Users Manual Model 686 / 686 HT AVERY DENNISON Manual Edition 7.
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Contents Scope 4 Introduction ............................................................................................................................... 4 Safety Issues / Warnings 4 Caution....................................................................................................................................... 4 Warranty Information 5 Customer Responsibility 7 Location of Printer .....................................................................................................
Front Panel Menu Map ............................................................................................................31 Front Panel Power Up / Home Screens....................................................................................32 Front Panel Mode Descriptions................................................................................................35 Adjustments / Maintenance 45 Print Head Handling ..............................................................................
Printhead Fail Modes ............................................................................................................... 78 Printhead Cleaning Procedure ................................................................................................. 79 Printhead Installation and Removal Procedures ...................................................................... 80 Static Checks for 686 / 686 HT Printers ..................................................................................
Scope Introduction This user manual was arranged for the person who is going to operate the printer. The information is arranged in the order that is needed to install and then operate the printer. It starts with general information, then to unpacking the carton, setup, installing the ink and stock, printer operation, control panel operation, and finally care and maintenance of the printer.
Warranty Information Warranty Policy Avery Dennison Retail Information Systems, In-Plant Printing Solutions provides the following warranty policy. Scope Warranties against defects from workmanship for equipment and parts manufactured and sold from Sayre, PA. Includes time and material except as otherwise noted below. Time − − − New equipment and parts: 6 months Refurbished equipment and parts: 90 days Warranty period starts when equipment ships from selling location.
office where the equipment or parts are operated to ensure machine coverage. For example, if an agent purchases a printer in the US, exports to Brazil, and then needs warranty coverage, Avery Dennison Brazil has no obligation to provide warranty coverage. The agent must purchase services from Avery Dennison Brazil.
Customer Responsibility Location of Printer The printer weighs approximately 57 Lbs (~26Kg) 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" wide to 30" deep to 32" high. (See Figure 1). Figure 1 - Recommended Workstation Layout. The location of the AVERY DENNISON 686 / 686 HT printer should be based on human factors.
AC Power Line AVERY DENNISON requires that the electrical 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 that 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.
In some cases, a double box has been used to ship your printer. Figure 2 - Shipping Carton. Save the shipping materials to relocate the printer 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 686 / 686 HT shipping container. If anything is missing, notify AVERY DENNISON immediately - in the U.S.A. at (570) 888-6641. In other countries please contact your local AVERY DENNISON supplier.
Printer Setup Installing the Stacker (Option) Remove the stacker from the separate packaging. Remove the packaging from around the stacker and save with the rest of the printer packing supplies. Swing open the top cover to the printer. Locate the large knob and two round pins on the right hand side of the printer. Loosen the knob enough to allow the stacker to slide between the printer housing and the knob. The stacker will rest on the two pins.
Fuse Configuration The main fuse(s) on the AVERY DENNISON 686 / 686 HT are located inside the AC entry. The entry has a fuse drawer that holds the fuse(s) and selects the appropriate line voltage. If the voltage in the window DOES NOT match the AC line amplitude intended to be supplied to the printer, DO NOT plug the power cord in. Reconfigure as follows: 1) Using a flat blade screwdriver, open the AC entry by lifting the tab just above the voltage indicator window. AC Entry 2) Remove the red fuse drawer.
Configuration Number Two: Line voltage within the range of (See 230VAC Fuse Placement) 180 - 265VAC @ 50 - 60Hz 1) Install two 990757 6.0A 250V Fast Acting 5 x 20MM NOTE: The fuse jumper must be removed to install both 5 x 20mm fuses. 115VAC Fuse Placement 230VAC Fuse Placement A B C The fuses must be between points A and B as shown not B and C. 5 X 20MM Fuse Placement 5) Reinsert the fuse drawer into the AC entry with the desired voltage up.
TCB Dip Switch Settings DIP SWITCH # 8 DEFINITION 686 / 686 HT 7 6 5 DOWNSTACKER/ LOKPRINT UNUSED UNUSED STACKER JAM 4 3 2 1 MACHINE TYPE MACHINE TYPE UNUSED PRINTHEAD DPI DOWNSTACKER ON LOKPRINT® OFF OFF OFF ENABLE ON DISABLE OFF ON ON ON ON – 300 DPI N/A OFF 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.
Installing the PC Interface Cable The 686 / 686 HT 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 number 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 at the TCB (refer to the P.C. Board Identification section in this manual). The female end of the cable is made to fit a 9pin male RS232 connector on the back of a PC.
Product Description Printer Description The AVERY DENNISON model 686 / 686 HT thermal printer (See Figure 4) is an electronic printer that can print on Card Stock, Size Stickers, and Pressure Sensitive rolled stocks. The printer interfaces to a computer or a mainframe system thus allowing electronic data input or even custom design of labels with AVERY DENNISON’S “PcMate Platinum" program. This printer can generate a complete tag printed on one side.
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 686 / 686 HT Printer. The AVERY DENNISON 686 / 686 HT Printer uses a Windows version of “PcMate Platinum”. 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. When using PCMate™ Platinum 5.
