Users Manual Model 676 AVERY DENNISON Manual Edition 9.
This page intentionally blank Users Manual Model 676
Contents Scope 6 Introduction................................................................................................................................ 6 Safety Issues / Warnings 6 Caution....................................................................................................................................... 6 Warranty Information 7 Warranty Policy .........................................................................................................................
Adjustments 40 Feed Roller Pressure ................................................................................................................ 40 Sensors..................................................................................................................................... 40 Sensor Adjustments: ................................................................................................................ 41 Print Head ...................................................................
Appendix F 80 Platen Rollers for 6x6 and 676 Printers ................................................................................... 80 Electrical Assembly Drawings 85 Machine Wiring ....................................................................................................................... 85 Electrical System Schematic .................................................................................................... 86 Motherboard Power Connectors ...................................
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.
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.
− Equipment purchased and exported to regions outside local Avery Dennison office coverage are not covered by warranty. The purchasing agent must acquire a service contract from the Avery Dennison 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.
Description / Specifications Printer Description The AVERY DENNISON MODEL 676 THERMAL PRINTER (Figure 1) is an electronic two-side printer that can print on Fabric Tapes, Card Stock, Heat Seal, and Pressure Sensitive rolled stocks. 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.
Printer Specification Print method: Wide web thermal transfer or thermal direct two sided printer Speed - up to 5 IPS (127mm/second) Label Size Min: 1" (25.4mm) web x 1" (25.4mm) feed Max: (standard stacker) 1" (25.4mm) web x 5/8” (15.8mm) feed (optional 4 ¼” stacker) 5.125" (130.2mm) web x 7" (177.8 mm) feed (standard stacker) 4.25" (108mm) web x 1 ¾”" (44.45 mm) feed (optional 4 ¼” stacker) 5.125" (130.2mm) web x 14" (355.
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 - Se
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 Printer. The AVERY DENNISON 676 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.
Customer Responsibility Location of Printer The printer weighs approximately 70 Lbs (32 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" wide to 30" deep to 32" high. Refer to Figure 2. Figure 2 - Recommended Workstation Layout. The location of the AVERY DENNISON 676 printer should be based on human factors.
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 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.
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 Crate. 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.
Fuse Configuration The main fuse(s) on the AVERY DENNISON 676 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.
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.
Printer Operation Loading Stock WEB TURN BAR INK DECURLER WEB GUIDE / KNOB HEAD 2 KNIFE HEAD 3 HEAD 1 DRIVE / AUX SENSOR / KNOB Figure 4 - Stock 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. Adjust the unwind width down to the stock size without clamping the core.
8) As the stock exits the sensor area, continue to slide the stock through the print stations. 9) Once the stock reaches the feed rollers it may be necessary to hold the feed pressure knob open in order to pass between the rollers. After exiting the feed rollers enter the aux. feed and then through the knife into the stacker. 10) Check that the stock is centered and tracking straight through the printer. Adjust as needed. 11) Close the feed roller and only the print stations needed for the format.
stock. If a large distance is to be covered loosen the plastic thumbscrew and slid the collar into the new position then retighten the thumbscrew. The third are the funnel type guides located befor the print station. Rotate the adjustment guide until it contacts the edge of the material. Do No Pinch the sides of the web. 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.
Users Manual Model 676 Printer Operation • 21
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.
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.
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.
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 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
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 6 7 6 / 3 0 0 B A T C H E S OR B A T C H P C L 0 0 1 I D Q U A N T I T Y 1 0 Press the MODE/Down arrow button will cycle the panel through the following main screens.
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 E N T E R F O R V E R I 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).
HOME SCREEN R E A D Y F O R 6 7 6 / 3 0 0 B A T C H E S OR B A T C H P C L 0 0 1 I D Q U A N T I T Y 1 0 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.
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.
P R I N T P O S I T I O N V A L U E : ± X X N E W S T A T I O N 3 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 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.
C H A N G E S T R O B E S T A T I O N 1 V A L U E : ± X X N E W V A L U E : ± Y Y This screen is the first screen under PRINTHEAD SETUP screen. This screen allows the user to adjust the strobe for station 1. The 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.
H E A D C A T E G O R Y S T A T I O N 2 V A L U E : ± X X N E W 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 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.
