User Manual
Model 676 - LOKPRINT™
Machine Configuration 2 over 1, 1 over 1 & 2 over 0
AVERY DENNISON
Manual Edition 3.0
20 August 2004
Manual Part Number 371389
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Contents
Scope
1
Introduction................................................................................................................................1
Safety Issues / Warnings
1
Caution.......................................................................................................................................1
Warranty Information
2
Description / Specifications
3
Printer Description.....................................................................................................................3
Printer Specification ..................................................................................................................5
Personal Computer Specifications .............................................................................................6
Customer Responsibility
7
Location of Printer.....................................................................................................................7
AC Power Line ..........................................................................................................................9
Printer Unpacking / Installation
9
Unpacking..................................................................................................................................9
Inventory of Components.........................................................................................................10
Fuse Configuration...................................................................................................................11
Installing the Power Cord ........................................................................................................12
Installing the PC Interface Cable .............................................................................................12
Installing the PC Software .......................................................................................................12
TCB Dip Switch S2 Settings....................................................................................................12
Printer Operation
13
Loading Stock..........................................................................................................................13
Butt Splice ...............................................................................................................................14
Web Guides .............................................................................................................................14
Print Head Operation ...............................................................................................................15
Installing Ink Ribbon ...............................................................................................................17
Splices......................................................................................................................................18
Control Panel Operation
19
Printer Controls........................................................................................................................19
Indicator Lights........................................................................................................................20
Display Modes.........................................................................................................................22
User Manual Model 676 LOKPRINT®
Scope • iii
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Adjustments
32
Feed Roller Pressure................................................................................................................32
Sensors.....................................................................................................................................32
Sensor Adjustments: ................................................................................................................32
Machine Set Up Sequence .......................................................................................................33
Maintenance
34
Cleaning...................................................................................................................................34
Print Head Handling ................................................................................................................35
Print Head Replacement ..........................................................................................................36
Lubrication Procedure..............................................................................................................39
Electrical Trouble Shooting
40
Power Up / Sign On / Communications ...................................................................................40
Stock / Ink Advance.................................................................................................................42
Print .........................................................................................................................................43
Mechanical Trouble Shooting
44
Stock........................................................................................................................................44
Ink............................................................................................................................................45
Print .........................................................................................................................................45
Appendix A
46
Error Messages ........................................................................................................................46
Appendix B
47
Software Upgrade Chip Placement Positions...........................................................................47
Front Panel Diagnostic Descriptions........................................................................................49
Appendix C
50
Printhead Life Extension..........................................................................................................50
Printhead Fail Modes...............................................................................................................51
Printhead Cleaning Procedure..................................................................................................52
Printhead Installation and Removal Procedures.......................................................................53
Electrical Assembly Drawings
54
Machine Wiring.......................................................................................................................54
Electrical System Schematic....................................................................................................55
Motherboard Power Connectors ..............................................................................................56
Mechanical Assembly Drawings
57
Unwind Assembly Drawing .....................................................................................................58
Unwind Parts List ....................................................................................................................59
Web Guide Assembly Drawing................................................................................................60
Web Guide Parts List...............................................................................................................61
Drive Assembly Drawing.........................................................................................................62
Drive Parts List........................................................................................................................63
Top - Printhead Assembly Drawing.........................................................................................64
iv • Scope
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Top - Printhead Parts List........................................................................................................65
Bottom – Printhead Assembly Drawing...................................................................................66
Bottom – Printhead Parts List..................................................................................................67
Ink Unwind / Rewind Assembly Drawing................................................................................68
Ink Unwind / Rewind Parts List...............................................................................................69
Web Tension Guide Assembly Drawing..................................................................................70
Web Tension Guide Parts List.................................................................................................71
Drive Belt Routing Drawing....................................................................................................72
User Manual Model 676 LOKPRINT®
Scope • v
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Scope
Introduction
This user manual was arranged for the person who is going to operate the machine.
The information is arranged in the order that is needed to install and operate the
machine. It starts with general information, then to unpacking the crate, installing the
stock and ink ribbon, printer operation, control panel operation, and finally care and
maintenance of the printer.
We at AVERY DENNISON hope that you will come to appreciate the efforts and
quality that has gone into producing your AVERY DENNISON 676LKP Printer and
wish to remind you that you are our number one priority. We welcome any
constructive comments or criticisms so that we may continue to offer you the best
printer in the industry for years to come.
Safety Issues / Warnings
Caution
This machine has some pinch points. All of these areas have been well guarded and
it is recommended that the safety features of this machine are never altered or
defeated.
User Manual Model 676 LOKPRINT®
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Warranty Information
Limited Warranty
AVERY DENNISON extends the following warranties to the original purchaser of a
AVERY DENNISON 676LKP that has been installed and operated using
recommended procedures and operating conditions.
Parts
Parts found defective in material or workmanship will be replaced at no charge for a
period of six months following the machine's shipment date. Parts damaged by
negligence, abuse, or normal wear are not covered. AVERY DENNISON 676LKP
parts classed as normal wear items include print heads, feed and platen rollers, and
knife blades.
Service
Service to replace defective parts as defined above, shall be provided at no charge for
a period of six months following the shipment date.
When ordering machines and supplies in the U.S.A., reference all correspondence to
the address below.
AVERY DENNISON
One Wilcox Street
Sayre, Pa. 18840
Call:
Fax:
1-800-967-2927 or (570) 888-6641
(570) 888-5230
For spare parts, requests for service or technical support
AVERY DENNISON
One Wilcox Street
Sayre, Pa. 18840
Call:
Fax:
1-800-967-2927 or (570) 888-6641
(570) 888-5230
For parts and service in other countries please contact your local AVERY
DENNISON supplier.
AVERY DENNISON reserves the right to incorporate any modifications or
improvements in the machine system and machine specifications which it considers
necessary and does not assume any obligation to make said changes in equipment
previously sold.
2 • Warranty Information
User Manual Model 676 LOKPRINT®
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Description / Specifications
Printer Description
The AVERY DENNISON MODEL 676 LKP THERMAL PRINTER (Figure 1) is
an electronic printer that can print on noncoated polyester stocks. The printer is
available as a 2 station single sided printer, a 2 over 1- two-sided printer and as a 1
over 1 - two-sided printer. The printer interfaces to a computer or a main frame
system that allows for computer input or even design of a label with AVERY
DENNISON’S PCMate Plus's “FORMATTER” program. The printer can generate a
complete label printed on one side, with two colors on the top, two sided with either
two colors on top with a third on the bottom, or one color on top with a second color
on the bottom.
• Design your own labels on a PC
• Computer interface = IBM Compatible
• Mainframe direct interface
• RS232 9 Pin D shell female Serial interface connector
Figure 1 - AVERY DENNISON MODEL 676LKP LABEL
PRINTER
User Manual Model 676 LOKPRINT®
Description / Specifications • 3
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4 • Description / Specifications
User Manual Model 676 LOKPRINT®
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Printer Specification
Print method:
Label Size
Narrow web thermal transfer printer
Speed – 3,4, and 5 IPS (76.2, 101.6, and 127mm/second) – w/ Lokprint II, 5” only
Min: 1.062" (27mm) web x 1" (25.4mm) feed
Max: 2.0" (51mm) web x 1.0" (25.4 mm) feed
2.0" (50.8mm) web x 5.0" (127 mm) feed
No cutter included on printer
Cutting
Print Area
Min: None
Max: up to 2" (50.8mm) web x up to 13.875" (352.4 mm) feed
300 DPI x 300 DPI
Resolution
Fonts
- Resident in the printer and tested in Lokprint applications: Swiss 721Bold, Swiss 721 Heavy,
Swiss 721 black condensed, Swiss 721 Medium.
recommended
for 676LKP
printers
- Tested, must be ordered as an option: Swiss 721 BT 0003
- 7pt up to 96pt (300 DPI),
- All rotations 0°, 90°, 180°, 270°
Logos
No restriction on number or size per tag (up to maximum image area)
All rotations 0°, 90°, 180°, 270°
Care Symbols
Full Ginetex Care Symbol set and full NAFTA / ASTM Care Symbol Set
Fully Scaleable
All rotations 0°, 90°, 180°, 270°
Justification
Stock
Left, Right, and Center field selectable
Support for blank sublimation fabric only
Interface
AVERY DENNISON PCL via RS232 serial port - 9 pin D-shell
Push-button printer function with 2 Line x 24 Character International LCD Backlit Display
Control Panel
Dimensions
17.0" (431.8mm) high x 33" (838.2mm) wide with 10” O.D. supply roll (30” (762mm) printer
only) x 20.0" (508.0mm) deep
Weight
107 Lbs. (48.5Kg.)
Shipping Weight = 130 Lbs. (58.9Kg.)
Electrical
Temperature
Humidity
90-132 / 180-265 VAC 50-60Hz 10Amp 1 Ph User selectable through AC entry fuse config.
41°F (5°C) to 104°F (40°C)
5% to 90% non-condensing
User Manual Model 676 LOKPRINT®
Description / Specifications • 5
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Other Features
-
-
-
-
-
-
Downloading of information while machine is operating
Sequenced Fields
Time/Date Stamping (Both month/day/year and day/month/year format)
Life Counts
Operator adjustable: strobe, cut position, print position, baud rate, and buffer size
Error Detection of: stock out, ink out, print head open, feed open, full stacker, stacker jam,
and print head over-temperature
-
-
Display: labels left to be cut and stacked in a batch, batch ID, total life inches, total life
cuts
Self Diagnostics
Ink Ribbon
Options
AVERY DENNISON high energy dye sublimation
-
-
-
PCMate Plus w/Formatter – 800264 on 3 ½” disks or 800264CD on CD disk
Spare Parts Kit – 370016 for all head configurations
International Hardware Kit - 370014
Personal Computer Specifications
This specification describes the hardware and application software requirements for
the Personal Computer that is used to download to the AVERY DENNISON 676
LKP Printer.
The AVERY DENNISON AVERY DENNISON 676 LKP Printer uses a Windows
version of “PcMate Plus / Formatter”. This application will create the tag or label
formats (layouts) then fill and transfer data to the printer through the serial port of the
computer.
“PcMate Plus / Formatter ” Requires the following;
•
•
IBM® PC or compatible
Microsoft Windows® 98 2nd edition or higher
(Including Win 2000, ME, NT, and XP)
64 Megabytes RAM
•
•
•
•
1 Gigabyte Hard Drive
Pentium or Pentium Type processor - 400 Mhz or higher
3-1/2" floppy drive and CD Rom
DISK DRIVES: You will need a hard disk with at least 100 megabytes of free disk
space to store the PCMate Plus program. Additional space will be required to store
formats, batches, etc.
Refer to your specific software package for proper installation procedures.