Printer Specification Print method: Thermal transfer, one sided, near edge printhead printer for tags and pressure sensitive labels. Speed - up to 12 IPS (305mm/second) - 7"(178mm), 10"(254mm), & 12"(305mm) Label Size Max: 686 - Up to 5.125" (130.2mm) web x up to 7" (177.8 mm) feed - cut and stacked 686HT - Up to 3.00" (76.2mm) web x up to 7" (177.8 mm) feed - cut and stacked Transfers tested as of June 9, 2006 - Up to 14.0" (355.6mm) feed w/ Rewind Min: 1" (25.4mm) web x 1" (25.
Other Features - Downloading of information while printer is operating - Sequenced Fields - Time / Date Stamping - Life Counts - Operator adjustable: strobe, cut position, print position, baud rate, and buffer size - Error Detection of: stock out, ink out, print head open, full stacker, stacker jam, and print head over-temperature - Display: labels left to print in a batch, batch ID, total life inches, total life cuts - Self Diagnostics - Missed sense mark detection and correction - Slot, Notches, Hole or
Printer Operation & Quick Set-Up Loading Ink INK ROLLER (NOT SUPPLIED IN 686 HT) FIXED TURNBAR TRANSFER STOCK INK UNWIND TAG STOCK ADJUSTABLE TURNBAR ADJUSTABLE TURNBAR PRINTHEAD DRIVE KNIFE FIXED TURNBAR WEB GUIDE 686 686 HT Figure 5 - Ink Threading Path The ink ribbon comes 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 above for loading the ink.
Loading Stock INK ROLLER (NOT SUPPLIED IN 686 HT) FIXED TURNBAR TRANSFER STOCK INK UNWIND TAG STOCK ADJUSTABLE TURNBAR ADJUSTABLE TURNBAR DRIVE PRINTHEAD KNIFE FIXED TURNBAR WEB GUIDE 686 686 HT FIGURE 6 – Tag Stock / Transfer Threading 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.
6) Open the print head by turning the knob. 7) After looping the leading edge of the stock over the two-decurler bars, slide it through the web guides. 8) As the stock exits the web guide, continue to slide the stock through the print station. 9) Push the stock until it touches the blue roller. 10) Clear all errors on the front panel. Push and hold the upper feed button to move the stock through the drive, knife, and into the stacker. The bottom feed button can be used to reverse the stock if necessary.
Butt Splicing Stock NOTE: DO NOT RUN BUTT SPLICES THROUGH THE PRINT STATION. The AVERY DENNISON 686 / 686 HT has been designed so that supplies can be changed / replenished quickly. Removing the stock trailer remaining in the printer and re-threading the stock altogether is quicker than butt splicing. Web Guide Adjustment The AVERY DENNISON 686 / 686 HT printer has been designed with only three web guides in the printer that need to be changed as the width of the rolls change from format to format.
Modified Drive Assembly The spring loaded drive assembly mounted in the 686 / 686 HT printer has been modified to prevent it from being left in the “Drive Open” position. In addition the drive open sensor has been eliminated. The drive can be opened, if necessary, to clear a jam or remedy other problems, but must be held in the open position. To aid in threading, the printer is equipped with a button controlled drive system. The buttons are on the lower right side of the front housing.
Sensor Adjustment The hole and top reflective registration sensor can be adjusted by turning the knob as shown above. Move the sensor over the desired registration mark. To ensure the sensor is in the right location - hold the feed lever open and move the stock back and forth. If the sensor LED in the front panel flashes as the hole passes through the sensor - it is in the correct location. If the sensor LED does not flash, readjust the sensor.
Ink Guide Adjustment 686 The ink guides on the 686 / 686 HT will move together as shown above and below. To adjust the guides - loosen the thumbscrew and slide the ink guide into position, then retighten the thumbscrew.
686 The ink guides must be even with each other in order for the system to work correctly.
Print Head Operation The print head module is to be opened and closed for threading the stock and ink. The head must also be opened to clean the head and for print head replacement. Later in the manual, under Print Head Cleaning, and Print Head Replacement, cleaning and replacement will be covered. The print head has an interlock switch that prevents the printer from running with the head in the open position. If the head is open the display will read - HEAD OPEN.
Control Panel Operation Control Buttons 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 the head and knife will be cut and stacked as finished labels. - Stock moves through in one continuous strip. - Stock moves through without printing. - Ink will not advance; ink save on the 686 / 686 HT will automatically be activated. - The print head must be closed.
Test - TEST and START must both be used. - Test will stop when the buttons are released. - Labels between the head and 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 head must be closed. Stop - The stop button will stop the printer at the end of the current label being printed. Indicator Lights The AVERY DENNISON 686 / 686 HT has three Indicator lights.
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 setting over a stock sensor mark hole. - 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.