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 “PRINT HEAD SETUP”. 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 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. Place the stock hole/slot sense mark under the sensor.
B O T R E F L O V E R V A L U E : 0 0 0 N E W M A R K V A L U E : 0 0 0 This screen follows TOP REFL NOT OVER MARK under CALIBRATE SENSORS. Place stock over the sensor so that the reflective mark is over the sensor and when NEW VALUE is at is largest value press ‘Enter’. 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 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 0 0 0 0 0 0 0 0 0 0 P R O D U C E D This screen follows the LABEL COUNTER 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.
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 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.
N E W 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 This screen follows the PROTOCOL screen. This screen allows the serial communications speed to be changed. Use the 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.
VERIFIER SETUP P R E S S E N T E R F O R V E R I F I E R S E T U P This screen follows the "FEATURE SETUP" screen. Pressing ENTER will take the user to the "VERIFIER SETUP" screens. Pressing the MODE/Down Arrow key will take the user back to the "PRINT/CUT POSITIONS" screen. Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
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.
Jam An optical sensor located in the stacker will detect each cut label as it leaves the cutter. If a cut fails to occur or a label remains in the sensor sight path, the machine will stop. Full Stacker A micro switch in the stacker rails allows the printer to detect a full load of labels in the stacker. The stack full condition will stop the machine when the stacker is full.
4) Compare the actual feed length of the sense mark stock being run with the feed length set in the format. 5) Repeat the sensor alignment procedure. 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 bale is adjusted by carefully bending it as needed.
- Are the correct width platen rollers installed in the print stations for the stock width loaded in the printer? To actually adjust the tangent continue as follows: 1) Determine the print station that adjustment is needed. 2) Using the sight hole on the front of that print station, observe the present location of the print line on the print head in relation to the platen roller. 3) As the printer is printing labels use the adjustment thumbscrew to move the head left and right.
Stock Width Adjustment Loosen the two thumbscrews behind the stacker uprights and adjust the stacker upright nearest to the operator to the desired stock width position. Re tighten. Stacker Angle Adjustment Loosen the lever located on the side of the stacker assemble nearest the operator and adjust the angle of the stacker with a few cut labels in the stacker so that there is a slight gap under the last label as it hangs over the last belt drive roller. Re tighten.
Machine Set Up Sequence 1) Power off the printer, remove the media and ink and thoroughly clean it from the unwind to the stacker 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 resolve any remaining error conditions.
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.
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 is clean of all debris.
hands before handling the print head. Oils from your hands can contaminate the print line and quickly destroy the printing elements. 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.
Caution: 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. C) Using the left () arrow key set the HEAD CATEGORY as called out in the PRINTHEAD CATEGORY CHART below. D) Press the ENTER key to enter the value.
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. 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.
Electrical Trouble Shooting Power Up / Sign On / Communications Problem Machine fails to power up with no light present in the AC power switch. Probable Cause Corrective Action 1) Incorrect power amplitude. 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. 2) Check that both ends of the power cord are plugged in securely.
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 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. Users Manual Model 676 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 machine with start automatically). 2) An interlock condition exists. 2) Determine the number and type of interlock(s) by reading the front panel display.
Print Problem Machine advances stock but does not print. Machine stops after ever third label. Print registration is off in the feed 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 slot or hole passes under the sensor. 2) Miss adjusted print head position. 2) Set print head position. Refer to "Print Head Tangent Point". 3) Miss adjusted print head pressure.
Problem Print registration is off in the web direction. Print contrast is too light or dark. Voids in print image in the feed direction. Machine continually stops with an erroneous interlock condition. Users Manual Model 676 Probable Cause Corrective Action 1) Machine incorrectly threaded. 1) Check and rethread the media as needed. Refer to "Loading Stock". 2) Web guides incorrectly adjusted. 2) Check and adjust as needed. Refer to "Web Guide Adjustment". 3) Unwind incorrectly adjusted.
Cut / Stack Problem Machine 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 setup menu. 1) Enable the knife in the setup menu via the front panel. 2) Knife cable unconnected. 2) 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".
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 web guides to touch stock roll but not pinch the roll. Machine fails to stop at end of roll. 1) Incorrect adjustment of stock-out sensor. 1) Adjust contact strip so that a “click” will be heard when supply roll is lifted.