6 • Description / Specifications
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Customer Responsibility
Location of Printer
The printer weighs approximately 250 Lbs (113.4 Kg) and requires a table of
sufficient quality and strength to handle this load while the printer is operating.
AVERY DENNISON recommends an industrial type worktable having the
approximate dimensions of 96" (245.8cm) wide to 30" (76.2Ccm) deep to 32"
(81.3cm) high. Refer to Figure 2.
Figure 2 - Recommended Workstation Layout.
The location of the AVERY DENNISON 676 LKP printer should be based on
human factors. The printer should be located in an area that maintains optimum flow
of your product while providing for the operator’s comfort. AVERY DENNISON
has taken significant steps to ensure that the operator controls and operations are
easily accessible. This goal can only be met, however, if the printer is also located
with human factors in mind. These include the height of the printer, the space around
the printer, and the accessibility to the printer.
The AVERY DENNISON 676 LKP printer is a high-resolution 300 DPI thermal
printer. While AVERY DENNISON has designed the printer to be reasonably quiet,
it is recommended to locate the printer in an area where printing and cutting
repetitious noise is acceptable.
The AVERY DENNISON 676 LKP printer is designed to operate in conjunction
with the AVERY DENNISON Lokprint™ II box and either an Ultrasonic Finisher, a
Cold Knife Finisher or a Rewind Unit.
User Manual Model 676 LOKPRINT®
Customer Responsibility • 7
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The unit should always be operated with the cover closed to minimize the amount of
dust and dirt in the machine.
8 • Customer Responsibility
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AC Power Line
AVERY DENNISON requires that the electric service be 10 Amps @ 115VAC or 10
Amps @ 230VAC. This will allow the computer and any additional support or
service equipment to be plugged into the same service.
Any electrical service which is supplying a AVERY DENNISON printer or
peripheral equipment connected to a AVERY DENNISON printer should follow
standard electrical code practices including proper grounding and neutral
requirements.
The AVERY DENNISON printer was designed to operate in an industrial setting for
extended periods of time; however, the printer is controlled by a microprocessor
which is very sensitive to brownouts or power spikes. For this reason as well as the
minimum recommended current supply, AVERY DENNISON recommends that a
separate “clean” service be installed or reserved for the exclusive use of the AVERY
DENNISON printer and it’s peripherals.
Printer Unpacking / Installation
Unpacking
The AVERY DENNISON printer is shipped in a large cardboard box that may be
difficult to move by hand.
DO NOT REMOVE THE PRINTER FROM THE PACKAGE OR UNPACK
IN THE SHIPPING / RECEIVING DEPARTMENT.
NOTE: Unpacking in the shipping / receiving department is not recommended for
the following reasons.
First: The box in which your AVERY DENNISON printer was shipped allows the
printer to be moved with a forklift, forkcart or handcart. Because of the
weight of the printer, it is easier and safer to use one of these devices to
move the printer to its intended installation location.
Second: Leaving the printer in the crate while it is being moved within your
facility will help to protect the printer during the movements to this new
location. Once the printer has reached its intended location you should
begin the unpacking process.
Open the box from top by removing the two (2) banding straps and cutting the tape
seam on top of the printer. (See Figure 3).
Remove the plastic over the printer.
Remove all the smaller loss items from in and around the printer.
There is a sleeve to lift the printer from the box for easy removal.
Lift the printer onto the table.
User Manual Model 676 LOKPRINT®
Printer Unpacking / Installation • 9
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Inspect the machine for shipping damage. If obvious damage is discovered, contact
AVERY DENNISON for further instructions - in the U.S.A. at (570) 888-6641. In
countries other than the U.S.A. please contact your local AVERY DENNISON
supplier.
Figure 3 - Shipping Box.
Save the shipping materials to relocate the unit or return to factory for service.
Inventory of Components
The following list shows the additional parts (pieces) that should be included in your
AVERY DENNISON 676 shipping crate. If anything is missing, notify AVERY
DENNISON immediately - in the U.S.A. at (570) 888-6641. In countries other than
the U.S.A. please contact your local AVERY DENNISON supplier.
- AVERY DENNISON 676 LKP "User's Manual"
- A quick-disconnect power cord
- A serial communications cable with adapter
- Optional software ordered to drive the printer.
- Tool kit
NOTE: Some of the above parts may be inside the envelope that contains the tool
kit.
AVERY DENNISON 676LKP TOOL KIT (#371391)
241149
241132
921309
101330
921304
921364
351156
Anti-Static Gloves (2)
Anti-Static Wrist Strap
Hex Key Set
9/64” Ball Driver
5/32” Ball Driver
3/16" Long Ball Driver
Chip Removal Tool
371389
921353
676LKP Users Manual
Phillips Head Screwdriver
921338
T-T Printer Cleaning Kit
10 • Printer Unpacking / Installation
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Fuse Configuration
The main fuse(s) on the AVERY DENNISON 676 LKP are located inside the AC
power entry receptacle. The entry has a fuse drawer that holds the fuse(s) and selects
the appropriate line voltage. If the number in the window DOES NOT match the AC
line intended to be supplied to the printer, DO NOT plug the power cord in. Re
configure as follows:
1) Using a flat blade screwdriver, open the AC entry by lifting the tab just above the
voltage indicator window.
WARNING: Attempting to open the AC entry with the AC power cord inserted into
it will cause damage to the AC entry.
2) Remove the red fuse drawer.
3) Remove all fuses and the fuse jumper if it is present.
4) Insert into the fuse drawer the correct number and style of fuses and fuse jumper
for your application.
Configuration Number One:
Line voltage between the range of
90 - 132VAC @ 50 - 60Hz 1 Ph
1) Install one 921167 - 10.0A 250V Fast Acting 1/4 x 1 1/4"
2) Install one Fuse Jumper
See Figure FUSE1
Configuration Number Two:
Line voltage between the range of
180 - 265VAC @ 50 - 60Hz 1 Ph
1) Install two 921168 10.0A 250V Fast Acting 5 x 20MM
NOTE: The fuse jumper must be removed to install both 5 x
20mm fuses.
The fuses must be between points A and B as shown not B and C.
See Figure FUSE2
FUSE 1
FUSE 2
Fuse Jum per
5 x 20 m m fuse
FRONT
FRONT
Location of 115V Text
Location of 115V Text
A
C
B
Location of 230V Text
Location of 230V Text
One 1/4 x 1 1/4" Fuse Far Side
Two 5 x 20MM Fuses One Each Side
5) Reinsert the fuse drawer into the AC entry with the desired voltage up.
6) Close the AC entry and verify the correct voltage is now visible.
User Manual Model 676 LOKPRINT®
Printer Unpacking / Installation • 11
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Installing the Power Cord
A power cord is shipped with each printer. The cord for 115-volt printers will use
the standard three-prong plug used in the U.S.A. A 230-volt printer and some other
115-volt configurations must have the receptacle end of the connector removed and
the proper plug installed. It is the customers’ responsibility to have the plug and
alteration work done by a certified electrician. AVERY DENNISON supplies
printers to many countries with many variations. Therefore we leave this to the
customer to make the proper selection for their country.
Installing the PC Interface Cable
The 676 requires a 9-pin RS232 cable. This cable is provided with the printer. If the
cable was not found it can be ordered from AVERY DENNISON (Part no. 351124).
The male end of the cable should be connected to the 9-pin D-shell female connector
that is located on the right side of the printer. The female end of the cable is made to
fit a 9-pin male RS232 connector on the back of the PC.
Installing the PC Software
The software to drive the AVERY DENNISON family of printers is covered in
separate documentation. The “Formatter” software to create formats for the AVERY
DENNISON 676 printer is a Windows application. The original software “Selfform”
will not create formats for the 676. The new "PCMate" package is capable of making
formats for all AVERY DENNISON control printers.
PCMate Plus Ver. 3.21.32 will support the 676LKP. Lower versions may not contain
the test drivers.
The printer is also capable of operating directly from a mainframe when using the
RS232 interface and AVERY DENNISON's PCL command language.
TCB Dip Switch S2 Settings
DIP SWITCH #
DEFINITION
LOKPRINT™
UNUSED
UNUSED
STACKER
MACHINE
TYPE
676 LOKPRINT™
8
7
6
5
4
OFF
OFF
OFF
OFF
ON
3
MACHINE
TYPE
ON
2
1
UNUSED
300 DPI
OFF
ON
12 • Printer Unpacking / Installation
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Printer Operation
Loading Stock
TAKE-UP
HEAD 2
SUPPLY
HEAD 3
SUPPLY
HEAD 2
TAKE-UP
HEAD 3
INK
FABRIC
INK
HEAD 2
HEAD 3
WEB GUIDE
HEAD 1
DRIVE / AUX
STOCK
TAKE-UP
HEAD 1
SUPPLY
HEAD 1
Figure 4 - LOKPRINT® Threading Diagram
Loading Stock For The First Time
1) Adjust the unwind width wider than the roll of stock to be loaded. Set the stock
roll on the unwind between the guides with the stock unwinding from the top
clockwise. Adjust the unwind width down to the stock size with the outer guide
contacting the roll. Turn the knob an additional ½ turn clockwise. This will
activate the constant backpressure device.
2) Adjust the web guides to a width wider than the stock.
3) Remove the tape or pull the glued end of the stock loose from the supply roll of
stock. Pull off about 2 feet (.5 m) of stock to thread it through the printer.
NOTE: If the material was glued to the core, cut off all material that has glue on any
surface.
4) Open the hinged cover to the machine.
5) Open all print heads that are in use by pulling the release knob and then rotating
the print heads into the open latched position. The print stations have a pin in
the rear to hold them open.
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6) Open the feed rollers by rotating the feed pressure knob counterclockwise.
7) After looping the leading edge of the stock over the decurler slide it through the
web guides. Keep the stock in the center, as the printer is center justified.
8) As the stock exits the web guides, continue to slide the stock through the print
stations.
9) Once the stock reaches the feed rollers it maybe necessary to hold the feed
pressure knob open in order to pass between the rollers.
10) Check that the stock is centered and tracking straight through the printer. Adjust
as needed.
11) Allow feed to close (spring loaded). Close the printheads that are in use. Do not
run a station closed that is not in use. This will cause premature head failure.
12) Rewind any loose stock back onto the supply roll.
13) Adjust the web guides on the decurler down to the edges of the stock without
deforming the stock.
Butt Splice
NOTE: DO NOT RUN BUTT SPLICES THROUGH THE PRINT STATIONS
The AVERY DENNISON 676 LKP has been designed keeping the operators need to
change supplies quickly and often in mind. Re threading the stock is quicker than
butt splicing is. If however you have determined a butt splice is necessary, after
loading a new roll of stock onto the unwind tape the free ends together. Remove all
slack by rotating the supply roll counterclockwise. To prolong print head life it is
highly recommended that all hand splices be advanced beyond the print stations
before printing is resumes. This can best be accomplished by using the stock
presently in the print stations to manually pull the new stock through and into the
stacker. Once the butt splice is in the stacker close the feed rollers and those print
stations needed for the format.