Front Panel Menu Map Ready For Batches Print/Cut Positions Print Head Setup Calibrate Sensors Life Counts/Versions Feature Setup Verifier Setup Print Checkout Format Change Head Strobe Hole / Slot In Sensor Label Counter Cutter Is Enabled Print Verifier History Print Position Change Head Category Hole / Slot Not In Sensor Total Labels Produced Emulation Mode: Print Verifier Setup Change Cut Position Top Refl Over Mark
Front Panel Power Up / Home Screens POWER UP (DIAGNOSTICS TESTS) 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 - (orange, green, amber and off).
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.
Pressing the MODE / Down Arrow key will take the user to the various mode screens listed below (refer to the Front Panel Mode Descriptions section in this manual). Pressing the EXIT / Up Arrow key at any time will take the user back to the "HOME" screen.
Front Panel Mode Descriptions There are six (6) 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: PRESS ENTER FOR PRINT / CUT POSITIONS PRESS ENTER FOR PRINT HEAD SETUP PRESS ENTER FOR CALIBRATING SENSORS PRESS ENTER FOR LIFE COUNTS / VERSIONS PRESS ENTER FOR FEATURES SETUP PRESS ENTER FOR VERIFIER SETUP Use the EXIT ↑ to move to the HOME screens.
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 This screen follows the "BATCH ID / BATCH QTY" screen if there are batches to be printed, otherwise it follows the "READY FOR BATCHES / MODEL DPI" home screen. Pressing ENTER will take the user to the "PRINT / CUT POSITIONS" 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.
Pressing the MODE / Down Arrow key will take the user to the "DOT SHIFT" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen. D O T S H I F T V A L U E : ± X X N E W V A L U E : ± Y Y This screen follows the "CHANGE CUT POSITION" screen. This screen allows the print position to be adjusted in the WEB direction. The buttons are used to change the new shift value. The value is displayed in a positive / negative format.
CALIBRATE SENSORS P R E S S E N T E R T O C A L I B R A T E S E N S O R S This screen follows the "PRINT HEAD SETUP" screen. Pressing ENTER will take the user to the "CALIBRATE SENSORS" 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. H O L E / S L O T V A L U E : 0 0 0 I N S E N S O R N E W V A L U E : 0 0 0 This is the first screen under "CALIBRATE SENSORS".
T O P R E F L N O T O V E R M A R K V A L U E : 0 0 0 N E W V A L U E : 0 0 0 This screen follows the "TOP REFL OVER MARK" screen. Place the stock under the sensor so that the stock is under the sensor but the reflective mark is not under the sensor and when NEW VALUE is at is smallest value press ‘Enter’. Pressing the MODE / Down Arrow key will take the user to the "BOT REFL OVER MARK" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
LIFE COUNTS / VERSIONS P R E S S E N T E R L I F E C O U N T S F O R / V E R S I O N S This screen follows the "CALIBRATE SENSORS" screen. Pressing ENTER will take the user to the "LIFE COUNTS / VERSIONS" screens. Pressing the MODE / Down Arrow key will take the user to the "FEATURE SETUP" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
I M A G E R V E R S I O N U S A 1 9 . 0 1 This screen follows the "CONTROLLER VERSION" screen. This screen shows operating system version for the imager (AT). Pressing the MODE / Down Arrow key will take the user back to the "LABEL COUNTER" screen. 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". Pressing ENTER will take the user to the "FEATURE SETUP" screens.
Arrow key will take the user to the "LANGUAGE" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen. N E W 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 This screen follows the "DEFAULT TRANSFER TYPE" screen. This screen allows the front panel display language to be changed. Use the keys to move between the supported languages on the pr1nter.
I N K S A V E I S E N P R E S S E N T E R T OR I S D I I N K S A V E P R E S S E N T E R T A B L E D O D I S A B L E S A B L E D O E N A B L E This screen allows inksave to be enabled or disabled. Inksave is an option that is available on certain models. It must be enabled in the format to operate. If inksave is enabled in the format, it can be disabled using this screen. Pressing ENTER will toggle from ENABLED to DISABLED and vice versa.
Note: This screen for SV-70 Verifier only P R E S S C L E A R E N T E R T O S C A N M E M O R Y This screen follows the "PRINT VERIFIER SETUP" screen. Pressing ENTER will clear the verifier scan memory. Pressing the MODE / Down Arrow key will take the user to the "VERIFIER ENABLE" screen. Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.
Adjustments / Maintenance 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.
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.
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. 3mm SCREWS 1) The head can then be removed by loosening the two 3.0mm screws simultaneously.
select the head category. The head category is based on the mean resistance of the print head being used. The printhead will have a value for the average printhead resistance, for example “Rav = 1438Ω”, printed on a label on the printhead. Look up the value in the following table and enter the appropriate head category. Press the ENTER key to enter the value. The printer must be turned off and back on for the change to take effect.
Print Head Adjustment Clean Platen Roller You may determine if the print head has been adjusted properly by performing a test pattern as documented under Control Buttons in this manual. A properly adjusted print head will produce an even grid of rectangles when the test pattern is performed. Before making any judgments as to the quality of the print head, it is absolutely necessary to ensure that the platen roller and the printhead is clean of all debris.
