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DTG Kiosk Troubleshooting Guide

Print head is leaking ink on to the shirt

Printed colors are not correct or not the same as the computer screen

One or more of the LED Ink chip lights are flashing

One or more of the LED Ink chip lights are solid

The shirt is showing through the underbase

Banding

Printer is printing vertical or horizontal gaps in the image

Printer is printing but no ink is coming out

Error eject is flashing together with LED ink lights

Error eject is flashing alternately with LED ink lights

Error eject is flashing with Power light

Error eject is flashing rapidly

Tray bed does not load all the way

White underbase starts out printing good but begins to fade as it prints

Yellow prints out green or White Ink looks muddy or grey

The eject and load sensors have lost orientation when the tray bed moves further out

Fonts are not printing correctly or not printing at all.

White underbase prints out a box instead of the image shape

Printed from graphic program but the printer did not print

Printer stops in the middle of a print

Printer pauses for long periods during printing

Printed image is jagged or has visible pixels

Image is printing at the wrong size and in the wrong place.

Color bleeds or appears splotchy on white underbase

RIP Pro prints programming script instead of image

White underbase has holes where real white should be

White underbase peaks out from under the color layer on one side

Color looks dull after curing

Image on the shirt is washing out, fading or peeling.

Inks stick to Teflon sheet or parchment paper when curing the final print.

 
PROBLEM: Print head is leaking ink on to the shirt
Reasons, Solutions, and Prevention:
  1. Dirty or clogged capping station

    Solution: Clean the capping station by applying window cleaner on the capping pad.

    Prevention: Follow suggested maintenance routine.


  2. Ink build-up around the print head

    Solution: Clean build-up around the bottom of the print head with a soft damp cloth.

    Prevention: Follow suggested maintenance routine.


  3. Excessive ink build-up on the print head wiper assembly

    Solution: Clean the wiper blades with a damp paper towel.

    Prevention: Follow suggested maintenance routine.


  4. Damaged print head from slamming into a shirt board

    Solution: Replace the print head. Download instructions

    Prevention: Always check platen height.

 
PROBLEM: Printed colors are not correct or not the same as the computer screen
Reasons, Solutions, and Prevention:
  1. One or more of the CMYK color channels are not printing

    Solution 1: Print head needs to be primed by doing a few head cleanings.

    Solution 2: Bottle of ink has run empty. Fill the bottle and ink tubes and prime the print head with head cleanings.

    Prevention: Top off ink bottles regularly.

    Solution 3: Open any valves that may be off.

    Solution 4: Print head is clogged. Use head cleanings or flush with cleaning solution. If that doesn't work replace the print head. Download instructions

    Prevention: Run head cleanings on days that the printer is not printing. For periods longer then a week, flush ink out of system using distilled water. Run cleaning solution through the system and leave the cleaning solution in the system until you need to print again.

    Solution 5: Damper has hole or is clogged. Replace damper.


  2. Computer monitor needs to be adjusted

    Solution 1: Make sure the RGB (Red Green Blue) values are balanced.

    Solution 2: Adjust the brightness if necessary.


  3. Color profiles are being used in graphic program such as Photoshop.

    Solution: During the print process from the graphic program make sure that no color management is selected. RIP pro will handle the color profiling.

 
PROBLEM: One or more of the LED Ink chip lights are flashing
Reasons, Solutions, and Prevention:
  1. Printer thinks the ink cartridge is running out of ink

    Solution: Because the DTG uses a Bulk Ink System the standard Epson ink chip counters often need resetting. Because so much White Ink is used the white ink chips usually need resetting. Turn the machine off and unplug the power cord to reset the ink chips.

 
PROBLEM: One or more of the LED Ink chip lights are solid
Reasons, Solutions, and Prevention:
  1. Printer thinks the ink cartridge is out of ink

    Solution: Because the DTG uses a Bulk Ink System the standard Epson ink chip counters often need resetting. Because so much White Ink is used the white ink chips usually need resetting. Turn the machine off and unplug the power cord to reset the ink chips.