NOTE: Whenever stock of a different type or width is put on the printer, a sample
run should be performed. If the print quality / position is acceptable, you
can immediately begin your production run. If the print quality / position
needs to be optimized, refer to the Adjustments section and perform the
procedure needed to make the necessary improvement.
Web Guides
The AVERY DENNISON 676 LKP printer has been designed with the operators'
needs in mind. Therefore there are only two sets of web guides in the printer that
need to be changed as the width of the rolls change for various width stocks. Neither
of these adjustments require a tool.
The first guide is on the unwind itself. A knob located on the front of the unwind
adjusts the width of the guides on the unwind while maintaining center justification.
To increase the width, turn the knob counter clockwise - to decrease the width, turn
the knob clockwise. Adjust the unwind width wider than the roll of stock to be
loaded. Set the stock roll on the unwind between the guides with the stock
unwinding from the top clockwise. Adjust the unwind width down to the stock size
14 • Printer Operation
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with the outer guide contacting the roll. Turn the knob an additional ½ turn
clockwise. This will activate the constant backpressure device.
The second set of guides are located on the decurler just to the left of the stock
registration funnel. Once a stock is loaded and tracking straight through the machine
adjust this set of web guides down to the edges of the stock without deforming the
stock. If a large distance is to be covered - loosen the plastic thumb screw and slide
the collar into the new position - then retighten the thumbscrew. Fine adjustments of
the stocks web position can be made by simply moving the collar as a set in or out. If
the guides are too tight, the stock will have rolled up edges.
CENTER
FRAME
REAR
WEB GUIDE
SHOULDER BOLT
PRESSURE ASSEMBLY
373093 (NEW)
989995 (NEW)
8-32 NUT
990069 (NEW)
Print Head Operation
The print head modules are to be opened and closed for threading of stock and ink.
The unit must also be opened to clean the head and for print head replacement. Later
in the manual, under separate headings, cleaning and replacement will be covered.
For clarity the print stations have been assigned numbers one through three from left
to right. The far-left print station prints the back, it is print station number one. The
center and right print stations print on the top, they are stations two and three. Each
print station has an interlock switch that prevents the printer from running with any or
all print stations in the open position if that print station is assigned in the format
being printed. If a print station is open, the display will read HEAD OPEN
STATION X.
WARNING: DO NOT TOUCH THE PRINT HEAD WITHOUT WEARING THE
ANTI-STATIC GLOVES AND THE ANTI-STATIC WRIST STRAP.
To open the print heads for threading supplies or cleaning pulling the release knob
and then rotating the print head into the open latched position (see figure 5). The top
two print stations have a pin in the rear to hold them open. The bottom print station
will remain open via gravity - however it has a hole in the rear to hold the print head
in a slightly open position to act as a bridge when one is threading stock.
User Manual Model 676 LOKPRINT®
Printer Operation • 15
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Figure 5 - Print Head Open / Closed
To close the head again pull the release knob and then rotate the print head into the
closed latched position (see figure 5).
16 • Printer Operation
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Installing Ink Ribbon
The ink ribbon comes pre-packaged in a plastic bag. For best results, leave the ink
ribbon wrapped in this bag until you are ready to use it in the printer. Use the
procedure and diagram below for loading the ink.
TAKE-UP
HEAD 2
SUPPLY
HEAD 3
SUPPLY
HEAD 2
TAKE-UP
HEAD 3
INK
FABRIC
INK
HEAD 2
HEAD 3
WEB GUIDE
HEAD 1
DRIVE / AUX
STOCK
TAKE-UP
HEAD 1
SUPPLY
HEAD 1
Figure 6
1) Unwrap the ink ribbon and put it on the ink-ribbon supply arbor for the print
station to be loaded (Figure 6) by pressing it on to the arbor when the three slots
are lined up.
2) Make sure the ink ribbon comes off the roll in the direction shown and is threaded
as illustrated (Figure 6).
NOTE: A new ink ribbon has a leader that makes it easier to use when threading the
ribbon through the print area.
3) Place an empty ink-ribbon take-up core on the ink-ribbon take-up arbor for the
print station to be loaded. The ink take-up core must be at least as wide as the ink
supply.
4) Open the print head to the print station being loaded.
5) After starting the leader off the supply roll - pull enough ink off to thread though
the print station and onto the take up core. The adhesive on the supply roll of ink
will be used to fasten the leader to the take up core.
NOTE: Make sure that the ink-ribbon take-up core and the ink-ribbon supply roll
are both against the ink backer plate so that the ink ribbon tracks straight
through the print station.
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Splices
The sonic splices were dropped because they were damaging print heads and would
not pull through the web guides.
The new splice tape will not damage the printer, but will NOT print. The new splice
may cause a sensor error on the SS Finisher. However, they will sonically cut.
18 • Printer Operation
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Control Panel Operation
Printer Controls
Start
- Starts the printer
- ON LINE light must be GREEN
(Batches downloaded to be printed)
Feed
- FEED and START must both be used
- Feed will stop when the buttons are released
- Labels between print station one and the knife will be cut and stacked as
finished labels
- Stock moves through in one continuous strip
- Stock moves through without printing
- Ink will advance, ink save on print station two will automatically be
activated.
- The print heads must be latched in the down position.
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Test
- TEST and START must both be used
- Test will stop when the buttons are released
- Labels between print station one and the knife will be cut and stacked as
finished labels
- Stock moves through in one continuous strip
- Stock moves through with test pattern printing
- The ink will advance with the stock.
- The print heads must be latched in the down position.
Stop
- The stop button will stop the printer at the end of the current label being
printed.
Indicator Lights
The AVERY DENNISON 676 has three Indicator lights. These lights are used along
with the LCD display to tell the operator the current status of the printer.
On Line
OFF
- Has not been powered on.
- Is in its power - up sequence.
- Failed the system test
After Power Up Sequence:
- Printer is running.
20 • Control Panel Operation
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ORANGE
- System is operational
- Ready for batches to be downloaded
GREEN
- Batches to print, ready to start
Sensor
GREEN = "C" SENSOR
- Printer is stopped, - light is on, - sensor is positioned over a web sensor
mark
- Flashing light while the printer is running, - the sensor is in-line with the
registration HOLES
ORANGE = REFLECTIVE SENSOR
- Flashing light while the printer is running, - the sensor is in-line with the
registration PRINTED MARKS
Error
ORANGE
- System inter-lock triggered, display for error LCD Display
The LCD display is a 2 line, 24 character, with back lighting feature for easy
readability. The first line of the display, in most cases, will be a prompt or question -
the second line is the response.
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Display Modes
There are four (4) main mode levels that are selected and modified using the
following function keys:
Use the MODE ↓ key to move through the main mode screens shown below:
Pressing the EXIT / Up arrow button will put the user at one of these two screens.
HOME SCREEN
R E A D Y
F O R
B A T C H E S
6 7 6
/
3 0 0
/
L O K P R I N T
I
I
OR
B A T C H
I D
Q U A N T
I
T Y
1 0
P C L 0 0 1
Press the MODE / Down arrow button will cycle the panel through the following
main screens.
PRINTER ADJUSTMENTS
P R E S S
E N T E R
F O R
P R I N T / C U T
P O S
I
T
I O N S
PRINTHEAD ADJUSTMENTS
P R E S S
P R I N T
E N T E R
F O R
H E A D
S E T U P
CALIBRATE SENSORS
P R E S S
E N T E R
F O R
C A L I B R A T I N G
S E N S O R S
LIFE COUNTS / VERSIONS
P R E S S
F E
E N T E R
F O R
L
I
C O U N T S / V E R S I O N S
22 • Control Panel Operation
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SETUP SCREEN
P R E S S
E N T E R
F O R
F E A T U R E
S E T U P
VERIFIER SETUP SCREEN
P R E S S
V E R I
E N T E R
F O R
F
I
E R S E T U P
POWER UP DIAGNOSTICS
D I A G N O S T I C
T E S T
1
This screen is displayed while the Front Panel is initializing and waiting for the
Thermal Control Board (TCB) response. While this screen is displayed the code will
check the functionality of the LED's and the display. Each state of the LED's will be
checked - (red, green, amber and off). The LCD is checked by writing a character to
the display, checking for communications and then reading the character back and
comparing with the code. If an error occurs, the code will halt the diagnostic test and
blink the ERROR LED.
The keypad is also checked during DIAGNOSTIC TEST 1. Each key is tested to see
if it is stuck on. If a fault condition is detected, the test is halted and the screen will
display the first error key found with the following display:
( B U T T O N
N A M E )
K E Y
S T U C K
The (BUTTON NAME) will be one of the push button names on the front panel -
START, FEED, TEST, STOP, EXIT, MODE, <YES, NO>, OR ENTER.
When the code has finished the above tests, the code will attempt to communicate
with the Control Board (TCB).
D I A G N O S T I C
T C B V E R S I O N
T E S T
0 0
# # #
0 0
.
This screen will be updated with diagnostic numbers as the TCB and AT go through
different stages of PowerPC initialization.
The diagnostic test screen will also be displayed when the Diagnostic tests that are
runable from the front panel are being executed.
Once the diagnostic tests are complete, the Front Panel should display the HOME
screen.
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HOME SCREEN
R E A D Y
F O R
B A T C H E S
6 7 6 3 0 0
/
OR
B A T C H
I D
Q U A N T
I
T Y
1 0
P C L 0 0 1
When the printer is powered up and all initializations are complete, if there aren’t any
Batches to print, the "HOME" screen will be "READY FOR BATCHES" and the
model and print head density.
When there are Batches to be printed, the "HOME" screen will be the
"BATCH ID
QTY" screen. The Batch ID / Batch Qty screen displays the
currently cutting batch ID and labels remaining to be cut.
Note: Look into suppressing leading zeros on batch quantity.
When the Batch Id / Qty screen is the home screen and the user presses the EXIT
button the Model and DPI are displayed briefly before the Batch Id / Qty screen is
shown.
If the printer is performing a FEED or a TEST pattern, the screen will show
"FEEDING" or "PRINTING TEST PATTERN" respectively on line two, the top line
will be blank
F E E D I N G
P R I N T I N G
T E S T
P A T T E R N
Pressing the MODE / Down Arrow key will take the user to the "PRINT / CUT
POSITIONS" screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
24 • Control Panel Operation
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PRINT / CUT POSITIONS
P R E S S
E N T E R
F O R
P R I N T / C U T
P O S
I
T
I O N S
This screen follows the Batch ID / Batch Qty screen if there are batches to print,
otherwise it follows the “Ready for batches” / Model DPI “HOME” screen.
Pressing ENTER will take the user to the PRINTER ADJUSTMENTS screens.