Stacker Adjustments The stacker has four adjustments that can be made without a tool to accommodate different types and widths of stock. Stock Length Adjustment Loosen the two thumbscrews at the base of the stacker uprights and slide the uprights to a position that allows the cut tag or label to hang over the last belt roller approximately 1/4" (6mm). Retighten.
Roller Drop (686) – Not on 686 HT An optical sensor on back of the printer upright allows the printer to control and register the platen roller position to perform ink save. 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. Jam An optical sensor located in the stacker will detect each cut label as it leaves the cutter.
Print Registration Sensor Web Position Adjustment If you are running sense mark media with a hole, slot, or preprinted mark for registration - the registration sensor web position must be adjusted for the sense mark media being run. The type of sensor mark registration is selected in PC Mate Plus Label Design Menu (attributes). Hole Registration 1) Move the stock until the registration hole or slot desired is under the sensor and over the red LED.
Sensor Calibration Optical Sensor Electrical Calibration The troubleshooting section will recommend when re-calibration is required. The following guidelines indicate the proper procedure used to calibrate these sensors. Note: Clean all optical sensors with clean compressed air or canned air prior to adjustment, as dust and debris will adversely affect their performance. Supplies - Always use clean supplies when cleaning the sensor and LED. - NEVER use anything abrasive on the sensor and the LED.
Lubrication Procedure General The 686 / 686 HT series printers are factory equipped with either composition bearings not requiring lubrication or pre-lubricated bronze bearings. The one exception is the rub cams on either end of the rotary knife. Periodic cleaning of the printer and removal of dust will greatly enhance the length of the time the printer will function.
Printer Set Up Sequence 1) Power off the printer, remove the stock and ink and thoroughly clean the printer from the unwind to the stacker using alcohol and a clean soft cloth. The print head should be cleaned as per the Print Head Cleaning section in this manual. 2) NEVER use an alcohol-based solution when cleaning the sensors or LED. 3) Load a full roll of an average width stock and ink on the printer. 4) Power on the printer.
Electrical Trouble Shooting Power Up / Sign On / Communications Problem Printer fails to power up. Front panel displays no text or nothing at all. Probable Cause Corrective Action 1) Incorrect AC power supplied to printer. 1) Confirm that the AC entry is configured for the line voltage intended to be applied to the printer. Failure to do so can damage the printer's internal power supply (refer to the Fuse Configuration section in this manual). 2) Lack of power to printer.
Problem Front panel does not complete diagnostics test 2. Printer does not receive batches. Probable Cause Corrective Action 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. 1) Serial communications cable loose or unconnected. 1) Check and secure both ends of the serial cable with the thumbscrews. 2) Printer not powered on or has not completed diagnostics tests.
Stock / Ink Advance Problem Stock does not advance when the start button is depressed. Ink does not advance when the start button is depressed. Probable Cause Corrective Action 1) No batches to be printed. 1) Download batch (if batch downloaded uses the same format as a previously downloaded batch the printer with start automatically). 2) An interlock condition exists. 1) Determine the number and type of interlock(s) by reading the front panel display.
Print Problem Printer advances stock but does not print. Printer stops after ever third label. Print registration is off in the feed direction. Print registration is off in the web direction. Probable Cause Corrective Action 1) Stock registration sensor miss aligned. 1) Adjust sensor position so that the sensor light on the front panel flashes as a sense mark hole passes under the sensor. 2) Print head cable unconnected or faulty.
Problem Print contrast is too light or dark. Voids in print image in the feed direction. Printer continually stops with an erroneous interlock condition. Probable Cause Corrective Action 1) Incorrect strobe setting selected in the format. 1) Using PcMate Platinum - check and adjust the strobe setting according to the stock and ink being used. 2) Printer strobe setting is incorrect. 1) Enter the Print Head Setup Mode on the front panel and readjust the Strobe setting as needed.
Cut / Stack Problem Printer fails to cut labels (the rotary knife does not rotate). The stacker fails to run. Probable Cause Corrective Action 1) The cut is disabled in the Feature Setup mode. 1) Enter the Feature Setup Mode on the front panel and Enable the knife. 2) Knife cable unconnected. 1) Power off and remove the power cord from the AC entry. Remove the back cover and inspect the cable and connector to the knife module (refer to the Electrical System Schematic section in this manual).
Mechanical Trouble Shooting Stock Problem Stock will not roll or jumps Probable Cause 1) Incorrect adjustment of unwind web guides Corrective Action 1) Be sure stock roll is as flat as possible and does not extend over core. 2) Adjust unwind knob until back plate and front post touch roll. Do not over-tighten. Roll must rotate smoothly. 3) Adjust the web guide to the edge of stock. Do not pinch web. Printer fails to stop at end of roll. 1) Stock roll is too tight in guides.
Problem Probable Cause Corrective Action Cracks or craze marks appear on face of finished labels. 1) Incorrect adjustment of decurler. 1) Move decurler turn-bar toward unwind end of printer until cracks no longer appear. Stock jams in bridge blade rollers or knife area. 1) Knife not cutting full width of stock. 1) Loosen knife shear adjustment screws and move outer end of knife until full cut is accomplished. 2) Stacker not operating or nip rollers not turning.