Problem Stock jams in bridge blade rollers or knife area. Will not stack. Knife will not cut or partial cut Probable Cause Corrective Action 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. 2) Knife not cutting full width of stock.
Ink Problem Ink wrinkles or will not pull smoothly. Ink rolls loosely on take-up roller. Users Manual Model 676 Probable Cause Corrective Action 1) Incorrect adjustment of unwind roller brake resistance. 1) Adjust knurled knob clockwise as far as possible without breaking ink or stalling ink motor. Do not bottom adjustment knob. Replacement of fiber brake disc may be required if printer has high hours. 2) Unwind roller and ink take-up roller misaligned.
Print Problem Poor print - uneven or no print (mechanical). Also see electrical trouble shooting. Probable Cause Corrective Action 1) Incorrect tangent position. 1) Refer to tangent adjust procedure in Print Head section. 2) Broken ink. 2) Replace ink and readjust (see INK trouble shooting). 3) Ink not rewinding. 3) Readjust (see INK trouble shooting).
Knife Problem Double Cuts, extra knife cycle Skips cut, double length label Noisy Rattle when not cutting but motor turning Probable Cause Corrective Action 1) Solenoid sticking in 1) Check proper assembly of washers. Clean plunger with alcohol and completely dry. 2) Worn Trip Arm on Clutch actuator. 2) Replace Actuator 3) Worn Stop roll pin on clutch 3) Replace Clutch if not solved above. 1) Solenoid did not pull in 1) Check gap on the trip arm to clutch body must be about .040 inches.
Problem Knife stops during cut in stock Slight Long and Short Tags Stock popping in front of knife Knife does not cycle Continuous Knife cycling Probable Cause Corrective Action 1) Check life of blades 1) If warn and dull, may stall in stock. If life is greater than 2 million, replace blades. 2) Clean cams and lubricate 2) Make sure oiler is on knife. Instruct Operator to oil weekly. Make sure oil is available.
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 Thermal Control Board P/N 371105TT U 22 U 36 U 18 U 3 U4 U 23 U 19 U 20 U 21 THERMAL CONTROL BOARD Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.
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.
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.
Appendix C Ink and Stock Transfer Types Transfer Type values associated with the XT commands.
Value 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 68 • Appendix C Transfer Type Pressure Sensitive & HR-4111 Ink Uncoated Tag Stock & HR-4111 Ink Fabric 2800 & HR-4111 Ink Fabric 2795 & HR-4111 Ink New Pressure Sensitive (no xfer) & TT-3111 Ink New Pressure Sensitive (no xfer) & TT-1111 Ink New Pressure Sensitive (no xfer) & TW-1111 Ink New Pressure Sensitive (no xfer) & TW-1151 Ink New Pressure Sensitive (no xfer) & HR-11
Value 117 118 119 120 121 122 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 Users Manual Model 676 Transfer Type 591SST/601SST Fabrics & CT-1114 Ink 601SST Fabric & CT-1111 Ink 591SST/601SST Fabrics & CT-1115 Ink 591SST/601SST Fabrics & CT-1117 Ink 591SST Fabric & CT-1112 Ink 601SST Fabric & CT-1112 Ink 4900NWT / 4900HSA & HS1111 1800FRA & TW1111 1800FRA & GP1111 2085NWT / 2495NWT / 2360NWT & HS1111 2360NWT / 2800NWT & XC3111 28
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.
Appendix E Printhead Life Extension NOTE: This section was written specifically for the 636/656 – but the information is useful and applicable for the 676 as well. 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.
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 tangent locking 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 from the shield. 5. Disconnect the wire pack and carefully remove the printhead.
Static Checks for 636/656 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: a) Check the grounding clip is installed and making physical contact with the main stacker roller. Sometimes, the clip is installed but moved off the roller.
Steps for initial set up on a AVERY DENNISON 636 or 656 1. Software: In Formatter, open the format. From the Format menu, select Attributes. Select the “Ink Setup” tab. Check that the combination of stock and ink types matches what is running on the machine. 2. Pressure: Open the printhead such that it hangs at an angle. Loosen the printhead pressure knob enough to that it just sticks and does not slide from gravity. Position the knob in the center of the ink. Close the printhead, tighten 3/4 of a turn. 3.