Pressing the MODE / Down Arrow key will take the user to the "PRINTHEAD
SETUP" screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
PRINTER ADJUSTMENTS
P R E S S
P R I N T
E N T E R
T O
C H E C K O U T
F O R M A T
This screen is the first screen under PRINTER ADJUSTMENTS. Pressing ENTER
will cause the printer to print the checkout format. The printer will setup to do the
checkout format and start printing. The front panel will remain on this screen so the
user can use the MODE / Down Arrow key to get to the printer adjustments. When
the EXIT / Up Arrow key is pressed the printer stops printing the checkout format
and goes back to what it was doing before the checkout was requested.
Pressing the MODE / Down Arrow key will take the user to the first screen of this
group. Pressing the EXIT / Up Arrow key will take the user back to the "HOME"
screen.
P R I N T
P O S
I
T
I O N
N E W
S T A T I O N
1
V A L U E : ± X X
V A L U E : ± Y Y
Station 1 not used.
P R I N T
P O S
I
T
I O N
N E W
S T A T I O N
2
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows the first screen under PRINTER ADJUSTMENTS. This screen
allows the print position of station 2 to be adjusted.
The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive / negative format. The value ranges for XX and
YY can be from a -9 to a +9
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME .
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P R I N T
P O S
I
T
I O N
N E W
S T A T I O N
3
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows the second screen under PRINTER ADJUSTMENTS. This
screen allows the print position of station 3 to be adjusted.
The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive / negative format. The value ranges for XX and
YY can be from a -9 to a +9
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME .
S T A T I O N
2
D O T
N E W
S H I F T
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows the CHANGE CUT POSITION screen. This screen allows the
print position of station 2 to be adjusted in the WEB direction.
The <YES / NO> buttons are used to change the shift value.
The value is displayed in a positive / negative format. The value ranges for XX and
YY can be from a -16 to a +16 dots. (One dot is 1/300")
Pressing the MODE / Down Arrow key will take the user to the first screen under
PRINTER ADJUSTMENTS.
Pressing the EXIT / Up Arrow key will take the user back to the HOME.
PRINTHEAD SETUP
P R E S S
E N T E R
F O R
P R I N T H E A D
S E T U P
This screen follows the PRINT POSITIONS screen.
Pressing ENTER will take the user to the PRINTHEAD SETUP screens.
Pressing the MODE / Down Arrow key will take the user to the "LIFE COUNTS /
VERSIONS" screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
C H A N G E
S T R O B E
N E W
S T A T I O N
2
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows strobe adjust for station 1. This screen allows the user to adjust
the strobe for station 2. The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive / negative format. The value ranges for X and Y
can be from a -7 to a +7. Pressing ENTER will change the CURRENT STROBE
value to the NEW STROBE value.
Pressing the MODE / Down Arrow key will take the user to the next screen. Pressing
the EXIT / Up Arrow key will take the user back to the HOME screen.
26 • Control Panel Operation
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C H A N G E
S T R O B E
N E W
S T A T I O N
3
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows strobe adjust for station 2. This screen allows the user to adjust
the strobe for station 3. The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive / negative format. The value ranges for X and Y
can be from a -7 to a +7. Pressing ENTER will change the CURRENT STROBE
value to the NEW STROBE value.
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
H E A D
C A T E G O R Y
N E W
S T A T I O N
2
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows HEAD CATEGORY STATION 1. The screen allows the user to
enter the head category for station 2. The <YES / NO> buttons are used to change
the head category value. The value ranges from 1 to 8. Pressing ENTER will change
the head category value to the new value. See the section “PRINTHEAD
REPLACEMENT” for instructions on setting the head category.
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
H E A D
C A T E G O R Y
N E W
S T A T I O N
3
V A L U E : ± X X
V A L U E : ± Y Y
This screen follows HEAD CATEGORY STATION 2. The screen allows the user to
enter the head category for station 3. The <YES / NO> buttons are used to change
the head category value. The value ranges from 1 to 8. Pressing ENTER will change
the head category value to the new value. See the section “PRINTHEAD
REPLACEMENT” for instructions on setting the head category.
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
S T A T I O N
A C T
I
V A T I O N
P R E S S
2 3
C L O S E H E A D S
E N T E R
This screen follows HEAD CATEGORY STATION3. The screen allows the user to
configure the printer for the number of heads in the system. The numbers ’2’, ’3’
stand for stations 2 and 3. If the number appears on the screen then it means that
station is activated. If the number doesn’t appear on the screen then that station is
not activated and the printer will not print, look for ink out, or look for head open on
that print station.
The printer determines if a head is in the system by checking the head open switch
when the ‘Enter’ button is pressed. If the user would like to disable a station that is
User Manual Model 676 LOKPRINT®
Control Panel Operation • 27
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in the machine for reasons of convenience then they can just open the head for that
station and press enter.
If the operating system has been changed or TCBSETUP has been used to re-
initialize the machine it will show all print stations active as the default. If it is a 1/1
printer that doesn’t have station 3 installed then the user will have to come to this
screen and press ‘Enter’ to deactivate station 3, otherwise the printer will show INK
OUT STATION3 errors when it is run.
Pressing the MODE / Down Arrow key will take the user to the first screen under
PRINTHEAD SETUP.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
LIFE COUNTS / VERSIONS
P R E S S
F E
E N T E R
F O R
L
I
C O U N T S / V E R S I O N S
This screen follows the CALIBRATE SENSORS screen.
Pressing ENTER will take the user to the Life Count and Operating system version
number Screens.
Pressing the MODE / Down Arrow key will take the user to the SETUP screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
L A B E L
P R E S S
C O U N T E R : 0 0 0 0 0 0
E N T E R
T O
R E S E T
This screen is the first screen under LIFE COUNTS / VERSIONS.
This screen shows total labels since last counter reset.
Pressing the ENTER key will reset the counter.
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
T O T A L
L A B E L S
P R O D U C E D
0 0 0 0 0 0 0 0 0 0
This screen follows the LABEL COUNTER screen. This screen displays the total
labels since the factory. This counter is NOT resettable by the user.
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
T O T A L
I N C H E S
O F
S T O C K
0 0 0 0 0 0 0 0 0 0
This screen follows the TOTAL LABELS SINCE FACTORY screen. This screen
displays the total inches since the factory. This value is NOT resettable by the user.
Pressing the MODE / Down Arrow key will take the user to the next screen. Pressing
the EXIT / Up Arrow key will take the user back to the HOME screen.
28 • Control Panel Operation
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C O N T R O L L E R
T C B 1 0 9 3 4
V E R S I O N
This screen follows the FRONT PANEL VERSION screen.
This screen shows operating system version for the controller (TCB).
Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
I M A G E R
U S A 1 9
V E R S I O N
0 1
.
This screen follows the controller version number screen.
This screen shows operating system version for the imager (AT).
Pressing the MODE / Down Arrow key will take the user to the first screen under
Counts / Version.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
FEATURE SETUP SCREEN
P R E S S
E N T E R
F O R
F E A T U R E
S E T U P
This screen follows the LIFE COUNT \ VERSIONS screen.
Pressing ENTER shows the first screen under setup.
Pressing the MODE / Down Arrow key will take the user to the PRINT / CUT
POSITIONS screen.
Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.
C U T T E R
P R E S S
I
S
E N A B L E D
E N T E R T O D I S A B L E
OR
D I S A B L E D
E N T E R T O E N A B L E
C U T T E R
P R E S S
I
S
This screen is the first screen of SETUP. This screen allows the cutter to be enabled
or disabled. Pressing ENTER will toggle from ENABLED to DISABLED and vice
versa. Pressing the MODE / Down Arrow key will take the user to the next screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
E M U L A T I O N
M O D E : N O N E
M O D E : 6 3 0
N E W E M U L A T I O N
This screen follows the CUTTER ENABLE / DISABLE screen. This screen allows
the EMULATION MODE to be changed. Use the <YES and NO> keys to move
between NONE, 630, and 650 modes. Pressing ENTER will update the emulation
mode with the selection after new emulation mode. Pressing the MODE / Down
Arrow key will take the user to the next screen. Pressing the EXIT / Up Arrow key
will take the user back to the "HOME" screen.
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D E F A U L T
V A L U E : X X X
Station 1 not used.
T R A N S F E R
T Y P E 1
N E W
V A L U E : Y Y Y
D E F A U L T
T R A N S F E R
T Y P E 2
V A L U E : X X X
N E W
V A L U E : Y Y Y
This screen follows the DEFAULT TRANSFER TYPE1 screen IF emulation mode is
something other than none. This screen allows the DEFAULT TRANSFER TYPE to
be changed. This transfer type is used when the printer is in 630 or 650 emulation
mode for print station 2. The 630 and 650 do not send valid 676 transfer types in
their PCL code. This default is used for those formats. Use the <YES and NO> keys
change the number value at the cursor position. Pressing ENTER will update the
current position with the selection and move the cursor to the next position. All three
positions must be entered. (I.e. 053 for type 53). After ENTER is pressed on the last
digit the TRANSFER TYPE on the top line will be updated. Pressing the MODE /
Down Arrow key will take the user to the next screen. Pressing the EXIT / Up Arrow
key will take the user back to the "HOME" screen.
D E F A U L T
T R A N S F E R
T Y P E 3
V A L U E : X X X
N E W
V A L U E : Y Y Y
This screen follows the DEFAULT TRANSFER TYPE2 screen IF emulation mode is
something other than none. This screen allows the DEFAULT TRANSFER TYPE to
be changed. This transfer type is used when the printer is in 630 or 650 emulation
mode for print station 3. The 630 and 650 do not send valid 676 transfer types in
their PCL code. This default is used for those formats. Use the <YES and NO> keys
change the number value at the cursor position. Pressing ENTER will update the
current position with the selection and move the cursor to the next position. All three
positions must be entered. (I.e. 053 for type 53). After ENTER is pressed on the last
digit the TRANSFER TYPE on the top line will be updated. Pressing the MODE /
Down Arrow key will take the user to the next screen. Pressing the EXIT / Up Arrow
key will take the user back to the "HOME" screen.
L A N G U A G E :
L A N G U A G E :
X X X X X X
Y Y Y Y Y Y
N E W
This screen follows the "DEFAULT TRANSFER TYPE" screen. This screen allows
the front panel display language to be changed. Use the <YES and NO> keys to
move between the supported languages on the pr1nter. Any number of front panel
languages can be stored on the Flash Disk Module (dependent on available space). If
no additional languages other than the default are available on the printer XXXXXX
and YYYYYY will be the same value. Pressing ENTER will update the display
language with the selection. Pressing the MODE / Down Arrow key will take the
user to the "PROTOCOL" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.
Warning: Mis-matched communication protocols may result in the inability to
communicate with the printer and / or loss of data.