Ink Problem Ink wrinkles or will not pull smoothly. Ink rolls loosely on take-up roller. Probable Cause Corrective Action 1) Unwind roller and ink take-up roller misaligned. 1) Align rear edge of ink with rear of print area (allow approximately 1/8" (3mm) overlap). Loosen thumb cap screw on ink roll locator plate and adjust until it touches rear of ink roll on unwind arbor. Slide rewind cores toward rear of printer until it just contacts plate. 2) Ink buildup on turn bar(s). 1) Clean with alcohol.
Electrical Drawings Users Manual Model 686 / 686 HT Electrical Drawings • 65
Printer Wiring PRINT HEAD INK MOTOR 24V POWER SUPPLY 511116 SYSTEM HARNESS FEED MOTOR ROLLER DROP MOTOR FRONT PANEL KNIFE MOTOR ORANGE J8 GRAY J7 ORANGE J10 RED J12 ORANGE J11 OPEN J13 BROWN J1 VERIFIER BROWN J5 THERMAL CONTROL BOARD, 371105NE BROWN J2 STACKER J9 BROWN J3 GRAY J7 BROWN J2 HEAD DRIVER BOARD, 341106NE SERIAL J6 66 • Electrical Drawings Users Manual Model 686 / 686 HT NC J1
Electrical System Schematic AC ENTRY 341111 115V 230V HARNESSED 24V POWER SUPPLY 511116 CONN 6 LINE LINE CORD 181134 A L B N GROUND 115V STRAP NEUTRAL C 115V STRAP D G DIODE 990998 +24V RETURN 115V OPERATION ONE 10.0A 250V 1/4 X 1 1/4 FUSE 921167 230V OPERATION TWO 10.
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 illustrate the proper method of attaching the connectors.
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 keys, which will "Scroll" through additional errors if any. XX is the total number of errors at the time of error detection.
Appendix B Software Upgrade Chip Placement Positions Head Driver Board P/N 341106NE JP2 D31 D6 D18 D42 D30 U 14 C20 C10 C13 R31 R29 C21 U 15 C12 R26 U14 R40 JP 1 C19 JP 1 U 10 C18 U6 U7 U8 C17 U5 J5 U1 J4 R64 C15 C11 C7 A1 A45 C5 J6 HEAD DRIVER BOARD, Upgradeable software I.C.'s include U1, U14, U17. PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow. (Use chip removal tool P/N. 351156 for square I.
Thermal Control Board P/N 371105NE U 22 U 36 U 18 U3 U4 U 23 U 19 U 20 U 21 THERMAL CONTROL BOARD, Upgradeable software I.C.'s include U3, U4, U18 - U23, U36. PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow. DIP CHIPS align notch on chip with the notch on the socket (U3 & U4 chips are four pins smaller than U3 & U4 sockets, position chips towards top of socket so that the unused socket pins are at the bottom closest to the notch.
Front Panel Board P/N 511108 FRONT PANEL BOARD, Upgradeable software I.C.'s include U1. PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow. (Use chip removal tool p/n. 351156 for square I.C.
Appendix C Ink and Stock Transfer Types Transfer Type values associated with the XT commands.
Appendix D Knife MFG Guideline Solenoid Trigger Setting +.000 -.020 1. After the clutch and actuator is mounted to the knife, attach the solenoid assembly to the inside support using two 6-32 x 3/8 cap screws, flat washers, and lock washers. Make sure the plunger moves freely and does not bind. Motor and faceplate must be mounted also. 2. Check the gap between the actuator and the top of the pin on the clutch as shown in drawing. The plunger should be pushed in to make the measurement.
• Torsion Spring should be at an angle of 60±2°. Lay the spring over the drawing below to see if the spring is made properly. • Plunger pins should be centered on shaft. If either pin is loose DO NOT use the plunger. The pins should be checked before installing. • (Rev 3) Replace both roll pins on all reworked assemblies. • (Rev 4) Effective 3/3/97 a large nylon washer will be added between the coil pin and the c-clip on the plunger.
• There should be a .010-.020 gap (for roller clutch only) between the two clutch pieces. • (Test on the solenoid test box.) The knife must cut both fabric and card stock. The solenoid should operate on both the high and low settings. Excessive motor drag must be minimal at start / stop and while running. Replace or repair problem component. On old knife assemblies, there are bronze bushings in outer support. They may be causing a bind. Ream bushing and retest. (Do not ream if it is a roller bearing.
Appendix E Printhead Life Extension Matching stock and ink widths If you’re running multiple media and multiple widths on your AVERY DENNISON machine, Great! You 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.
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.
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.