Print Quality Adjustment !. Tangent - Move the tangent adjust knob left or right to improve print quality. In general, the best print will be slightly to the left of center. Style: Fall Color: Rose Platten roller Printhead Stock Ink 23456 78901 Ink Stock Specialty Brand Style: Fall Color: Rose 23456 78901 Printhead Specialty Brand Specialty Brand Printhead Ink Stock Platten roller Platten roller $5.95 Tangent too far left Tangent too far right Tangent properly adjusted 2.
Appendix F Platen Rollers for 6x6 and 676 Printers There are several types of platen rollers made for the 6x6 and the 676 series of controlled printers. The material printed will determine the color (hardness) of the roller as well as width of the cut down part of the platen. The green rollers are harder and used for fabric applications. The red rollers are softer and are used for tag applications. The rollers are determined by tapes / tags and is not dependant on the ink selection.
Standard Platen Roller Non Ink Save 636 / 656 All 676 Part Number 355009 – Red Part Number 355029 - Green _____________________________________________________________________________________________ Standard Platen Roller Ink Save 656 All 676 Part Number 355096 – Red Part Number 355083 – Green Users Manual Model 676 Appendix F • 81
Back Justified Platen Roller 3” Cut Down Non Ink Save 636 / 656 w/ Beige Covers Part Number 355044 - Green _____________________________________________________________________________________________ Back Justified Platen Roller 3” Cut Down w / Ink Save 656 w/ Beige Covers Part Number 355082 - Green 82 • Appendix F
Center Justified Platen Roller 1 3/8” Cut Down Non Ink Save 636 / 656 w/ Gray Covers 676 Part Number 375030 - Green _____________________________________________________________________________________________ Center Justified Platen Roller 1 3/8” Cut Down w / Ink Save 656 w/ Gray Covers 676 Part Number 375031K - Green Users Manual Model 676 Appendix F • 83
Center Justified Platen Roller 3” Cut Down Non Ink Save 636 / 656 w/ Gray Covers 676 Part Number 375026 - Green _____________________________________________________________________________________________ Center Justified Platen Roller 3” Cut Down Ink Save 656 w/ Gray Covers 676 Part Number 375025K - Green 84 • Appendix F
Electrical Assembly Drawings Machine Wiring INK SAVE (TW O) FEED SYSTEM HARNESS FRONT PANEL ROLLER DROP VERIFIER THERMAL CONTROL BOARD (REAR) 371105TT KNIFE ORANGE GRAY ORANGE RED ORANGE RED (NOT USED) PH2 PH3 GRAY BROW N PH1 GRAY BROWN HEAD DRIVER BOARD (FRONT) 371107T3 BROWN POW ER SUPPLY Users Manual Model 676 Electrical Assembly Drawings • 85
Electrical System Schematic MB POWER CONN 12 AC ENTRY 341111 115V 230V CONN 3 LINE LINE CORD 181134 HARNESSED +5V/+12V/+24V POWER SUPPLY 371116 POWER GOOD A L B N GROUND G C NEUTRAL CONN 2 STOCKOUT SWITCH HARNESS 371142 SWITCH 191120 D CONN 4 FEED OPEN SWITCH 191120 MACHINE COOLING FAN 511120 TOP 1 HEAD-OPEN SWITCH 375018 +12V 115V OPERATION ONE 10.0A 250V 1/4 X 1 1/4 FUSE 921167 NC NC +24V BOTTOM HEAD-OPEN SWITCH 375018 OPTIONAL PCMCIA BOARD 351181 +5V 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.
Mechanical Assembly Drawings Z:\Manual-Release\676\676 v9.0.
Unwind Assembly Drawing 90 • Mechanical Assembly Drawings Users Manual Model 676
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 (*NS) = Not Shown Z:\Manual-Release\676\676 v9.0.
