Users Manual LOKPRINT II Industrial Apparel Label Station Operation / Maintenance And Parts List AVERY DENNISON Manual Edition 4.
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Contents Scope 5 Introduction................................................................................................................................ 5 Safety Issues / Warnings 5 Caution....................................................................................................................................... 5 Heaters......................................................................................................................... 5 Feed Roller ................................
Lamp Replacement Procedure 20 Drive Cable Replacement Procedure 22 Installing the Drive Cable at the Capstan .................................................................................22 Troubleshooting 23 Interlock Trouble Shooting Guide ...........................................................................................24 Electrical Schematic 27 115 / 230 Volt Schematic.........................................................................................................
Scope Introduction This user manual was arranged for the person who is going to operate the system. The information is arranged in the order that is needed to install, and then operate the system. It starts with general information, then to unpacking the carton, setup, installing the supplies, machine operation, and then finally care and maintenance.
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.
Location / Power Requirements Location of LOKPRINT™ II System Recommended Work Station Layout. The LOKPRINT™ II requires a workstation with a minimum worktable of 30” (76.2cm) deep x 96” (243.8cm) long x 30” high (adjustable height may be desired depending on if the operator will be standing or seating). The worktable does not include a space for the computer. The table must be capable of supporting 300 Lbs. (136.1Kg).
power. Because of the higher current draw of the LOKPRINT™ II, the printer / Finishing Station or Cold Knife should be on a separate electrical service of 15A. Refer to the Printer and Finishing Station or Cold Knife serial number plates for their line requirements. Please check with your local electrical code and have the system wired by a qualified electrician. LOKPRINT™ II Main Line Protection The LOKPRINT™ II main AC power switch also serves as a resettable circuit breaker.
Unpacking / Inventory Unpacking The AVERY DENNISON equipment is shipped in a large cardboard box, which may be difficult to move by hand. DO NOT REMOVE THE MACHINE FROM THE BOX OR UNPACK IN THE SHIPPING / RECEIVING DEPARTMENT. NOTE: Unpacking in the shipping/receiving department is not recommended for the following reasons. First: The cardboard carton in which your AVERY DENNISON equipment was shipped allows the machine to be moved with a forklift, forkcart or handcart.
Inventory of Components The following is a list of additional parts (pieces) that should be included in your LOKPRINT™ II shipping container. If anything is missing notify AVERY DENNISON immediately – in the U.S.A. at (570) 888-6641. In other countries contact your local AVERY DENNISON supplier. – AVERY DENNISON LOKPRINT™ II “User’s Manual”. – Quick-disconnect power cord. – Printer / LOKPRINT™ II positioning template.
LOKPRINT™ II Assembly Installation Setup Procedure 1) Assemble the system components and connect all the interface cables between the three components. 2) Check / set the Printer TCB DIP switches for a 676 with stacker jam disabled (1, 3, and 4 ON / all others OFF). 3) Power on the Printer, Lokprint II, and Finishing Station for warm up.
) Once the oven position has been checked / adjusted - run the system and take note of the fabric position in relation to the oven as it enters the oven. Adjust the Lokprint II box forward or backwards on the bench in relation to the printer using the template / mount knob. The web position collars on the 676 are more for a reference then position. Do not use them to deflect the web, as wrinkling will occur.
Product Description Theory of Operation The LOKPRINT™ II was designed to receive labels printed on both sides from a AVERY DENNISON 676 printer or one sided from a AVERY DENNISON 636 printer using dye sublimation inks. The LOKPRINT™ II dye sublimates the labels and feeds a Finishing Station for ultrasonic or cold knife cutting.
(6) Web under temperature alarm. (7) Oven over temperature alarm. (8) Guard open. The recommended room temperature for the system is 60°F (15.5°C) to 90°F (32.2°C). If a cooling system is required it should not be pointed directly at the system to create drafts that could affect the sublimation process. LOKPRINT™ II Specification Sublimation method: Non-contact Narrow polyester web Dye sublimation thermal transfer inks Web speed: Speed – 5 IPS - (127mm/second) Web Size: Min: 1.