Printhead Installation and Removal Procedures Printhead removal procedure 1. Attach the grounding strap to your wrist and the printer. 2. Turn the machine off. 3. Leaving the printhead shut, completely loosen the two mount screws but leave them loose in the holes. 4. Slowly open the printhead carriage assembly. Maneuver the printhead down and to the right, pulling the wire pack out. 5. Disconnect the wire pack and carefully remove the printhead. Printhead installation procedure 1.
Static Checks for 686 / 686 HT Printers 1. Stacker: With an ohmmeter, check continuity between the main stacker roller, which has the belts on it, and the chassis ground. Chassis ground can be any screw near the serial cable. Check that these two important enhancements are functioning: Washer a) Check the stacker-mounting knob has a large washer installed. Make sure to tighten the knob all the way. Stacker knob removed Ink arbors 2.
Print Quality Adjustment 1. Tangent is factory set and should not be adjusted. Head pressure is fixed without adjustment. 2. Strobe - Adjust strobe for print darkness and bar code scanability. Adjust one increment at a time.
Assembly Drawings Users Manual Model 686 / 686 HT Assembly Drawings • 83
Unwind Assembly Drawing 84 • Assembly Drawings Users Manual Model 686 / 686 HT
Unwind Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part # 373012 373009 373011 373010 353002 105023 373014 373013 191120 989973 990069 990000 990065 371142 990513 Description Web guide, Rear Lead screw, Tape unwind Adjuster, Outer web guide Rod, Web guide, Outer Bracket, Unwind Impression adj, Knob / SS Kit Bracket, Sensor mount Bracket, Stock out Micro switch 4-40 x ½ Cap screw 8-32 Hex nut 2-56 x ¼ Cap screw 8-32 x 3/8 Button head screw Stock out switch harness (*ns) Small wire tie (*ns) Qty 1
Unwind Turnbar Assembly Drawing 86 • Assembly Drawings Users Manual Model 686 / 686 HT
Unwind Turnbar Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Users Manual Model 686 / 686 HT Part # 554014 554015 554017 554029 554016 990138 990133 551002 514090 194020 990374 990484 990121 990328 Description Bracket, Unwind arm mount Bracket, Web roller mount Shaft, De-curler roller Web turn shaft Nut, Roller shaft lock 1/4-20 x 3/4 Knurled cup point 1/4-20 x 3/4 Flat head screw Frame, Upright 686, Ink save Assembly, Tape idler roller Web turn shaft Collar, 1/2 1/4-20 x 1/2 Nylon slotted screw 1/4-
Contrast Sensor Assembly Drawing 88 • Assembly Drawings Users Manual Model 686 / 686 HT
Contrast Sensor Parts List Item 1 2 3 4 5 6 7 8 9 10 Part # 990484 990374 194020 514019 514017 990111 990056 990133 990121 990313 Description ¼-20 x ½” Slotted Nylon screw ½” Collar Web turn shaft Bracket, Sensor guide Shaft, Ink turn bar 10-32 x ¾” Flat head screw 8-32 x ½” Flat head screw ¼-20 x ¾” Flat head screw ¼-20 x 5/8” Cap screw #10 Thumb screw knob Users Manual Model 686 / 686 HT Qty 2 2 4 1 1 3 4 5 3 1 Item 11 12 13 14 15 16 17 Part # 990083 514019 514016 511112 281140 514020 990268 514098
Web Guide / Sensor Assembly Drawing 13 12 19 2 11 6 26 40 41 42 28 1 27 4 5 7 14 27 3 34 8 3 21 10 15 31 3 19 32 9 33 43 17 4 16 21 18 30 10 39 35 10 18 29 25 90 • Assembly Drawings 20 37 36 24 22 23 38 Users Manual Model 686 / 686 HT
Web Guide / Sensor Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part # 554064 554057 554088 554051 554053 554054 554055 554056 554061 990091 554089 990262 554065A 554058 554059 990015 990312 990090 Description Drive, Sensor adjust gear Cover, Gear cluster Assembly, Bracket, Front plate Shaft, Sensor adjust Bracket, Mount, LED Bracket, Mount, Upper sensor Nut, Plastic, Lower Nut, Plastic, Upper Bracket, LED secure 10-32 x 1/2 Button head screw Assembly, Bracket, Web guide Snap r
Drive Assembly Drawing 5 6 19 14 8 15 12 20 1 18 10 7 11 21 3 4 9 13 14 17 2 16 7 92 • Assembly Drawings Users Manual Model 686 / 686 HT 5