30 • Control Panel Operation
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P R O T O C O L
P R O T O C O L
:
:
X X X X X X
Y Y Y Y Y Y
N E W
This screen follows the LANGUAGE screen. This screen allows the
communications protocol to be changed between the supported types. Use the <YES
and NO> keys to move between the supported protocols – RTS / CTS is considered
hardware handshaking and XON / XOFF is considered to be software. Pressing
ENTER will update the communications protocol with the selection. Pressing the
MODE / Down Arrow key will take the user to the next screen. Pressing the EXIT /
Up Arrow key will take the user back to the "HOME" screen.
B A U D
B A U D
R A T E : X X X X X X
R A T E : Y Y Y Y Y Y
N E W
This screen follows the PROTOCOL screen. This screen allows the serial
communications speed to be changed. Use the <YES and NO> keys to move
between the supported speeds – typical is 9600 dependent on serial communication
cable length. Pressing ENTER will update the communications speed with the
selection. Pressing the MODE / Down Arrow key will take the user to the
“CHANGE DATE AND TIME” screen. Pressing the EXIT / Up Arrow key will
take the user back to the "HOME" screen.
C H A N G E
0 3 1 4
D A T E
0 0 1 2
A N D
0 5
T
I M E
/
/
:
P M
This screen follows the “BAUD RATE” screen. This screen allows the system date
and time to be changed. When this screen appears, the first digit of the month will be
blinking. (The date is shown in US format, MM/DD/YY.) Pressing the <YES and
NO> keys will change the digit up and down respectively. Pressing ENTER will
move to the next digit. Only the digits and the A or P in AM or PM can be changed.
When all changes are complete, pressing the MODE / Down Arrow key will take the
user to the “INKSAVE ENABLE / DISABLE” screen, and pressing the EXIT / Up
Arrow key will take the user back to the “HOME” screen. If an illegal date or time is
entered, this screen will be re-displayed with the original date or time. A valid date
and time must be entered before the user can go on.
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Adjustments
Feed Roller Pressure
General
The rubber pressure roller is supported by an eccentric shaft mounted in bearings
located in vertical slots in the front and rear mounting plates of the drive module.
This roller is mounted in an extension spring controlled arm so no pressure
adjustment is required.
Sensors
Sensor Identification:
Stock Out
A micro switch located on the back of the unwind will detect when the stock core is
lifted when the stock is consumed and stop the printer. AVERY DENNISON stocks
are fastened to the supply core and will lift the core at the end of the roll. Supplies
that do not have this feature will fail to stop the printer.
Ink Out
Optical sensors located on each print station’s ink unwind arbor allow the printer to
monitor the availability of ink.
Feed Open
A micro switch on the back of the feed module will detect the position of the feed
module pressure knob and only allow the printer to operate with the feed pressure
knob closed.
Sensor Adjustments:
All the micro switches and optical sensors in your 676 LKP printer were calibrated at
the time your printer was manufactured, however from time to time it may become
necessary to readjust / recalibrate due to the large variety of stocks and inks that can
be run on the machine.
Stock Out
With a full roll of stock loaded on the unwind with the unwind web guides properly
adjusted you should heard the switch click as you raise and lower the roll. If not the
switch bail is adjusted by carefully bending it as needed.
32 • Adjustments
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Feed Open
If the switch is in need of adjustment - first check and adjust as needed the feed
pressure as it will affect the switch adjustment. With the machine rear cover
removed while opening and closing the feed pressure knob you should heard the
switch clicking. If not, the switch bail is adjusted by carefully bending it as needed.
Machine Set Up Sequence
1) Power off the printer, remove the media and ink and thoroughly clean it from the
unwind to the stock exit using alcohol and a clean soft cloth. The print heads
should be cleaned as per the Print Head Cleaning instruction section in the manual.
2) Load a full roll of an average width media and ink on the printer.
3) Power on the printer. After passing diagnostics tests the front panel should display
READY FOR BATCHES if not then resolve any remaining error conditions.
4) Arrow down to the PRINT / CUT POSITIONS mode and press enter. Cycle
through all the prints, cut, and station two dot shift values to get a feel for their
present settings.
5) Cycle back to the beginning of the Printer Adjustment and press enter at Print
Checkout Format.
6) If all three print stations or stations two and three are present, adjust station
number two by moving the dots with the dot shift on the front panel so that the
tracking line on the front of the label becomes one continuous line.
The machine is now ready for production formats at which time the operator should
need only to fine-tune the prints and strobes via the front panel.
User Manual Model 676 LOKPRINT®
Adjustments • 33
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Maintenance
Cleaning
Print Head Cleaning
CAUTION: TURN OFF THE POWER TO THE PRINTER BEFORE
STARTING ANY CLEANING.
NEVER REMOVE THE HEAD FROM THE PRINTER EXCEPT FOR
REPLACEMENT.
The Anti-static wrist strap (which must contact the skin and be
tight) and anti-static gloves must be worn at all times when
handling a print head to avoid damaging the print head.
Supplies:
- Always use clean supplies when cleaning the head.
- Never use anything abrasive to the head.
- NEVER use anything metallic on or near the printhead.
- Alcohol and a cotton swab are the recommended items to use when cleaning the
printhead.
RECOMMEND AVERY DENNISON "MASTER CLEANING KIT" # 921338
Procedure:
-The Printhead should be cleaned every two to four hours of continuous usage. A
good cleaning of the print head after eight to twelve hours of continuous usage
should be done. This cleaning must be done with the print head in the printer.
- Apply a liberal amount of alcohol to a swab.
- Rub the swab across the print line of the printhead to remove the build-up.
- The platen roller and feed rollers should also be cleaned with alcohol to remove ink
and card dust build-up.
34 • Maintenance
User Manual Model 676 LOKPRINT®
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Clean Platen Roller
You may determine if the printhead has been adjusted properly by performing a test
pattern as documented elsewhere in this manual. A properly adjusted print head will
produce an even grid of chevrons when the test pattern is performed. Before making
any judgments as to the quality of the printhead, it is absolutely necessary to
ensure that the platen roller and the printhead are clean of all debris. Clean the
platen roller located immediately beneath the print head with a clean cloth and a
small amount of alcohol. Be careful not to damage the platen roller while cleaning.
If the roller is worn, replace the roller.
Supplies:
- Always use clean supplies when cleaning the sensor and light bar.
- Never use anything abrasive to the sensor and light bar.
- NEVER use an alcohol-based solution when cleaning the sensor or light bar.
- Dry air or a cotton swab are the AVERY DENNISON recommended items to use
when cleaning the sensor and light bar.
Print Head Handling
Warning
Print heads can be damaged easily, and are subject to premature failure if not cleaned
on a regular basis. Please follow the procedures carefully to help ensure print head
life and print quality.
Thermal print heads are very sensitive and must be handled with care to help ensure
longer print head life. Because print heads may be damaged through a number of
ways, AVERY DENNISON has developed the following procedures;
Handling
Static discharge is very detrimental to thermal print heads. To avoid contacting print
heads with a static charge, follow these simple procedures:
- All print heads should be kept in original anti-static bags until they are
placed in the machine.
- The 676 LKP printer is supplied with an anti-static wrist strap. Locate the
strap - it must be worn at all times when handling the print heads.
- Do not touch any terminals extending from the print head or the print line.
- Anti-static gloves are provided with your machine upon installation and
extras may be ordered from AVERY DENNISON. These gloves must
be worn at all times when handling the print head. If an anti-static glove
is not available, make absolutely certain to thoroughly wash and dry your
hands before handling the print head. Oils from your hands can
contaminate the print line and quickly destroy the printing elements.
User Manual Model 676 LOKPRINT®
Maintenance • 35
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Print Head Replacement
NEVER REMOVE THE PRINT HEAD FROM THE PRINTER EXCEPT FOR
REPLACEMENT.
TURN OFF THE POWER TO THE PRINTER BEFORE STARTING ANY
ELECTRONIC COMPONENT REPLACEMENT.
NOTE: The Anti-static wrist strap (which must contact the skin and be tight) and
anti-static gloves must be worn at all times when handling a print head to
avoid damaging the print head.
1) Review the Printhead Handling Procedure Sheet packaged with each print head to
determine if any procedures have changed before beginning this procedure.
2) Remove the media and ink from the machine for easy print head removal.
3) Unplug the cables that connect to the print head. Unplug the cable by firmly, but
gently pulling it out.
4) Loosen (2) 6-32 Phillips screws visible through holes in the upper print head
holder. Slide the head toward unwind end of printer.
NOTE: Screws are fitted with washers.
6-32 PHILLIPS SCREWS
5) Place your hand (with static gloves on) underneath the print line of the print head
and pull down guiding screws through keyhole slots. This will remove the print
head assembly from the mount plate. You may need to "help" the print head out
by pushing on the heat sink with your left hand.
6) Remove the two print head mount screws located on the top of the print head with
a Phillips head screwdriver.
36 • Maintenance
User Manual Model 676 LOKPRINT®
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7) Remove the old printhead carefully from the heat sink.
HEAT SINK
PRINTHEAD
8) Place the new print head onto the heat sink.
9) Replace the two print head mount screws. Be sure that the head is resting flat on
the heat sink before tightening these screws.
10) Replace the print head assembly in the printer, sliding screw / washer (Paragraph
4) into the holes in the mount plate. Make sure that the screw / washer slides all
the way to the front of the holder. Tighten screws.
HEAD TOUCHES
11) Reconnect the print head cable connectors, making sure that the connectors are
seated tightly.
NOTE: If the cable is not connected correctly, the print head will be destroyed when
the machine is powered on. Check to see that the cable is tight by observing
from underneath the print head. The cable’s connectors should be inside of
the connectors located on the print head.
12) Replace the media and ink and double-check your work. Power the machine on
and make sure that no adverse effects are noted. Before printing - the printhead
category must be set to match the new printheads mean resistance as labeled
on the head itself.
A) On the front panel arrow down to PRINT HEAD SETUP using the
MODE button and press ENTER.
B) Arrow down to HEAD CATEGORY for the print station you
replaced the head in.
User Manual Model 676 LOKPRINT®
Maintenance • 37
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C) Using the left (<YES) or right (NO>) arrow key set the HEAD
CATEGORY as called out in the PRINTHEAD CATEGORY
CHART below.
D) Press the ENTER key to enter the value. The printer must be turned
off and back on for the change to take effect.
PRINTHEAD CATEGORY CHART
MEAN
RESISTANCE
PRINTHEAD
CATEGORY
obtained from
printhead label
entered in front panel
for print station
containing head
1190 – 1243
1244 - 1295
1296 – 1348
1349 - 1400
1401 – 1453
1454 - 1505
1506 – 1558
1559 – 1610
1
2
3
4
5
6
7
8
13) As a final test of the print head installation, run a test pattern to check the print
quality. You should observe an even grid of chevrons. If you do not see such a
grid, make sure both the front and the back printheads are moved all the way to
the right.