Web Guide / Light Bar Assembly Drawing 36 33 32 31 34 35 8 14 28 15 29 13 5 2 5 24 21 1 12 9 9 4 1 21 30 20 22 23 26 19 27 7 9 3 25 16 21 17 18 6 37 1 10 11 1 9 92 • Mechanical Assembly Drawings Users Manual Model 676
Web Guide / Light Bar Parts List ITEM PART NO. 1 374059 2 374060 3 374055 4 374061 5 374051 6 374049 7 374050 8 514102 9 999100 10 554059 11 554058 12 554005 13 554004 14 374058 15 554064A 16 105023K 17 551169 18 532015 19 371128 DESCRIPTION SHAFT, SENSOR GUIDE SHAFT, WEB GUIDE ADJUST SENSOR GUIDE HOLDER WEB GUIDE ADJUST BRACKET, WEB GUIDE BRACKET, LED MOUNT BRACKET, SENSOR MOUNT ASSY.
Drive Assembly Drawing 3 2 25 11 23 14 18 7 6 5 13 9 22 20 8 15 6 28 7 4 26 16 2 24 10 17 1 27 19 12 21 22 94 • Mechanical Assembly Drawings Users Manual Model 676
Drive Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part # 514009K 990261 514010K 514002 374044 990080 990313 514003 354008A 354009A 514094 374047 991170A 990023 Description Spring lever, Front Snap ring, 3/16 Spring lever, Rear Slide, Idler shaft Bridge plate, Web 10-32 x 3/8 Cap screw Thumb screw knob, #10 Pin, Spring anchor Gear, Idler Gear, Driven Lift cam ass’y Feed knob / SS Extension spring 6-32 x 1/2 Flat head screw Z:\Manual-Release\676\676 v9.0.
Top Auxiliary Feed Assembly Drawing 2 5 6 7 6 2 5 3 4 1 3 96 • Mechanical Assembly Drawings Users Manual Model 676
Top Auxiliary Feed Parts List Item 1 2 3 4 5 6 7 Z:\Manual-Release\676\676 v9.0.
Top - Printhead Assembly Drawing 15 33 19 32 14 8 16 1 9 28 18 21 2 13 7 23 11 34 12 37 17 29 6 26 4 31 3 27 30 5 25 24 36 35 10 22 98 • Mechanical Assembly Drawings 20 Users Manual Model 676
Top - Printhead Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part # 375087 375085 990135 355029 356020 375088 375014 990083 990122 375005 990497 990328 355037 376051 376052 990448 991081 991025 990006 Description Support rear ass’y Support beam print assembly 1/4-20 x 3/4 Button head screw 90 Durometer molded roller 636 Roller, Molded (ink) Support front assembly Shaft, Head mount 10-32 x 3/4 Cap screw 1/4-20 x 3/4 Cap screw Plate, Print head mount Washer, 1/2" Wave Snap ring, 1/2 "e" R
Ink-Save Printhead Assembly Drawing 5 4 30 29 4 2 31 3 30 37 29 8 13 27 33 32 10 18 14 24 19 6 7 9 11 35 25 21 15 28 22 34 1 12 26 23 16 20 38 100 • Mechanical Assembly Drawings 17 36 Users Manual Model 676
Ink - Save Printhead Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part # 991081 376051 376052 990448 990006 375044 991124 375043 375039 355037 375005 375016 375087 375085 375088 355004 355083 375014 375021 Description Spring, Compression Bracket, Static brush, Mount Bracket, Static brush Washer, .125 x .313 x .
Bottom - Printhead Assembly Drawing 21 22 31 10 18 19 8 33 32 26 20 9 24 13 25 11 23 29 34 27 2 6 30 1 7 28 5 14 4 35 16 12 15 3 36 17 37 102 • Mechanical Assembly Drawings Users Manual Model 676
Bottom - Printhead Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part # 356020 355029 375089K1 375083 990135 375014 990328 375084 990083 990122 375085 355037 376032 990037 990016 376051 376052 375003 375086 Description Qty Roller, Molded (ink) 1 90 Durometer molded roller 1 Print head holder ass’y kit (sta #1) 1 Support front ass'y (bottom) 1 1/4-20 x 3/4 Button head screw 1 Shaft, Head mount 1 Snap ring, 1/2 e-Ring 1 Support rear ass’y (bottom) 1 10-32 x 3/4 Cap screw 1 1/4-20 x 3/4 Cap
Ink Unwind Assembly Drawing 104 • Mechanical Assembly Drawings Users Manual Model 676
Ink Unwind Parts List Item 1 2 3 4 5 6 7 8 Part # 356010 990042 990490 999009 356053 376088 990133 376026 Description Shaft, Lock 8-32 x 3/16 Knurled Cup Point Spring, Comp 5/16 Thrust Bearing Shaft, Unwind Arbor, Unwind Assembly ¼-20 x ¾ Flat Head Screw Unwind Fiber Spacer (*NS) = Not Shown Z:\Manual-Release\676\676 v9.0.