    Prevention: Turn the machine off and unplug to reset the ink chips every 5 to 10 shirts depending on how much white ink is being printed.

 
PROBLEM: The shirt is showing through the underbase.
Reasons, Solutions, and Prevention:
  1. Not enough White Ink pre-treatment

    Solution: Increase the amount of spray.


  2. Not setting the White Ink pre-treatment correctly on the heat press

    Solution: Press the pre-treated shirt for no more than 10 seconds.


  3. Not enough pressure on the heat press

    Solution: Increase the pressure slightly. Increase more if needed. The heat press should flatten the surface of the cotton.


  4. Not the right RIP Pro settings for the color of shirt

    Solution: White Ink requires a health coat for good results. The darker the shirt the more coverage it needs. Setting a higher DPI for the White underbase increases the amount ink that is printed.


  5. White Ink is not primed in the print head

    Solution: Run at least 10 head cleanings using the ink button on the control panel and try a test print. Repeat if it improved but needs more.


  6. White Ink jets are clogged

    Solution 1: Flush the inks with distilled water thoroughly. Flush the lines with cleaning solution to remove most of the residue. Run head cleanings from the control panel with cleaning solution in the print head just like ink. Let cleaning solution soak in the print head for a few hours and run a few more head cleanings with the Ink button on the control panel. Flush cleaning solution and refill the system with ink. Print a nozzle check or a test image to see if the jets are unclogged.

    Solution 2: Replace the print head. Download instructions

    Prevention: Run head cleanings on days that the printer is not printing. For periods longer then a week, flush ink out of system using distilled water. Run cleaning solution through the system and leave the cleaning solution in the system until you need to print again.


  7. White Ink damper or dampers are clogged or clogging

    Solution: Replace dampers

    Prevention: Run head cleanings on days that the printer is not printing. For periods longer then a week, flush ink out of system using distilled water. Run cleaning solution through the system and leave the cleaning solution in the system until you need to print again.

 
PROBLEM: Banding
Reasons, Solutions, and Prevention:
  1. Print head is not primed

    Solution: Run several head cleanings using the Ink button on the control panel.


  2. Print head jets are clogged

    Solution 1: Flush the inks with distilled water thoroughly. Flush the lines with cleaning solution to remove most of the residue. Run head cleanings from the control panel with cleaning solution in the print head just like ink. Let cleaning solution soak in the print head for a few hours and run a few more head cleanings with the Ink button on the control panel. Flush cleaning solution and refill the system with ink. Print a nozzle check or a test image to see if the jets are unclogged.

    Solution 2: Replace the print head. Download instructions

    Prevention: Run head cleanings on days that the printer is not printing. For periods longer then a week, flush ink out of system using distilled water. Run cleaning solution through the system and leave the cleaning solution in the system until you need to print again.


  3. Damper is clogged

    Solution: Replace damper

    Prevention: Run head cleanings on days that the printer is not printing. For periods longer then a week, flush ink out of system using distilled water. Run cleaning solution through the system and leave the cleaning solution in the system until you need to print again.


  4. Damper has a hole

    Solution: Replace damper


  5. Capping station needs cleaning

    Solution 1: Use the syringe to apply window cleaner on the capping pad. Push the Ink Fill button to draw the window cleaner through the Waste Ink system.

    Solution 2: Clean the rubber rim around the capping pad to remove any strands of dry ink that could interfere with the capping station forming a seal with the print head.

    Prevention: Follow suggested maintenance routine


  6. Blocked breather holes on ink bottle caps

    Solution: Make sure the small holes on the caps are not blocked or clogged. Clear anything that is blocking the hole. Make sure no debris falls into the ink.

    Prevention: Follow suggested maintenance routine


  7. Printer needs a head alignment

    Solution: Run a head alignment from the maintenance section of the Epson Stylus Photo 2200 driver. Head alignment can not be run with white ink in the system. It must have seven colors.