38 • Maintenance
User Manual Model 676 LOKPRINT®
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Lubrication Procedure
General
The 676 series printers are factory equipped with either composition bearings not
requiring lubrication, pre-lubricated bronze bearings, or pre-lubricated needle
bearings. Periodic cleaning of the printer and removal of dust will greatly enhance
the length of the time the printer will function.
Composition (Iglide) Bearings
1) If field replacement of an assembly fitted with a plastic bearing is performed, a
single drop of spindle oil should be applied to assist in bearing break-in.
2) If, after long use, a plastic bearing starts to "squeak", disassemble the component
containing the bearing and lightly abrade the shaft surface. Clean the bearing
(dust or old oil) with alcohol, re-lubricate with 1 drop of light oil and reassemble.
No other printer lubrication should be required in normal use.
User Manual Model 676 LOKPRINT®
Maintenance • 39
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Electrical Trouble Shooting
Power Up / Sign On / Communications
Problem
Probable Cause
Corrective Action
Machine fails to power up
with no light present in
the AC power switch.
1) Incorrect power voltage.
1) Confirm that the AC entry is configured for the
line voltage intended to be applied to the
machine. Failure to do so can damage the
machine's internal power supply. Refer to the
"Fuse Configuration".
2) Lack of power to machine.
3) Missing or blown fuse(s)
2) Check that both ends of the power cord are
plugged in securely.
2A) Confirm that the outlet the machine is plugged
into has power.
3) Check that the fuse(s) located inside the AC
entry are present and intact. Replace as needed.
Refer to the "Fuse Configuration".
Machine fails to power up
with light present in the
AC power switch.
1) Unconnected cable / connector
inside machine.
1) Power off and remove the power cord from the
AC entry. Remove the back cover and inspect
the cables and connectors to and from the power
supply. Refer to the "Electrical System
Schematic".
2) Thermal Control Board
unplugged from the Mother Board
2) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat the
Thermal Control Board.
Front panel displays no text 1) Front panel cable unplugged.
or nothing at all.
1) Power off and remove the power cord from the
AC entry. Remove the back cover and inspect
the cable and connectors to and from the front
panel. Refer to the "Electrical System
Schematic".
40 • Electrical Trouble Shooting
User Manual Model 676 LOKPRINT®
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Problem
Probable Cause
Corrective Action
Front panel does not
complete diagnostics test 2.
1) One or more PC board(s)
unplugged from the Mother
Board.
1) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat the
offending board.
Machine does not receive
batches.
1) Serial communications cable
loose or unconnected.
1) Check and secure both ends of the serial cable
with the thumbscrews.
2) Machine not powered on or has 2) Power machine on and wait until machine
not completed diagnostics tests.
displays "Ready for batches". Re-download
data.
3) Data sent to wrong printer.
3) In PCMate change to the printer the data is
intended to be sent.
4) Configuration incorrect in
PCMate.
4) Re configure PCMate for AVERY DENNISON
PCL printer as per your PCMate manual.
5) Faulty Thermal Control Board.
5) Replace Thermal Control Board.
6) Jumpers not configured
correctly.
6) Contact AVERY DENNISON Service.
User Manual Model 676 LOKPRINT®
Electrical Trouble Shooting • 41
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Stock / Ink Advance
Problem
Probable Cause
Corrective Action
Stock does not advance
when the start button is
depressed.
1) No batches to be printed.
1) Download batch (if batch downloaded uses the
same format as a previously downloaded batch
the machine with start automatically).
2) An interlock condition exists.
2) Determine the number and type of interlock(s)
by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 901 Stock Out" reload stock).
3) Feed motor unplugged or faulty.
3) Check feed motor cable and or replace feed
motor.
4) Thermal Control Board
unplugged or faulty.
4) Check Thermal Control Board / AT board
connection and or replace Thermal Control
Board.
5) Feed roller not gripping stock.
5) Adjust the feed pressure. Refer to "Mechanical
Adjustment Of Feed Roller Pressure".
6) Feed rollers bound.
7) Stock bound.
6) With power off check that all rollers turn freely.
7) With the print head and feed open check that the
stock will pull through the printer with little to no
resistance.
Ink does not advance when 1) No batches to be printed.
the start button is
depressed.
1) Download batch (if batch downloaded uses the
same format as a previously downloaded batch
the machine with start automatically).
2) An interlock condition exists.
2) Determine the number and type of interlock(s)
by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 901 Stock Out" reload stock).
3) Ink motor unplugged or faulty.
3) Check ink motor cable and or replace ink motor.
4) Thermal Control Board
unplugged or faulty.
4) Check Thermal Control Board / AT board
connection and or replace Thermal Control
Board.
5) Ink roller bound.
6) Ink bound.
5) With power off check that all rollers and arbors
turn freely.
6) With the print head open check that the ink will
pull through the printer with little to no
resistance.
42 • Electrical Trouble Shooting
User Manual Model 676 LOKPRINT®
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Print
Problem
Probable Cause
Corrective Action
Machine advances stock
but does not print.
1) Print head cable unconnected or
faulty.
1) Power off the machine and reinsert the
offending connector or replace cable.
2) Print head faulty.
2) Replace print head.
3) Head Driver Board unplugged or
faulty.
3) Check Head Driver Board / AT board
connection and or replace Head Driver Board.
Print registration is off in
the feed direction.
1) Print position is incorrect.
1) Enter the setup menu and readjust the print
setting as needed.
2) Field(s) position incorrect in the
format.
2) Using formatter - check and readjust the field(s)
position(s) as needed.
3) Bound platen roller.
3) Check that the platen roller turns freely on it's
shaft. If it does not replace it.
Print registration is off in
the web direction.
1) Machine incorrectly threaded.
2) Web guides incorrectly adjusted.
3) Unwind incorrectly adjusted.
1) Check and rethread the media as needed. Refer
to "Loading Stock".
2) Check and adjust as needed. Refer to "Web
Guide Adjustment".
3) Check and adjust as needed. Refer to "Web
Guide Adjustment".
4) Incorrect DIP switch settings on
the Thermal Control Board.
4) Check and reset DIP switches as needed. Refer
to "TCB Dip Switch S2 Settings".
Print contrast is too light or 1) Incorrect strobe setting selected
1) Using Formatter - check and adjust the strobe
setting according to the media and ink being
used.
dark.
in the format.
2) Incorrect strobe setting in the
machine setup.
2) Enter the setup menu and readjust the strobe as
needed.
Voids in print image in the
feed direction.
1) Ink misaligned with format.
1) Adjust ink position on the arbors to achieve full
ink coverage over all fields on the format.
2) Print head dirty.
2) Power off the machine clean the print head and
platen. Refer to "Print Head Cleaning".
3) Faulty print head.
3) After cleaning head and running the test pattern
to confirm that a void still exists. Replace the
print head.
4) Worn platen roller.
6) Replace platen roller.
Machine continually stops
with an erroneous
interlock condition.
1) Ink Sensor uncalibrated.
1) Recalibrate the sensor from the front panel using
the “Calibrate Sensors” mode. Refer to "Optical
Sensor Electrical Calibration".
2) Ink Sensor position misadjusted.
2) Relocate correctly.
3) Ink sensor type (light / dark)
incorrect in the format for the ink
type being used.
3) Either change the ink or the ink type in the
format.
User Manual Model 676 LOKPRINT®
Electrical Trouble Shooting • 43
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Mechanical Trouble Shooting
Stock
Problem
Probable Cause
Corrective Action
Stock will not roll or jumps 1) Incorrect adjustment of unwind
web guides
1) Be sure stock roll is as flat as possible and does
not extend over core.
2) Adjust web guides to touch stock roll but not
pinch the roll.
Machine fails to stop at end 1) Incorrect adjustment of stock-out
1) Adjust contact strip so that a “click” will be
heard when supply roll is lifted.
of roll.
sensor.
Stock does not pull
smoothly through
printhead module.
1) Web guides on unwind arm too
tight.
1) Adjust web guides to touch outer edges of stock
with minimum pressure required to keep stock-
out switch closed.
2) Web guides too tight
2) Adjust guides to touch edge of stock.
Stock jams in bridge blade
rollers or knife area.
1) Knife mounted bridge blade too
close to stationary bridge blade.
1) Loosen screws in upper knife securing bridge
blade roller assembly and slide up (holes in blade
are slotted) until rollers just contact stock.
Tighten screws.
44 • Mechanical Trouble Shooting
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Ink
Problem
Probable Cause
Corrective Action
Ink wrinkles or will not pull 1) Ink buildup on turn bar(s).
smoothly.
1) Clean with alcohol.
2) Incorrect ink width.
2) Use an ink width no wider than stock being
printed. This is especially critical when using a
narrow web with cut down rollers.
Ink rolls loosely on take-up 1) Take-up roller not turning.
roller.
1) Assure roller does not bind and is clean.
2) Take-up core binding on locator
plate.
2) Move core .015" - .030" (.38mm - .76mm) away
from plate.
3) Take-up roller too full.
3) Remove used ink roll. It is designed to hold
only 1 full roll.
Print
Problem
Probable Cause
Corrective Action
Poor print - uneven or no
print (mechanical). Also
see electrical trouble
shooting.
1) Broken ink.
1) Replace ink and readjust (see INK trouble
shooting).
2) Ink not rewinding.
2) Readjust (see INK trouble shooting).
User Manual Model 676 LOKPRINT®
Mechanical Trouble Shooting • 45
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Appendix A
Error Messages
On the Machine's detection of errors / error, the displays will show the first error encountered and allow the
displaying of any other errors with the <YES / NO> keys, which will "Scroll" through additional errors if any.
XX is the total number of errors at the time of error detection.
ERROR SCREENS:
The screen advances to next error with each depression of the "NO>" key
The screen retreats to prior error with each depression of the "<YES" key
The screen reverts back to the first error when the “EXIT” key is pressed.
X X
E R R O R ( S )
O U T
S T O C K
9 0 1
Error Message
Error
404
405
406
901
902
904
905
906
908
910
912
913
919
920
921
922
HEAD 1 OVER TEMP
HEAD 2 OVER TEMP
HEAD 3 OVER TEMP
STOCK OUT
CHECK STACKER
INK OUT STATION 1
INK OUT STATION 2
INK OUT STATION 3
MISSED SENSE MARK
FEED OPEN
VERIFIER HALT 1
VERIFIER HALT 2
IMAGER ERROR
HEAD OPEN STATION 1
HEAD OPEN STATION 2
HEAD OPEN STATION 3
46 • Appendix A
User Manual Model 676 LOKPRINT®
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Appendix B
Software Upgrade Chip Placement Positions
Thermal Control Board P/N 371105TT
U 22
U36
U 18
U 19
U 20
U 3
U 4
U 23
U 21
THERMAL CONTROL BOARD
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.
