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Try Foxit PhantomPDF. It's a stupid name but it's a legit software. I use it instead of Adobe actually. It's free but they will ask you to upgrade to a premium account that allows all features to be used. The free version still allows you to print to PDF from there and it uses it's own virtual...
With my method you setup the cut settings on the cutter itself and don't allow the software to control that. Then if you send the spot color file over, it should just use the settings for which ever tool you chose. But maybe Onyx doesn't support this.
I don't use Onyx so this may not work but, have you tried using the spot color method of setting up the file? Basically you make a spot color and name it, "CutContour" and the RIP should interpret it as a cut line. Then you can make a spot color called, "CutContourHalf" and it will interpret it...
Unfortunately I don't have anything for that model but you might find the service manual online. A lot of times someone here on Signs101 will have one to send you. Good luck!
Looks like the black is deflecting pretty bad but the LC and LM are better minus the missing nozzles in the LC. I'd pop in some new cap tops and flush the pump tubes to see if I could recover the those heads a little better.
If your tech was out there and thinks the printer is functioning properly, i.e. no missing nozzles or drop out during prints, you need to make a custom profile if you want to reach the full potential of your machine's gamut. You can either buy the equipment and do it yourself or hire someone to...
In my experience if a head can't be recovered with flushes and soaks, it's not coming back. Usually when you see as many deflections you have in your test print, the head either sat for a very long time, which we know, and/or the nozzles are physically damaged. Once there is physical damage...
I don't have a lot of experience with that model but if the line is horizontal, it could be the encoder disc near the print feed motor. If that's dirty or damaged it will give you light lines like that.
Edit: Looks like you already cleaned the disc. Look for damage as well.
There are just too many deflecting nozzles to get a clean print. You could try head soaks and a new cap top but it's probably not going to improve much.
In that case maybe it is an electrical issue. The HDC board basically controls the heads so if there is a bad voltage regulator or something similar that could be the case. It's just weird that it works for a few hours and then starts to clog again.
If ink cross contaminated like you describe...
If that were the case I think you'd be blowing fuses left and right. Unfortunately it sounds like one of those tough ones. It doesn't seem to be a flow issue. And missing a few random nozzles would be very rare, if not impossible, to be electronic. That only leaves clogging in my opinion.
Do...
I'm sure many people have had good experiences with 20/20 inks but as a company who sells parts and works on machines in the field, we have a policy that we won't work on a machine with 20/20 inks unless you want to convert to OEM or another 3rd party ink.
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