LOKPRINT™ II Operation / Adjustments JAM SENSOR Jam Sensor The jam sensor (illustrated with the bridge removed) is looking for the presence of the fabric for the printer to start and continue to operate. If the fabric in not present, the system will not start and the printer front panel will display a message “Check Stacker”. If the fabric breaks during operation and pulls out of the sensor, the system will stop and printer front panel will again display “Check Stacker”.
VAPOR FILTER SNAP ON COVER Ventilation The LOKPRINT™ II is equipped with a ventilation system comprising of two fans with carbon filters and multiple internal machine compartments / components. One filter is used to reduce the odors that are exhausted from the heat chamber while the other is used to filter the ambient air drawn in to cool the electronics compartment. Vapors created during the sublimation process have an odor and may be seen as smoke escaping from the heat chamber area.
Feed Roller The feed roller has two torsion springs that supply even tension for tracking. If the fabric fails to track properly through printer, check to see if one of the springs have come loose, broken or been stretched out of shape. The feed is equipped with a hand knob used to thread the machine. This knob should turn freely with very little resistance. If resistance occurs, check to see if the roller bearings need to be greased / replaced. Use standard multi purpose grease to lubricate the bearings.
INCORRECT WEB TENSION CORRECT WEB TENSION Heat Chamber Care In the unlikely event that the fabric touches the bulbs - it will melt onto them and / or the inner oven. Remove as many of the un-melted pieces as possible without touching the bulbs. DO NOT attempt to scrape melted fabric from the bulbs. Any remaining fabric residue will burn off, much like a self-cleaning oven. Simply re-thread a fresh section of fabric and continue printing.
Lamp Replacement Procedure 1. Remove rear cover from machine chassis. Disconnect the lamp wires from the two terminal blocks located on the back of the lamp oven for the defective lamp(s). 2. At front of the machine, open clear, plastic oven guard and move lamp oven forward. Oven top is hinged. Swing oven top upward to expose lamp guards and lamps. 3. Unscrew lamp holders from lamp guards and remove the defective lamp(s) and lamp holders. Replace old or defective lamp(s). 4.
LAMP HOLDER TERMINAL BLOCK UPPER WIRE GROMMET OVEN TOP BACK OF OVEN TERMINAL BLOCK LOWER WIRE GROMMET Users Manual LOKPRINT™ II Lamp Replacement Procedure • 21
Drive Cable Replacement Procedure Installing the Drive Cable at the Capstan BOTTOM VIEW BACK OF MACHINE STOP SLEEVE CABLE RIGHT SIDE 3 4 CABLE LEFT SIDE 1 2 STOP SLEEVE GROOVE CAPSTAN FRONT OF MACHINE 1: Feed the drive cable in from left hand side and wind around the Capstan five times, starting from the top and working down to the bottom. 2: Wrap the Drive Cable into the Stop Sleeve Groove so that the Stop Sleeve fits.
Troubleshooting Problem Web will not advance Probable Cause Corrective Action 1) Insufficient feed pressure. 1) 2) 3) 4) 2) Defective feed component. 1) 2) 3) 4) 5) Web will not sublimate completely. 1) IR lamp(s) out 2) 3) 4) 5) Smoke coming from the front of Heat Chamber. Defective IR sensor Defective sensor controller Blocked filters Web is not tracking through the middle of the heat chamber. 1) Blocked filter 1) 1) 1) 1) 2) Fan not operational 1) Check blown fuse. 2) Replace defective fan.
Interlock Trouble Shooting Guide The following is a list of Lokprint II problems along with possible causes / remedies of each that will stop the host printer with a check stacker error: Problem No lights on / in Lokprint II Check Stacker error cannot be cleared. System will not start. Lokprint II READY light is not on. Check Stacker error cannot be cleared. System will not start. Probable Cause Power switch position. Toggle power switch on back of Lokprint II box. Power switch over current trip.