 
PROBLEM: Printer is printing vertical or horizontal gaps in the image
Reasons, Solutions, and Prevention:
  1. Vertical gaps is either a dirty encoder strip or a damaged encoder strip

    Solution: Clean or replace encoder strip.

    Prevention: Follow suggested maintenance routine.


  2. Horizontal gaps is a misaligned encoder wheel sensor

    Solution: Contact support for help to determine if it can be repaired or if it needs replacing.

 
PROBLEM: Printer is printing but no ink is coming out
Reasons, Solutions, and Prevention:
  1. Valves are closed

    Solution: Set valves to draw ink.


  2. Print head is not primed

    Solution: Prime print head by running a few head cleaning cycles using the Ink button on the control panel.


  3. Damper has come loose causing a lose of pressure in the ink system

    Solution: Reseat damper.


  4. Capping station has become severely dirty or clogged

    Solution: Clean the capping station

    Prevention: Follow suggested maintenance routine.


  5. Print head is severely clogged

    Solution: Replace the print head. Download instructions

    Prevention: Run head cleanings on days that the printer is not printing. For periods longer then a week, flush ink out of system using distilled water. Run cleaning solution through the system and leave the cleaning solution in the system until you need to print again.

 
PROBLEM: Error eject is flashing together with LED ink lights
Reasons, Solutions, and Prevention:
  1. Data spooling is incomplete or interrupted.

    Solution 1: Power off and unplug to reset the printer.

    Solution 2: If resetting printer did not solve the problem, the encoder strip may be dirty. Clean the encoder strip with a damp cotton swab.

    Prevention: Follow suggested maintenance routine


  2. The print head or tray bed movement is being interfered with.

    Solution 1: Oil the print head carriage bars.

    Solution 2: Check the tray bed movement when loading and ejecting for friction or something foreign interfering.

    Prevention: Follow suggested maintenace routine

 
PROBLEM: Error eject is flashing alternately with LED ink lights
Reasons, Solutions, and Prevention:
  1. Waste ink counter has exceeded its limit.

    Solution: Reset waste ink counter

 
PROBLEM: Error eject is flashing together with Power light
Reasons, Solutions, and Prevention:
  1. Machine has been powered on with a print job in the print queue.

    Solution: Remove all jobs from the print queue and reset the printer.

 
PROBLEM: Error eject is flashing rapidly
Reasons, Solutions, and Prevention:
  1. This indicates something abnormal with the circuits.

    Solution: Contact your dealer for support.

 
PROBLEM: Tray bed does not load all the way
Reasons, Solutions, and Prevention:
  1. The printing surface is too high and the (optional) gap sensor beam has been interrupted.

    Solution: Adjust platen height or correct the error (wrinkle in the shirt or hoop sticking up) and press the load button again to continue loading.

    Prevention: Always check the platen height.


  2. Bed movement is being interfered with

    Solution: Remove the obstruction and turn the power off then on to clear the error and proceed.


  3. Encoder wheel is dirty

    Solution: Remove the left side black cover and clean the round graduated clear mylar wheel with lint free cloth and Windex. Turn the power off and on again to clear the error and proceed.

 
PROBLEM: White underbase starts out printing good but begins to fade as it prints
Reasons, Solutions, and Prevention:
  1. The print head has lost its prime, also known as ink starvation

    Solution 1: Remove the white ink dampers and back flush or replace the white ink dampers. Refer to the Kiosk User's Manual, Section 7, "Removing and Replacing Dampers".

    Solution 2: Completely flush the white ink lines. Refer to the Kiosk User's Manual, Section 9, "Transporting or Storing Your Printer".

    Solution 3: Replace the print head. Download instructions

 
PROBLEM: Yellow prints out green or White Ink looks muddy or grey
Reasons, Solutions, and Prevention:
  1. Other colors of ink have back-filled into the yellow damper

    Solution: Isolate affected dampers using the valves and run the ink fill button for 5 to 10 seconds to flush contamination out of the affected dampers. Remember to either open all valves or push the head off of the cap station before releasing the Ink Fill button as this could cause further contamination. Always perform a head cleaning after using the Ink Fill button to prep the head for printing.