Drive Parts List Item Part # Description 1 554099 Ass’y, Rear drive support 2 355018 Support, Knife / Drive / Print 3 554098 Ass’y, Front drive support 4 554042 Bracket, Right bridge blade 5 990080 10-32 x 3/8 Cap screw 6 554041 Bracket, Bridge plate (Web) center 7 990120 1/4-20 x 1/2 Cap screw 8 514094 Ass’y, Lift cam 9 354012 Roller, Grit 10 999146 Bushing, 3/8 x 1/2 x 1/2 11 514009K Spring lever, Front 12 514010K Spring lever, Rear 13 514012 Feed knob / SS 14 990261 Snap ring, 3/16 15 514003 Pin, Spring
Printhead Assembly Drawing 22 21 14 14 23 26 24 16 25 14 14 6 19 3 18 13 8 14 20 4 1 9 11 5 7 2 17 10 12 94 • Assembly Drawings Users Manual Model 686 / 686 HT 15
Printhead Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part # 555099 375085 376032 990497 990328 990083 555098 375014 990133 990135 555017 355096 375057 Description Ass’y, Rear support, Print head Ass’y, Support beam, Print head Ass’y, Ink turn roller Washer, 1/2 Wave E-ring, 1/2 10-32 x 3/4 Cap screw Ass’y, Front support, Print head Shaft, Head mount 1/4-20 x 3/4 Flat head screw 1/4-20 x 3/4 Button head screw Shaft, Eccentric 686 ink save Ass’y, Print head roller Contact, Ground Users Manual Model 686
Printhead Module Assembly Drawing 18 7 8 20 6 4 15 14 19 17 1 11 13 5 16 12 9 2 10 3 96 • Assembly Drawings Users Manual Model 686 / 686 HT
Printhead Module Parts List Item 1 2 3 4 5 6 7 8 9 10 Part # 555030 551131 551102 555034 555032 990073 990089 990919 991329 991308 Description Ass’y, Print head adjust Fan, Print head, Harnessed Print head (For references) Screw, Adjust Assy. Print head mount 8-32 x 1/2 B.H.C. Screw 10-32 x 1/4 B.H.C. Screw Bracket, Cable mount 4-40 x 1/4 Set screw w/ Nylon 4-40 x 5/8 F.H.C.
Printhead Adjustment Assembly Drawing 1 2 6 3 5 4 98 • Assembly Drawings Users Manual Model 686 / 686 HT
Printhead Adjustment Parts List Item 1 2 3 4 5 6 Users Manual Model 686 / 686 HT Part # 991217 555037 555038 991326 989983 555086 Description Spring, Compression Block, Slide Cover, Plate 4-40 x 3/4 Flat head screw 4-40 x 1/4 Button head screw Ass’y, Bracket, Head adjust Qty 2 2 2 2 4 1 Assembly Drawings • 99
Ink Drive 686HT Assembly 26 11 16 11 24 21 2 7 9 34 25 10 12 30 1 23 17 27 31 33 29 5 7 19 6 14 8 18 30 18 3 31 12 15 5 13 4 32 22 28 12 20 7 6 100 • Assembly Drawings Users Manual Model 686 / 686 HT
Ink Drive 686HT Parts List Item Part # Description 1 551002 Frame, 686 Upright ink save 2 194023 Standoff, 1-3/8" 3 551146A Motor, Ink save, Alt 4 245026 Stepper motor 5 554048 Bracket, Motor mount 6 221110 Motor, 24VDC 90ZIN 3100RPM 7 990081 10-32 x 1/2 Cap screw 8 284025 Pulley, 14T DFL 1/4 ID 9 554049 Housing, Bearing 10 999001 Bearing, R6FF 11 376035 Shaft, Unwind 12 356029 Pulley 26T 1/5P 13 555018 Print, Block, Eccentric stop 14 555020 Bumper, Sound barrier 15 555019 Bracket, Eccentric stop 16 555099
Ink Save Assembly 38 12 31 36 7 32 2 17 1 28 16 33 11 10 42 30 43 12 39 37 34 5 35 8 25 6 22 15 3 24 13 14 23 21 42 11 17 11 26 17 43 9 8 45 8 4 44 41 40 5 6 20 29 18 27 19 9 102 • Assembly Drawings 4 Users Manual Model 686 / 686 HT
Ink Save Parts List Item Part # Description Qty 1 551002 Frame, 686 Upright ink save 1 2 194023 Standoff, 1-3/8" 12 3 551146A Motor, Ink save, Alt 1 4 245026 Stepper motor 2 5 554048 Bracket, Motor mount 3 6 221113 Motor, 24VDC 90ZIN 3100RPM 2 7 991009 Standoff 2" 3 8 990081 10-32 x 1/2 Cap screw 32 9 284025 Pulley, 14T DFL 1/4 ID 2 10 554049 Housing, Bearing 2 11 999001 R6FF bearing 6 12 376035 Shaft, Unwind 2 13 556001 Housing, Bearing NS 1 14 999110 Bushing, 3/8 x 1/2 x 3/8 1 15 999061 Drive, 3/8 x 1/2 x
Ink Save PC Board Assembly 6 3 2 1 104 • Assembly Drawings 7 5 4 Users Manual Model 686 / 686 HT
Ink Save PC Board Parts List Item 1 2 3 4 5 6 7 Users Manual Model 686 / 686 HT Part # 551141 551140 551002 191104 551105 990017 989987 Description Harness, IADB to arbor motors Harness, TCB to AID Frame, 686 Upright, Ink save Standoff, 3/4 Pc board, IADB 6-32 x 1/2 Cap screw Hex nut, 6-32 E-S Qty 1 1 1 3 1 3 3 Assembly Drawings • 105