Problem Lokprint II READY light is on. Check Stacker error can be cleared. Oven travels out or attempts to travel out and immediately retracts. Probable Cause Oven obstacle. Remove / adjust obstacle so that oven travels freely. Oven to guard insulation strip misalignment. Oven out sensor misadjust / wiring error / fault. Oven drive line fault, mechanical or electrical. Adjust insulation strip for full oven engagement without interference.
Problem Lokprint II READY light is on. Check Stacker error can not be cleared. System will not start. Finishing Station displays Close Guard. U1 readout > 800°. Probable Cause Lokprint II guard open. Close guard. Finishing Station stacker platform at bottom of its travel. Finishing Station guard open. Remove labels and raise platform. U1 Sensor misalignment. AVERY DENNISON service to realign sensor. AVERY DENNISON service to confirm / reprogram as needed.
Electrical Schematic Users Manual LOKPRINT™ II Electrical Schematic • 27
115 / 230 Volt Schematic SEE NOTES 5, 6, 7, 8, & 9 115V 20A 990762 230V 10A 990764 HARNESSED SCR CONTROLLER 561106 SWITCHABLE CIRCUIT BREAKER AC ENTRY 990953 Y Y/W TB1 SCR1 R1 LINE TB4 R1 LINE CORD 561129 115V 1 GROUND CONN 7, 6-7 TB3 R2 SCR2 230V 2 NC R3 R1 C1 F5 1 LINE CORD 561130 230V TB4 R1 CONN 7, 1-5 NEUTRAL SEE NOTES 5, 6, 7, 8, & 9 CONN 4 SEE NOTES 5, 6, 7, 8, & 9 CONN 7, 6-7 990957 TH1 R2 6 T1 2 R1W R R2 990957 TH1 6 4 R3 R3 TB3 3 R4 MOUNT WITH GROUND D
Mechanical Assembly Drawings Users Manual LOKPRINT™ II Mechanical Assembly Drawings • 29
Cover Assembly 7 3 7 13 2 11 25 20 24 26 21 7 1 22 7 12 28 4 23 7 16 26 5 6 17 30 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II 10 14 18
Cover Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part # 561203 565008 561204 561206 561205 991199 990090 990052 565032 561210 990050 565034 224051 990728 Description Cover, Chassis, Main Bracket, Mount, Pulley Cover, Chassis, Back Hinge, Feed cover Cover, Feed Bumper, Rubber 8-32 10-32 x 3/8 Button head screw 10-32 x 1/2 Cap screw Bracket, In-out oven switch Cover, Controller 8-32 x 1/4 Cap screw Bracket, Control switch Hinge, Access cover Washer, #10 lock Users Manual LOKPRINT™ II Qty 1 1 1 1 1 5
Baffle Assembly 7 6 4 1 4 3 10 11 4 5 9 4 1 8 12 9 32 • Mechanical Assembly Drawings 4 Users Manual LOKPRINT™ II
Baffle Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Users Manual LOKPRINT™ II Part # 990811 561203 561217 990066 561211 561213 561212 990984 990985 990069 990512 990089 Description Strain Relief, 5/8 x 1/2 Cover, Chassis, Main (Ref Only) Guard, Top baffle 8-32 x 1/4 Button head screw Guard, Lower baffle Guard, Horizontal baffle Guard, SCR baffle Strain relief, 1/2 x 3/8 Strain relief, 1 x 3/4 Hex nut, #8 Tie wrap, TY534M 10-32 x 1/4 Button head screw Qty 3 1 1 16 1 1 1 1 3 1 1 2 Mechanical Assembly Drawi
Air Filter Assembly 4 6 3 5 2 1 7 8 34 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
Air Filter Parts List Item 1 2 3 4 5 6 7 8 Users Manual LOKPRINT™ II Part # 561137 990069 991198 991196 991196 565023 561140 990052 Description Fan, Exhaust Hex nut, 8-32 8-32 x 3/4 Flat head cap screw Assembly, Fan filter Assembly, Fan filter Filter, Lokprint Fan, Finger guard 8-32 x 1/2 Cap screw Qty 2 16 8 2 2 2 2 8 Mechanical Assembly Drawings • 35
Web Guide Assembly 6 3 4 2 5 1 36 • Mechanical Assembly Drawings 7 Users Manual LOKPRINT™ II