 
PROBLEM: Load and Eject buttons go inactive when Eject is pressed and held in the eject position
Reasons, Solutions, and Prevention:
  1. The eject and load sensors have lost orientation when the tray bed moves further out

    Solution: Turn machine off and power back on

    Prevention: There is no need to press and hold the Eject button after the tray bed is ejected.

 
PROBLEM: Fonts are not printing correctly or not printing at all.
Reasons, Solutions, and Prevention:
  1. True Type Fonts in vector graphics can have issues printing through postscript printer drivers.

    Solution 1: If printing 7 color with out RIP Pro convert the letters to a bitmap or raster image

    Solution 2: If printing with RIP Pro, go to the DTG Kiosk w/White ink driver and find the setting for True Type Fonts. Make sure it is set to Substitute with Device Font

 
PROBLEM: White underbase prints out a box instead of the image shape
Reasons, Solutions, and Prevention:
  1. The background is not 100% white.

    Solution 1: Use your graphic software to select the background pixels and make it 100% white - R:255 G:255 B:255.

    Solution 2: Remove the background.

    Solution 3: Convert the background to black and use the "Color Layer, Auto Mask (Black Background)" layer type.

 
PROBLEM: Printed from graphic program but the printer did not print
Reasons, Solutions, and Prevention:
  1. The wrong printer was selected during printing

    Solution 1: Make sure the Epson Stylus Photo 2200 is selected when printing without the RIP Pro.

    Solution 2: Make sure the DTG Kiosk w/ White Ink is selected when printing with the White Ink upgrade and RIP Pro


  2. The printer is not turned on or communication is unplugged

    Solution 1 : Make sure power is on.

    Solution 2: Make sure communication cable is plugged in.


  3. There is a driver issue

    Solution 1: If printing through Epson driver, look for multiple copies of the driver. If there are multiple copies, remove all drivers. Disconnect the communication cable and wait 30 seconds, then reconnect the communication cable. With the printer turned on the computer should detect and reinstall the driver.

    Solution 2: If printing through RIP Pro make sure that the output queue is pointing to the correct port. Refer to your DTG RIP Pro manual for proper input and output settings.

 
PROBLEM: Printer stops in the middle of a print
Reasons, Solutions, and Prevention:
  1. One or more LED Ink lights are solid and the printer thinks it is out of ink

    Solution: Power off the printer and unplug to reset ink chips


  2. Computer resources are not adequate

    Solution 1: Seven color process should have at least a Pentium 3 or higher, 512 MB RAM, Windows 2000 or higher

    Solution 2: RIP Pro should have at least a Pentium 4 or higher, 1 gig RAM, Windows 2000 or higher

    Prevention: The more powerful a computer, the better.


  3. USB cable may be too long

    Solution: Standard USB cable should not be longer then 10 feet.


  4. Image file may be corrupt

    Solution: Try a different image to determine that the image in question is the problem

 
PROBLEM: Printer pauses for long periods during printing
Reasons, Solutions, and Prevention:
  1. Computer resources are not adequate

    Solution 1: Seven color process should have at least a Pentium 3 or higher, 512 MB RAM, Windows 2000 or higher

    Solution 2: RIP Pro should have at least a Pentium 4 or higher, 1 gig RAM, Windows 2000 or higher

    Prevention: The more powerful a computer, the better.


  2. USB cable may be too long

    Solution: Standard USB cable should not be longer then 10 feet.


  3. Vectors with textured fills or large DPI images spooling large amounts of data

    Solution 1: Convert vectors with textured fills to raster bitmaps

    Solution 2: With raster bitmap images the larger the DPI the larger the amount of data to be spooled. 150 DPI at actual image size is all a tee shirt needs. Smooth rigid goods may require a higher resolution. Images should not exceed 300 DPI.

    Prevention: Images should be high enough in resolution to achieve good results but not so high that they slow down computer resources.