Timing Belt Threading Diagram 2 3 4 3 3 2 1 1 5 6 7 3 5 106 • Assembly Drawings 8 9 Users Manual Model 686 / 686 HT
Timing Belt Parts List Item 1 2 3 4 5 6 7 8 9 Users Manual Model 686 / 686 HT Part # 991391 991390 356029 991393 284025 991145 991392 555044 991393 Description Pulley, 10T Timing belt, 37T Pulley, 26T 1/5P Timing belt, 49T Pulley, 14T DFL ¼ ID Drive, 48T Timing belt Pulley, 20T w/ Hub Pulley, 20T Timing belt, 49T Qty 2 2 4 1 2 1 1 1 1 Assembly Drawings • 107
Timing Belt 686HT Threading Diagram 2 3 3 2 1 1 4 5 6 3 7 108 • Assembly Drawings 8 Users Manual Model 686 / 686 HT
Timing Belt 686HT Parts List Item 1 2 3 4 5 6 7 8 Users Manual Model 686 / 686 HT Part # 991391 991390 356029 284025 991145 991392 555044 991393 Description Pulley, 10T Timing belt, 37T Pulley, 26T 1/5P Pulley, 14T DFL ¼ ID Drive, 48T Timing belt Pulley, 20T w/ Hub Pulley, 20T Timing belt, 49T Qty 2 2 3 1 1 1 1 1 Assembly Drawings • 109
Knife Assembly Drawing 6 10 9 8 7 3 4 24 11 14 13 25 22 28 1 22 21 5 21 2 17 16 19 110 • Assembly Drawings 23 27 18 26 Users Manual Model 686 / 686 HT 15 12 20
Knife Parts List Item 1 2 3 4 5*3 6*2 7 8 9 10*2 11*3 12 13 14 15*2 16 Part # 357091 355018 357092 197308 357094 197311 990055 989978 990065 991067 357093 557090 990102 990123 357019 357016 Description Qty Bracket, Inner knife assembly 1 Support, Knife / Drive / Print 1 Bracket, Outer knife ass’y 1 Adjuster, Knife 1 Ass’y, Ground rotary 1 Cam, Knife homing 1 8-32 x 3/8 Flat head screw 1 Washer, #8 Star 1 8-32 x 3/8 Button head screw 1 8-32 x 5/16 Knurled cup point 2 Knife, Stationary Ass’y 1 Assembly, Kni
Stacker Assembly Drawing (Part 1) 22 21 9 23 16 7 11 16 17 15 16 13 14 11 12 21 29 20 13 18 19 10 26 7 26 6 16 26 4 27 30 2 25 3 7 8 5 24 2 4 1 28 112 • Assembly Drawings Users Manual Model 686 / 686 HT
Stacker Parts List (Part 1) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part # 558002 999014 378055 990066 378064 990037 990019 378060 378054 990403 999100 378050 518002 358016 378048 Description Bracket, Stacker support ¼ X 5/8 Flange ball bearing Roller, Front idler 8-32 x ¼ Button head screw Bracket, Jam sensor Washer, #6 SAE 6-32 x ¼ Button head screw Bracket, Sensor guard strip Bracket, Roller mount Rivet, 3/16 x ½ Flat head Bushing, FL.
Stacker Assembly Drawing (Part 2) 6 5 3 40 1 9 39 7 10 24 23 5 13 17 35 18 4 28 17 23 14 18 36 34 40 37 27 12 26 36 15 10 11 11 22 31 2 8 12 30 7 38 42 47 41 22 19 20 16 46 21 29 32 44 33 7 22 31 30 44 25 46 33 45 32 114 • Assembly Drawings Users Manual Model 686 / 686 HT 45
Stacker Parts List (Part 2) Item 1 2 3 4 5 6 7 Part # 558002 558001 558007 558006 990056 558008 999014 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 378056 378052 990028 990262 358094 990015 989976 990038 558010 990102 990085 558005 351161 378097 348015 990272 358015 Description Stacker base Stacker support, 686 Bracket, Roller lock, Rear Bracket, Roller lock, Front 8-32 x 1/2 Flat head screw Bearing support, 686 1/4 x 5/8 fl.
Back Reflective Sensor Option Assembly Drawing 4 1 6 5 2 3 116 • Assembly Drawings Users Manual Model 686 / 686 HT
Back Reflective Sensor Option Parts List Item 1 2 3 4 5 6 7 Users Manual Model 686 / 686 HT Part # 371128 990448 989984 554060 990002 554062 990513 Description Top & bottom reflective sensor harness Washer, .125 x .313 x .
Cover Assembly Drawing 12 17 16 15 4 27 19 2 6 5 11 9 26 16 15 1 25 20 23 21 22 10 3 8 18 7 14 13 118 • Assembly Drawings Users Manual Model 686 / 686 HT 24
Cover Assembly Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part # 511203 551001 341210 341209 511202 511209 551202 551201 551217 551218 551219 511214 551215 990065 Description Base plate Frame, Upright, 686 Feet, 1 1/2 Dia.