Web Guide Parts List Item 1 2 3 4 5 6 7 Users Manual LOKPRINT™ II Part # 353004 194020 990374 990484 565021 990133 990123 Description Roller mount Web turn shaft 1/2 Collar 1/4-20 x 1/2 Nylon slotted screw Bracket, Tie bar 1/4-20 x 3/4 Flat head screw 1/4-20 x 1 Cap screw Qty 1 1 2 2 1 1 1 Mechanical Assembly Drawings • 37
Drive Assembly 21 22 11 19 20 16 18 13 6 4 12 12 17 13 15 10 5 2 12 3 15 1 8 14 9 7 38 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
Drive 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 Users Manual LOKPRINT™ II Part # 564033 564005 564031 564034 564035 564030 105023 990058 990456 564010 564011 991194 990167 564013 999108 564016 990080 564032 378064 989983 378060 990019 Description Assembly, Mount plate, Front Bracket, Base, Feed Assembly, Grit roller Assembly, Pressure arm, Rear Assembly, Pressure arm, Front Assembly, Grit roller, Upper Knob, Impression adjust 8-32 x 1/4 Knurled cup point 8-32 x 1/2 Flat hd
Feed Assembly 2 12 8 4 11 6 10 9 7 6 10 3 1 5 40 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
Feed Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Users Manual LOKPRINT™ II Part # 221113 562001 562002 991113 990029 990102 224067 990095 990756 990080 564021 564090 Description Motor, Feed / Deflect harnessed Sprocket, 30T Timing Sprocket, 10T Timing Drive, Timing belt, 54T x 1/4 6-32 x 1/4 Flat head screw Washer, #10 SAE Bracket, Motor mount 10-32 x 3/8 Set screw 6-32 x 3/16 Set screw 10-32 x 3/8 Cap screw Bracket, Feed Ass'y, Feed, 2 Sided LKP Qty 1 1 1 1 4 6 1 2 1 6 1 1 Mechanical Assembly Drawings
Controller Assembly 2 4 1 3 42 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
Controller Parts List Item 1 2 3 4 Users Manual LOKPRINT™ II Part # 561138 564017 561148 990090 Description Controller, Chromalox, Programmed Bracket, Controller Controller, Fuji, Programmed 10-32 x 3/8 Button head screw Qty 1 1 1 2 Mechanical Assembly Drawings • 43
Heat Chamber Assembly 13 19 15 2 7 9 14 5 10 11 26 6 24 23 4 17 21 6 25 16 22 20 5 18 3 13 1 12 2 8 29 27 28 29 44 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
Heat Chamber Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No.
Slide Mechanism Assembly 1 5 21 21 9 7 22 26 27 1 18 1 10 6 1 22 8 15 13 24 21 4 13 18 12 11 14 15 21 14 11 23 17 20 19 4 18 1 5 3 25 28 21 16 8 46 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
________________________________________________________________________________________________________________________________ Slide Mechanism Parts List ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No.
Cable Routing Diagram CABLE RIGHT SIDE FRONT OF MACHINE CAPSTAN CABLE LEFT SIDE STOP SLEEVE FRONT OF MACHINE TOP VIEW CABLE RIGHT SIDE WIND FROM THIS SIDE (5X) CABLE LEFT SIDE REAR VIEW 48 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
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Home Sensor Assembly 50 • Mechanical Assembly Drawings Users Manual LOKPRINT™ II
Home Sensor Parts List Item 1 2 3 4 5 6 7 8 Users Manual LOKPRINT™ II Part # 565015 371131 358024 989976 990015 990728 990081 990000 Description Bracket, Sensor Harness, Ink out sensor Jam sensor bracket #6 Star washer 6-32 x 1/4 Cap screw #10 Lock washer 10-32 x 1/2 Cap screw 2-56 x 1/4 Cap screw Qty 1 1 1 2 2 2 2 1 Mechanical Assembly Drawings • 51