User Manual Model 676 LOKPRINT®
Appendix B • 47
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Head Driver Board P/N 371106TT
U - 30
U - 10
U - 20
U - 9
U - 5
U - 8
(Use chip removal tool p / n. 351156 for square I.C.'s)
HEAD DRIVER BOARD
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.
48 • Appendix B
User Manual Model 676 LOKPRINT®
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Front Panel Board P / N 351108
(Use chip removal tool p / n. 351156 for square I.C.'s)
FRONT PANEL BOARD, Upgradeable software I.C.'s include U1.
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.
Front Panel Diagnostic Descriptions
Diagnostic
Descriptions
Numbers
1
2
Front panel initialization
TCB Opsys initialization
5
6
Attempting Serial Host Initialization
Initializing Verifier
7
8
9
Executing Protected Mode Imaging Code
Checking Flash Disk Module
Attempting to read in scalable fonts.
Initializing Font Scaler
Attempting to load code pages
Attempting to read in logos
Attempting to read in care symbols
Waiting for Machine Definition from TCB
Attempting to create test pattern
Attempting to create strobe tables
Attempting to read in formats
Protected Mode Imaging Code initialization complete
Serial Communications Activated
Power up complete
10
11
12
13
14
15
16
17
18
19
0
User Manual Model 676 LOKPRINT®
Appendix B • 49
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Appendix C
Printhead Life Extension
NOTE: This section was written specifically for the 636 / 656 – but the
information is useful and applicable for the 676 series printers.
Matching stock and ink widths
If your customer is running multiple media and multiple widths on their AVERY DENNISON machine, Great!
They are taking advantage of one the most compelling features of our printers: multimedia capability. Our
printers can also reduce the width of the ink to only that area being printed. However, we run into printhead
problems when customers combine both these features.
The edge of the narrower stock not covered by the ink will gouge the printhead and cause dots to be
out.
Printhead
Here, the customer will have
much shorter printhead life
because of the edge of the
narrower, uncovered stock.
WRONG!
This edge which is
not covered by ink
will erode the
printhead.
Will have missing dots from
the eroded printhead when
this prints out.
Printhead
The solution is to make sure
that the narrower stocks
have at least 1/8” of ink
coverage over the edge.
The widest stock does not
need full ink coverage.
RIGHT!
Must have 1/8" inch
overlap to protect the
printhead from the
stock edges
Overlap unneccessary because
this is the widest stock being
printed
50 • Appendix C
User Manual Model 676 LOKPRINT®
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Printhead Fail Modes
Symptoms, Causes, Solutions
Symptom #1: A dot is leaving a line in the print direction. The dot appears to be dragging or failed on,
sometimes in the print area, and sometimes not. If in a barcode, the verifier will halt the printer.
Specialty
Brand
Specialty
Brand
Specialty
Brand
Specialty
Brand
Specialty
Brand
Cause: Paper dust or dirt on the printhead
causing the ink to print without printhead firing.
The dot is NOT failed on. The printhead is
DIRTY.
Style: Fall
Style: Fall
Style: Fall
Style: Fall
Style: Fall
Color: Rose
Color: Rose
Color: Rose
Color: Rose
Color: Rose
Lines of
print from
a dragging
dot
If not addressed immediately: the line will go
from black or gray to white and the dot will fail.
The printhead will be damaged.
$5.95
$5.95
$5.95
$5.95
$5.95
Solution: Immediately stop the printer and clean the printhead in the machine.
If problem continues: Remove the printhead and clean with hard pressure.
Symptom #2: Edges of barcode and text do not appear
crisp and sharp.
Cause: Strobe is too high. Printhead is dirty.
Solution: Reduce front panel strobe one increment at a time until
fuzzy printing goes away.
If problem continues: Clean the printhead as described below.
Fuzzy edges
Symptom #3: While printing along fine early in the printheads life (< 300,000 inches), a dot suddenly
appears missing. The verifier will halt the machine if the missing dot is in a barcode.
Cause: Most likely, the printhead failed from static.
Solution: Replace the printhead.
If problem continues: Check that the machine has all the static upgrades. Double check the connections
and wires.
User Manual Model 676 LOKPRINT®
Appendix C • 51
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Printhead Cleaning Procedure
Printhead performance and life are influenced by proper handling and cleaning.
•
•
Dirt on the printhead that causes problems is often too small to see.
Exercise care in handling printheads, as they are very susceptible to static. Use the wrist grounding strap
and anti-static gloves when handling.
•
It is OK to scrub the printhead HARD to clean it. Use rubbing alcohol and the “loop side” or “wool side” of
Velcro, followed by drying with rough, brown paper towels.
•
•
If the printhead doesn’t work, take it out and clean it again.
For maximum printhead life, clean the printhead after every roll change of ink or every 20,000 inches.
In Machine Cleaning Procedure
1. Stop the machine after the last batch has printed to
avoid loosing data.
2. Turn the machine off.
Dirt along the
print line.
3. Open the printhead carriage assembly.
4. Soak a small amount of rubbing alcohol on a cotton
swab and apply to the printhead.
5. Scrub the printhead several times with hard force
using the “wool side” of Velcro.
6. Dry the printhead with a dry, brown paper towel.
7. Shut the printhead carriage assembly and resume
printing.
8. If a problem continues, remove the printhead and
clean it.
Printhead cleaning when removed from the printer
1. Remove the printhead.
2. Place the printhead upside down on the edge of a
clean table with the connector pug over the edge of
the table.
Heavy finger
pressure here
3. Soak a small amount of rubbing alcohol a cotton
swab and apply to the print line.
4. Scrub the printhead several times using HARD
pressure with the “loop side” of Velcro.
5. Dry with a dry, brown paper towel.
6. Replace the printhead.
Scrub here,
hard pressure
Thumb here to
hold against
the table
Table edge
52 • Appendix C
User Manual Model 676 LOKPRINT®
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Printhead Installation and Removal Procedures
Printhead removal procedure
1) Loosen (2) 6-32 Phillips screws visible through holes in the upper print head
holder. Slide the head toward unwind end of printer.
NOTE: Screws are fitted with washers.
2) Place your hand (with static gloves on) underneath the print line of the print head
and pull down guiding screws through keyhole slots. This will remove the print
head assembly from the mount plate. You may need to "help" the print head out
by pushing on the heat sink with your left hand.
3) Remove the two print head mount screws located on the top of the print head with
a Phillips head screwdriver.
4) Remove the old printhead carefully from the heat sink.
Printhead installation procedure
1) Place the new print head onto the heat sink.
2) Replace the two print head mount screws. Be sure that the head is resting flat on
the heat sink before tightening these screws.
3) Replace the print head assembly in the printer, sliding screw / washer (Paragraph
1 - Printhead removal procedure) into the holes in the mount plate. Make sure
that the screw / washer slides all the way to the front of the holder. Tighten
screws.
4) Reconnect the print head cable connectors, making sure that the connectors are
seated tightly.
NOTE: If the cable is not connected correctly, the print head will be destroyed when
the machine is powered on. Check to see that the cable is tight by observing
from underneath the print head. The cable’s connectors should be inside of
the connectors located on the print head.
User Manual Model 676 LOKPRINT®
Appendix C • 53
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Electrical Assembly Drawings
Machine Wiring
FEED
SYSTEM HARNESS
15 PIN
OUTPUT
FRONT PANEL
CONNECTOR
VERIFIER
THERMAL
CONTROL
BOARD (REAR)
371105TT
ORANGE
GRAY
RED
ORANGE
RED
BROWN
(NOT USED)
PH2
PH1
PH3
GRAY
GRAY
HEAD DRIVER
BOARD
BROWN
(FRONT)
371106TT
BROWN
POWER
SUPPLY
54 • Electrical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Electrical System Schematic
AC ENTRY
115V
230V
341111
HARNESSED +5V/+12V/+24V
POWER SUPPLY
371116
CONN 3
POWER GOOD
LINE
GROUND
NEUTRAL
A
B
L
CONN 2
STOCKOUT SWITCH
HARNESS 371142 SWITCH 191120
N
G
LINE CORD
181134
FEED OPEN
SWITCH 191120
C
D
TOP 1 HEAD-OPEN
SWITCH 375018
TOP 2 HEAD-OPEN
SWITCH 375018
SEE NOTE 3
BOTTOM HEAD-OPEN
SWITCH 375018
+12V
CONN 4
CONN 4
CONN 4
CONN 2
CONN 4
CONN 4
CONN 3
CONN 4
OPTIONAL
PCMCIA
BOARD
TOP 1 INK-OUT
SENSOR 371118
115V OPERATION
ONE 10.0A 250V
+24V
TOP 2 INK-OUT
SENSOR 371118
1/4 X 1 1/4 FUSE 921167
351181
REGISTRATION GAIN
SWITCH 551170
BOTTOM INK-OUT
SENSOR 371118
CONN 3
230V OPERATION
+5V
TWO 10.0A 250V
FRONT PANEL ASSY
511108
5 X 20MM FUSES 921168
IR LED 551169
PCB 511110
OVERLAY 511111
CODE 800265
TOP REGISTRATION
SENSOR 371128
RETURN
J1
BOTTOM REGISTRATION
SENSOR 371128 OPTION
TCB TO FP
CABLE
371119
TOP CONTRAST SENSOR
510014 SICK OR 510012 OMRON OPTIONS
SYSTEM HARNESS
ASSEMBLY 371126
J13
J1
FEED MOTOR
J8
A
DIODE
990998
J3/J4
HARNESSED 371111
371140 FEED MOTOR CROSSOVER
15 PIN
FEED MOTOR
HARNESSED 421123
1
2
3
4
5
6
7
8
9
10 11 12
J14
OUTPUT
CONNECTOR
IDE 2 (J6)
CONN 2
J11
AT
BUS
MODULE, FLASH DISK
16MB MEMORY 341146A
LOKPRINT II
J10
MOTHER BOARD
371170
THRMAL CONTROL
BOARD
KNIFE FUSE HARNESS 359007
(FUSE 990755)
VL
BUS
KNIFE MOTOR
HARNESSED 351171
CONN 4
J12
371105TT
371137
341147
PROCESSOR
FAN
KNIFE SOLENOID
HARNESSED 351123
STACKER HARNESS
STACKER FUSE
HARNESS 359006
J9
J6
MACHINE COOLING
FAN 511120
351125
STACKER MOTOR
CONN 4
CONN 4
CONN 4
CONN 4
SERIAL CABLE
EXTERNAL 351124
HARNESSED 351161
551149
CONN 2
(FUSE 990915)
J7
J2
J5
FULL STKR SWITCH
HARNESSED 351160
CONN 3
CONN 3
NC
NC
JAM SENSOR
HARNESSED 371133
TCB TO HDB
351121
CONN 9
551114
370028
OPTIONAL
551115
VERIFIER
551144
OPTIONAL IN LINE
VERIFIER 550027
10
BASE T
ETHERNET
TO SERIAL
CONVERTER
NOTES:
1. ALL AC WIRE 18AWG 600V INTERNATIONAL
COLOR CODE:
LINE
NEUTRAL
EARTH GROUND
BROWN
LT. BLUE
GREEN W/ YELLOW STRIPE
J2/J3
J1
J8
J4
J6
PRINTHEAD
371102
TOP PRINTHEAD 1
CABLE 371123
PRINTHEAD
371102
TOP PRINTHEAD 2
CABLE 371123
J9
HEAD
DRIVER
BOARD
J7
2. DC OUTPUT OF POWER SUPPLY:
371106TT
+5V
RED
PRINTHEAD
371102
+12V
+24V
RETURN
YELLOW
GRAY
BLACK
BOTTOM PRINTHEAD
CABLE 371124
J10
3. FLASH DISK REPLACED PCMCIA BOARD, REMOVE IF FLASH
DISK IS INSTALLED.
