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Just a quick update. We're in the process of testing some potential fixes. Will post as we know more.

Do either the encoder or calibration issues jive with our "from a cold start, it typically seems to happen once we're into the 3rd banner" comment? Do the components involved get hot or whatever? In other words, why would it not happen when it's cold, but once it's been going for a little...

I took a few more photos in landscape mode (rotated from the first set of photos) to hopefully better show how it's "stepping" once the problem begins. One more thing. It seems to be kind of heat / use related? When the printer starts from cold, it almost always takes until the third banner...

We're printing on roll vinyl, so the length changes from banner to banner. In the VersaWorks program the length setting is greyed out. We haven't made any changes to these settings for the just about 5 years or so we've had it, and that setting has never been a problem.

Assuming you're referring to the red light, yes. Once just blowing it out, and later taking it apart and cleaning. Unfortunately that didn't fix it.

My first post. Thanks for this great forum. We're having an issue with a Roland SP-540V printer. Every 3 banners or so (generally 3' x 8' with minimal graphics), I get this alignment / stair stepping problem (I'm not really sure what to "call" it). We've already replaced the encoding strip...