 
PROBLEM: Printed image is jagged or has visible pixels
Reasons, Solutions, and Prevention:
  1. Image resolution is too low

    Solution: Obtain image with better resolution. Do not use images that were created for the web as these are typically low resolution, plus many have been compressed to reduce file size, making the image even more pixelated.


  2. Resolution was adequate but the size of the image was increased

    Solution: Obtain image at the right size and the right resolution

    Prevention: Set a minimum requirement for images you receive from your customers

 
PROBLEM: Image is printing at the wrong size and in the wrong place.
Reasons, Solutions, and Prevention:
  1. Page size is not set for the DTG

    Solution 1: Set the page size for 13 X 22 in the graphic program print setup and in the RIP Pro driver DTG Kiosk w/White Ink.

    Solution 2: If not using RIP Pro, set the page size in the graphic program print setup and in the Epson Stylus Photo 2200 driver.

 
PROBLEM: Color bleeds or appears splotchy on white underbase
Reasons, Solutions, and Prevention:
  1. Too much color ink on the white underbase

    Solution 1: Adjust ink densities in Rip Pro. This adjustment can be found under the Utilities, Printer and Ink Configuration.

    Solution 2: Decrease the color layer resolution. This solution may also increase the chance for horizontal banding. If this happens, perform a head alignment.

 
PROBLEM: RIP Pro prints programming script instead of image
Reasons, Solutions, and Prevention:
  1. DTG Kiosk w/White Ink driver is configured to print directly to the Epson Stylus Photo 2200 driver

    Solution: Contact your dealer for support

 
PROBLEM: White underbase has holes where real white should be
Reasons, Solutions, and Prevention:
  1. The color values for the effected pixels are 100% white like the background

    Solution: Use your graphic program to select any pixels other than background and make them a 1% cyan. RIP Pro can then distinguish between background that is not suppose to print and white areas of the image that should print.

    Prevention: Prepare all designs for RIP Pro software.

 
PROBLEM: White underbase peaks out from under the color layer on one side
Reasons, Solutions, and Prevention:
  1. Choke settings in RIP Pro need to be adjusted

    Solution: Go to Utilities on the tool bar and choose Printer & Ink Configuration. Choose Choke & Feed Adjustment. Make adjustments and test. Adjust more if needed.

 
PROBLEM: Color looks dull after curing.
Reasons, Solutions, and Prevention:
  1. Heat press is too hot

    Solution: Without White Ink: 1 minute and 30 seconds at 325 degrees
    With White Ink: 2 minutes and 30 seconds at 325 degrees


  2. Improper Pre-treatment

    Solution: Spray a bit more pre-treat


  3. White Ink on 50/50 or 100% polyester

    Solution: White Ink only works well with 100% cotton.

 
PROBLEM: Image on the shirt is washing out, fading or peeling.
Reasons, Solutions, and Prevention:
  1. Shirt was not cured properly

    Solution: Without White Ink: 1 minute and 30 seconds at 325 degrees
    With White Ink: 2 minutes and 30 seconds at 325 degrees


  2. Shirt was not pre-treated properly

    Solution 1: Too much time on the heat press when setting the white ink pre-treat will cause peeling. Press pre-treat on heat press for 10 seconds at 325 degrees.

    Solution 2: Too much pre-treat can also cause peeling. Cut back on the amount being sprayed.


  3. Printing on fabric that is not appropriate for inkjet printing.

    Solution: With white ink printing, always use 100% cotton. When printing without white ink, many fabric types can be used and 50/50 will give good results. Synthetic fabrics may require a poly pre-treatment.

 
PROBLEM: Inks stick to Teflon sheet or parchment paper when curing the final print.
Reasons, Solutions, and Prevention:
  1. Build up of pre-treatment on the Teflon sheet or parchment paper

    Solution 1: Clean Teflon sheet with water and soap and dry

    Solution 2: Use a new piece of parchment paper


  2. Too much pressure on the heat press

    Solution: Decrease the amount of pressure on the heat press.

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