User Manual Model 676 LOKPRINT®
Electrical Assembly Drawings • 55
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Motherboard Power Connectors
The power supply connector on any PC / XT or PC / AT compatible motherboard is made up of dual six-pin male connectors.
Two female connectors from the power supply plug directly onto these male connectors. The following diagrams illustrates
the proper method of attaching the connectors.
Ensure that all of the black wires are located next to each other in the center of the two connectors (as shown in the diagram
below), and that the clamps on the back side of the connectors ate secured along the PCB header. All pins should be covered.
Warning: Connecting the power supply incorrectly may cause irreversible (unwarranted) damage! Ensure that the power is
turned off before connecting the power supply. Make certain that the 115 / 230VAC fuse drawer is in the correct position
56 • Electrical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 57
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Unwind Assembly Drawing
58 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Unwind Parts List
Item Part #
Description
Qty
1
1
1
1
1
2
373012 Web guide, Rear
373009 Lead screw, Tape unwind
373093 Assy, Unwind pressure, LKP
373010 Rod, Web guide, Outer
353002 Bracket, Unwind
3
4
5
1
6
7
8
105023 Impression Adj, Knob / SS Kit
373014 Bracket, Sensor mount
373013 Bracket, Stock out
1
1
1
9
191120 Micro switch
1
10
11
12
13
14
15
16
989973 4-40 x ½ Cap screw
990069 8-32 Hex nut
2
2
2
1
1
1
1
990000 2-56 x ¼ Cap screw
990065 8-32 x 3/8 Button head screw
989995 3/15 x 5/8” Shld. Screw
371142 Stock out switch, Harness (*NS)
990513 Small wire tie (*NS)
(*NS) = Not Shown
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 59
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Web Guide Assembly Drawing
60 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Web Guide Parts List
Item Part #
Description
Qty
1
1
1
1
1
1
6
1
1
1
1
1
1
1
Item Part #
Description
Qty
1
3
1
1
2
2
1
2
1
1
1
1
1
1
1
2
374046 Frame, Web guide
374113 Shaft, Ink turn bar
15
16
17
18
19
20
21
22
23
24
25
26
27
28
105023 Knob / SS
990166 ¼-20 x 5/8” Button head screw
194020 Web turn shaft
990133 ¼-20 x ¾” Flat head screw
990196 10-32 x ½” Flat head screw
990416 ¼-20 x ½” Flat head screw
374110 Shaft, Spindle
343048 Bearing, Ball spindle
344063 Roller, Convex
344062 Spring, Compression
343101 Bearing, Retainer spindle
990016 6-32 x 3/8” Cap screw
554005 Adapter, Web guide
990025 6-32 x ¼” Set screw
3
4
5
999099 3/16 x 5/16 x ¼” Fl. Bushing
374111 R.H. Thread guide adj. Block
374104 Back (Top) Web guide
6
7
8
9
10
11
12
13
14
374103 Back (Bottom) Web guide
990090 10-32 x 3/8” Button head screw
374106 Shaft, Web guide adjust
374105 Bracket, Web adjust rod
374101 Front (Bottom) Web guide
374102 Front (Top) Web guide
374112 L.H. Thread, Guide adjust block
999100 3/16 x 5/16 x 1/8” Fl. Bushing
194013 Bracket, Web guide adjust
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 61
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Drive Assembly Drawing
62 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Drive Parts List
Item Part #
Description
Qty
1
1
4
1
2
2
1
1
1
1
2
1
1
1
5
1
1
1
4
1
1
2
3
4
5
6
7
8
355018 Support, Knife / Drive / Print
354004 Bridge blade, Lower
990086 10-32 x 3/8 Cap screw
374044 Bridge plate, Web
991170A Extension spring
514003 Pin, Spring anchor
514094 Lift cam assembly
514001 Shaft, Idler roller
9
10
11
374034 Tape roll idler, Molded
354094 Roller, Drive assembly
990325 3/16 “E” Ring
12 514009K Spring lever, Front
13
14
15
374087 Assembly, Outer drive support
374047 Feed knob / SS
990120 1/4-20 x 1/2 Cap screw
16 514010K Spring lever, Rear
17
18
19
20
374088 Assembly, Read drive support
990416 1/4-20 x 1/2 F.H. Screw
990313 #10 Thumb cap
514002 Sleeve, Idler shaft
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 63
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Top - Printhead Assembly Drawing
64 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Top - Printhead Parts List
Item Part #
1
2
3
4
Description
375076 Assy, Rear support, LKP
375077 Assy, Front support, LKP
375085 Support Beam, Print assembly
375054 Roller, 2-1/4” Cutdown (LKP)
356020 Roller, Molded (Ink)
Qty
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
1
1
2
1
2
2
5
6
7
990135 ¼-20 x ¾ Button head screw
990122 ¼-20 x ¾ Cap screw
8
9
990083 10-32 x ¾ Cap screw
371102 300 DPI Convex head
375081 Assembly, Printhead mount
989543 3mm x 6mm Flat head screw
375049 Bracket, Head mount
991141 6-32 x 3/8 Sems screw
991142 Pressure spring
10
11
12
13
14
15 375082K Assy, Printhead holder (Kit)
16
17
18
19
20
21
22
23
24
25
990025 6-32 x ¼ Knurled point set screw
375056 Pin, Head holder
376032 Assembly, Ink turn roller
375014 Shaft, Head mount
990497 ½” Wave Washer
990328 ½” “E” Snap ring
990273 #10 Belleville washer
375060 Bracket, Peel blade (LKP)
990051 8-32 x 3/8 Cap screw
990058 8-32 x 1/4 Knurled cup point
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 65
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Bottom – Printhead Assembly Drawing
66 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Bottom – Printhead Parts List
Item Part #
Description
Qty
1
2
1
1
1
1
1
1
2
2
1
1
1
1
1
2
1
1
1
1
2
1
1
1
2
1
2
3
4
5
6
7
8
9
356020 Roller, Molded (ink)
991142 Pressure spring
990135 1/4-20 x 3/4 Button head screw
375014 Shaft, Head mount
990497 1/2" Wave washer
375085 Support beam, Print assy
371102 300 dpi Convex head
375081 Assy, Plate print head mount
990058 8-32 x 1/4 Knurled cup point
10 989543 3mm x 6mm Flat head screw
11 990122 1/4-20 x 3/4 Cap screw
12 375049 Bracket, Head mount
13 990328 E-ring, 1/2"
14 990083 10-32 x 3/4 Cap screw
15 375078K Assy, Print head holder
16 991141 6-32 x 3/8 Sems screw
17 376032 Assy, Ink turn roller
18 375054 Roller, 2 1/4" Cutdown (LKP)
19 375056 Pin, Head holder
20 990025 6-32 x 1/4 Knurled cup point
21 990273 Washer, #10 Belleville
22 375080 Assy, Support rear print module
23 375079 Assy, Support front print module
24 375060 Bracket, Peel blade (LKP)
25 990051 8-32 x 3/8 Cap screw
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 67
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Ink Unwind / Rewind Assembly Drawing
68 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Ink Unwind / Rewind Parts List
2/0 2/1 1/1
Qty Qty Qty
Item Part #
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
356201 Magnetic clutch
4
2
2
8
2
4
2
2
2
2
2
2
2
4
2
2
2
4
6
3
3
12
3
6
3
3
3
3
3
3
3
6
3
3
3
6
4
2
2
8
2
4
2
2
2
2
2
2
2
4
2
2
2
4
356202 Collar, Sprocket mount
376022 Sprocket, Altered
991086 6-32 x 1 1/4 Cap screw
991018 Internal snap ring
999002 Bearing
376025 Bearing spacer
376023 Bearing spacer
376016 Bearing housing
990122 1/4-20 x 3/4 Cap screw
356203 Shaft, Rewind
356016 Shaft, Foil bracket
376002 Ink guide
376003 Collar, Foil guide
990080 10-32 x 3/8 Cap screw
990313 #10 Thumb Cap
376096 Assembly, Arbor unwind
991084 8-32 x 1/4 Knurled cup point
990355 “O” Ring, Foil 3/4"
10 15 10
20 356204K Assy, Rewind arbor w/ Bushings
2
4
8
2
3
6
12
3
2
4
8
2
21
22
23
991089 Collar, 1/2" Retaining ring
990016 6-32 x 3/8 Cap screw
376035 Shaft, Unwind
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 69
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Web Tension Guide Assembly Drawing
18
11
15
2
16
10
7
17
6
5
8
1
9
12
14
4
3
7
70 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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Web Tension Guide Parts List
Item Part #
Description
Qty
1
1
1
2
191120 Stock out micro switch
564088 Bracket, Roller
3
564087 Shaft, Support
1
4
564089 Shaft, Roller
1
5
990374 1/2 Collar
2
6
7
990484 1/4-20 x 1/2 Nylon slotted screw
194020 Web turn shaft
2
2
8
9
989973 4-40 x 1/2" Socket hd cap screw
563006 Bracket, Sensor
2
1
10
11
12
13
14
15
16
17
18
990050 8-32 x 1/4" Socket hd cap screw
563001 Bracket, Guide mount
564097 Bracket, Bridge blade
561165 Harness, Web tension switch
999099 3/16 x 5/16 x 1/4" FL. Bushing
990416 1/4-20 x 1/2" Flat hd cap screw
990056 8-32 x 1/2" Flat hd cap screw
990120 1/4-20 x 1/2" Socket hd cap screw
990058 8-32 Set screw
2
1
1
1
2
1
1
1
2
User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 71
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Drive Belt Routing Drawing
374006 - "LONG BELT"
DOUBLE SIDED
991143 - "SHORT BELT"
SINGLE SIDED
72 • Mechanical Assembly Drawings
User Manual Model 676 LOKPRINT®
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User Manual Model 676 LOKPRINT®
Mechanical Assembly Drawings • 73
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