Ink Rewind Assembly Drawing 106 • Mechanical Assembly Drawings Users Manual Model 676
Ink Rewind Parts List Item Part # Description 1 376026 Unwind Fiber Spacer 2 376092 Arbor Unwind Assembly 3 376003 Collar Foil Guide 4 376002 Ink Guide 5 990080 10-32 x 3/8 Cap Screw 6 990313 #10 Thumb Cap 7 356204K Arbor Rewind Assembly 8 990058 8-32 x ¼ Set Screw 9 356203 Shaft, Rewind 10 376016 Bearing Housing (*NS) = Not Shown Z:\Manual-Release\676\676 v9.0.
Ink Rewind w/ Head-Lift Assembly Drawing 108 • Mechanical Assembly Drawings Users Manual Model 676
Ink Rewind w/Head-Lift Parts List Item 1 2 3 4 5 6 7 8 9 10 Part # 376026 376092 376003 376002 990080 990313 356204 990058 356203 376016 Description Unwind Fiber Spacer Arbor Unwind Assembly Collar Foil Guide Ink Guide 10-32 x 3/8 Cap Screw #10 Thumb Cap Arbor 8-32 x ¼ Set Screw Shaft, Rewind Bearing Housing (*NS) = Not Shown Z:\Manual-Release\676\676 v9.0.
Ink Rewind - Station 3 - 1 over 1 - Assembly Drawing 110 • Mechanical Assembly Drawings Users Manual Model 676
Ink Rewind - Station 3 – 1 over 1 - Parts List Item 1 2 3 4 5 6 7 Part # 376028 376016 999002 376025 376023 376024 991018 Description Stub Shaft, Ink Rewind Bearing Housing Bearing Bearing Spacer Bearing Spacer Bearing Spacer Snap Ring, Internal (*NS) = Not Shown Z:\Manual-Release\676\676 v9.0.
Knife Assembly Drawing 6 10 9 8 7 3 4 24 11 14 13 25 22 28 1 22 21 5 21 15 12 20 2 17 16 19 112 • Mechanical Assembly Drawings 23 27 18 26 Users Manual Model 676
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 517099 990102 990123 357019 357016 Description Bracket, Inner knife assembly Support, Knife / Drive / Print Bracket, Outer knife ass’y Adjuster, Knife Ass’y, Ground rotary (6x6) Cam, Knife homing 8-32 x 3/8 Flat head screw Washer, #8 Star 8-32 x 3/8 Button head screw 8-32 x 5/16 Knurled cup point Knife, Stationary ass’y Assembly, Knife motor, 600 rpm Wa
Stacker Assembly Drawing (Part 1) 114 • Mechanical Assembly Drawings Users Manual Model 676
Stacker Parts List (Part 1) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part # 378050 378055 378057 378058 378060 378054 990403 999014 999100 144034 989979 990261 990446 990019 990037 Description Roller, Pressure Roller, Front Idler Bracket, Lock Bracket, Stacker Base Bracket, Sensor Guard Strip Bracket, Roller Mount Rivet, 3/16 x 1/2 Flat Head 1/4 x 5/8 FL. Ball Bearing Bushing, FL. 3/16 x 5/16 x 1/8 Feed Lock Knob 10-32 x 1 Knurled Cup Point Snap Ring, 3/16 .188 x .
