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Users Manual
Model 676
AVERY DENNISON
Manual Edition 9.0
09 June 2010
Manual Part Number 371398
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Users Manual Model 676
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Contents
Scope 6
Introduction................................................................................................................................ 6
Safety Issues / Warnings 6
Caution.......................................................................................................................................6
Warranty Information 7
Warranty Policy .........................................................................................................................7
Description / Specifications 9
Printer Description..................................................................................................................... 9
Printer Specification ................................................................................................................ 10
Personal Computer Specifications ........................................................................................... 12
Customer Responsibility 13
Location of Printer ................................................................................................................... 13
AC Power Line ........................................................................................................................ 14
Printer Unpacking / Installation 14
Unpacking................................................................................................................................ 14
Inventory of Components......................................................................................................... 15
Fuse Configuration................................................................................................................... 16
Installing the Power Cord ........................................................................................................ 17
Installing the PC Interface Cable ............................................................................................. 17
Installing the PC Software ....................................................................................................... 17
TCB Dip Switch S2 Settings.................................................................................................... 17
Printer Operation 18
Loading Stock .......................................................................................................................... 18
Butt Splice ............................................................................................................................... 19
Web Guides ............................................................................................................................. 19
Print Head Operation ............................................................................................................... 20
Installing Ink Ribbon ............................................................................................................... 22
Control Panel Operation 23
Printer Controls........................................................................................................................ 23
Indicator Lights........................................................................................................................ 24
Display Modes ......................................................................................................................... 26
Users Manual Model 676 Scope •••• 3
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Adjustments 40
Feed Roller Pressure ................................................................................................................ 40
Sensors..................................................................................................................................... 40
Sensor Adjustments: ................................................................................................................ 41
Print Head ................................................................................................................................ 42
Knife Squareness ..................................................................................................................... 43
Stacker ..................................................................................................................................... 43
Machine Set Up Sequence ....................................................................................................... 45
Maintenance 46
Cleaning................................................................................................................................... 46
Print Head Handling ................................................................................................................ 47
Print Head Replacement .......................................................................................................... 48
Lubrication Procedure.............................................................................................................. 50
Electrical Trouble Shooting 51
Power Up / Sign On / Communications ................................................................................... 51
Stock / Ink Advance................................................................................................................. 53
Print ......................................................................................................................................... 54
Cut / Stack................................................................................................................................ 56
Mechanical Trouble Shooting 57
Stock ........................................................................................................................................ 57
Ink............................................................................................................................................ 59
Print ......................................................................................................................................... 60
Knife ........................................................................................................................................ 61
Appendix A 63
Error Messages ........................................................................................................................ 63
Appendix B 64
Software Upgrade Chip Placement Positions........................................................................... 64
Front Panel Diagnostic Descriptions........................................................................................ 66
Appendix C 67
Ink and Stock Transfer Types .................................................................................................. 67
Appendix D 70
Knife MFG Guideline .............................................................................................................. 70
Appendix E 73
Printhead Life Extension.......................................................................................................... 73
Printhead Fail Modes ............................................................................................................... 74
Printhead Cleaning Procedure.................................................................................................. 75
Printhead Installation and Removal Procedures....................................................................... 76
Static Checks for 636/656 Printers .......................................................................................... 77
Print Quality Adjustment ......................................................................................................... 79
4 •••• Scope
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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 .............................................................................................. 87
Mechanical Assembly Drawings 89
Unwind Assembly Drawing ..................................................................................................... 90
