “Horizontal”, select “360 dpi, VSD Mode 3, High” under “Horizontal Motion Mode”, click “Bi-dir”, choose “Large” under “Dot mode”, and then click “Print” to start the bidirectional calibration print.
（Ensure the media is loaded and the printer is ready.）

• Observe the scale lines at the front and rear of the printing platform.
• Compare the scale values — if they are not the same, the film is tilted. A tilted film will cause partial misalignment during printing, so the installation angle must be adjusted before proceeding.

The front-end scale value is 6.1

The rear-end scale value is 5.9

4.1-4-Rear-Scale-Misalignment

When the front and rear scale values are inconsistent, it indicates that the film installation angle has deviated.

4.2 Adjust the film installation angle

4.2.1 Lift the pinch roller

Click the “Lift” button to lift the pinch roller, move and adjust the position of the film.

4.2.2 Adjust the film position to align the front and rear edges at the same scale value

With the pinch roller lifted, gently pull the middle of the film downward by about 1–2 cm to adjust its position. Then, check whether the front and rear scale values are aligned. If they are not the same, continue adjusting until both values are exactly equal.

4.2.2-1

4.2.2-2-The front-end scale value is 6.2

4.2.2-3-The rear-end scale value is 6.2

When the front and rear scale lines are aligned, the film is correctly positioned and parallel to the printing direction.

4.2.3 Put down the pinch roller

Click the “Down” button to lower the pinch roller so it presses down the film, ensuring it remains in position during printing.