Stacker Assembly Drawing (Part 2) 116 • Mechanical Assembly Drawings Users Manual Model 676
Stacker Parts List (Part 2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part # 184002 188008 348015 351161 358007 358013 358015 358017 358020 358033 358094 378005 378052 378056 378058 378097 999014 990313 990369 990641 990037 990450 Description Thumb Screw Lock Knob "T" Nut, Machined Square Shaft, Roller Pin Stacker Motor Harnessed Rail, Front Stacker Trip Rod Support, Roller Spring, Trip Rod Support, Label Side Bracket, Stacker Support Roller, Stacker Support Ass’y Rail, Rear Stacker Sh
Rewind Assembly Drawing 9 34 16 3 12 6 18 18 19 28 29 20 30 32 24 31 18 1 33 10 21 13 25 26 5 11 4 26 25 7 41 27 37 40 6 2 8 17 15 14 23 22 23 36 35 118 • Mechanical Assembly Drawings Users Manual Model 676
Rewind Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part # 111030 989974 111029 990812 351183 112036 351161 990091 112037 999147 112033 999116 111034 112034 990121 990090 197078 990374 990465 999017 990079 Description Upright, 656 Rewind 8-32 x 3/8 Cap screw Base, 656 Rewind Strain relief 636 / 656 Rewind harness Insulator, Motor Stacker motor, Harnessed 10-32 x 1/2 Button head screw Support, Shaft bearing Bushing, 1/2 x 5/8 x 3/4 Shaft, 6x6 Rewind Bushing, 1/2 x 5/8 x 3/8 Cover,
Optional 4 1/4” Stacker Specifications • 4 ¼” (108mm) Web x 3 1/2” (89mm) Feed • Will work on 636, 656, 676 and 545 • Old machines may require the knife strut to be replaced with one that has a mount hole – Part number 355018. • Fabric and heat seal only - not for pressure sensitive or tags. • Stack height dependent on material size and weight.
Optional 4 1/4” Pick-up Assembly 34 22 19 3 30 5 2 33 32 6 28 4 5 26 9 2 10 23 18 5 5 8 1 21 13 25 24 7 31 28 12 19 25 20 31 19 9 8 15 26 5 6 21 17 16 11 29 122 • Mechanical Assembly Drawings 27 14 19 22 Users Manual Model 676
Optional 4 1/4” Pick-up Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part # 378291 348107 378204 990066 990016 348105 348021 348109 348016 999012 378216 348006 348101 348094 348102 990167 990126 Description Oiler mount / Knife protector Support, Roller Sensor, Mount upper 8-32 x 1/4 Button head screw 6-32 x 3/8 Cap screw Support, Pick-up roller Roller, Idler Spacer, Pivot roller Conveyor, Bearing mount Bearing, 1/4 x 1/2 Flg ball Sensor, Mount, Lower Bracket, "T" Nut retainer Frame, Rear stac
Optional 4 1/4” Stacker Assembly 46 38 42 48 50 44 43 43 45 41 49 37 35 19 34 39 36 40 18 35 BELT DIAGRAM 31 32 35 4 17 24 27 33 47 14 7 13 11 12 25 29 3 15 5 2 9 28 10 1 30 26 23 6 21 30 16 8 22 20 124 • Mechanical Assembly Drawings Users Manual Model 676
Optional 4 1/4” Stacker Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part # 348026 348106 348027 348028 990029 990028 348020 351161 990102 990081 348024 348016 999012 Description Frame, Stacker, Rear Plate, Stacker support Frame, Stacker, Front Bracket, Rail slide 6-32 x 1/4 Flat head screw 6-32 x 3/8 Flat head screw Shaft, Roller Stacker motor, Harnessed Washer, #10 SAE 10-32 x 1/2 Cap screw Drive, Pulley 20 tooth Bushing, Conveyor bearing mount 1/4 x 1/2 Flg ball bearing (3/16 thick w/3/64 x 9/16 Flg)
Drive Belt Routing (2 over 1) Drawing 4 5 8 4 7 6 3 2 5 9 1 7 7 5 4 126 • Mechanical Assembly Drawings Users Manual Model 676
Drive Belt Routing (2 over 1) Parts List Item 1 2 3 4 5 6 7 8 9 Z:\Manual-Release\676\676 v9.0.
Drive Belt Routing (1 over 1) Drawing 4 8 4 7 6 3 2 5 9 1 7 7 5 4 128 • Mechanical Assembly Drawings Users Manual Model 676
Drive Belt Routing (1 over 1) Parts List Item 1 2 3 4 5 6 7 8 9 Z:\Manual-Release\676\676 v9.0.