Unwind Parts List .................................................................................................................... 91
Web Guide / Light Bar Assembly Drawing ............................................................................. 92
Web Guide / Light Bar Parts List............................................................................................. 93
Drive Assembly Drawing......................................................................................................... 94
Drive Parts List ........................................................................................................................ 95
Top Auxiliary Feed Assembly Drawing................................................................................... 96
Top Auxiliary Feed Parts List .................................................................................................. 97
Top - Printhead Assembly Drawing......................................................................................... 98
Top - Printhead Parts List ........................................................................................................ 99
Ink-Save Printhead Assembly Drawing ................................................................................. 100
Ink - Save Printhead Parts List............................................................................................... 101
Bottom - Printhead Assembly Drawing ................................................................................. 102
Bottom - Printhead Parts List.................................................................................................103
Ink Unwind Assembly Drawing............................................................................................. 104
Ink Unwind Parts List ............................................................................................................ 105
Ink Rewind Assembly Drawing ............................................................................................. 106
Ink Rewind Parts List............................................................................................................. 107
Ink Rewind w/ Head-Lift Assembly Drawing........................................................................ 108
Ink Rewind w/Head-Lift Parts List ........................................................................................ 109
Ink Rewind - Station 3 - 1 over 1 - Assembly Drawing ......................................................... 110
Ink Rewind - Station 3 – 1 over 1 - Parts List ........................................................................ 111
Knife Assembly Drawing....................................................................................................... 112
Knife Parts List ...................................................................................................................... 113
Stacker Assembly Drawing (Part 1)....................................................................................... 114
Stacker Parts List (Part 1) ...................................................................................................... 115
Stacker Assembly Drawing (Part 2)....................................................................................... 116
Stacker Parts List (Part 2) ...................................................................................................... 117
Rewind Assembly Drawing....................................................................................................118
Rewind Parts List................................................................................................................... 119
Optional 4 1/4” Stacker Specifications ..................................................................................121
Optional 4 1/4” Pick-up Assembly ........................................................................................ 122
Optional 4 1/4” Pick-up Parts List ......................................................................................... 123
Optional 4 1/4” Stacker Assembly .........................................................................................124
Optional 4 1/4” Stacker Parts List ......................................................................................... 125
Drive Belt Routing (2 over 1) Drawing ................................................................................. 126
Drive Belt Routing (2 over 1) Parts List ................................................................................ 127
Drive Belt Routing (1 over 1) Drawing ................................................................................. 128
Drive Belt Routing (1 over 1) Parts List ................................................................................ 129
Users Manual Model 676 Scope •••• 5
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Scope
Introduction
This user manual was arranged for the person who is going to operate the machine.
The information is arranged in the order that is needed to install and operate the
machine. It starts with general information, then to unpacking the crate, installing the
stock and ink ribbon, printer operation, control panel operation, and finally care and
maintenance of the printer.
We at AVERY DENNISON hope that you will come to appreciate the efforts and
quality that have gone into producing your AVERY DENNISON 676 Printer and
wish to remind you that you are our number one priority. We welcome any
constructive comments or criticisms so that we may continue to offer you the best
printer in the industry for years to come.
Safety Issues / Warnings
Caution
This machine has some pinch points. All of these areas have been well guarded and
it is recommended that the safety features of this machine are never altered or
defeated.
6 •••• Scope
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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.
General Conditions
Avery Dennison extends warranty coverage under the following conditions.
− Equipment and parts will perform within published specifications. Promised or implied statements by any
Avery Dennison employee or representative will not be deemed to vary the terms of the warranty.
− Equipment and parts must be installed and operated according to recommended procedures and
operating conditions.
− Consumable elements are not covered. Consumable elements are those that show normal wear from
typical equipment usage including, without limitation, printheads, knives, rollers in contact with the web,
and sonic units. Avery Dennison reserves the right to determine which elements are defined as
“consumable.”
− No customer maintenance may be performed except as directed by qualified Avery Dennison personnel.
− Equipment and parts damaged by negligence or abuse are not covered.
− Avery Dennison US reserves the right in its sole discretion to incorporate any modifications or
improvements in the machine system and machine specifications which it considers necessary but does
not assume any obligation to make said changes in equipment previously sold.
Equipment Purchased In US and Shipped In US
− Avery Dennison US covers warranty for equipment and parts installed and operated in the Americas
(United States, Canada, Mexico, Central America, Caribbean Region, and South America excluding
Brazil).
− Outside the US, the local Avery Dennison office is responsible for equipment and parts warranty.
Customers must ensure coverage during machine purchase.
Users Manual Model 676 Warranty Information •••• 7
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− 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. The agent must purchase services from Avery Dennison
Brazil.
THE WARRANTIES PROVIDED HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ANY IMPLIED
WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY
OF QUALITY OR PERFORMANCE, WHETHER EXPRESS OR IMPLIED. EXCEPT THE WARRANTY OF
TITLE, IN NO EVENT SHALL AVERY DENNISON BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, EVEN IF AVERY DENNISON HAS BEEN ADVISED OF THE POSSIBILITY
OF SUCH DAMAGES.
Service
When ordering machines and supplies in the U.S.A., reference all correspondence to the address below.
AVERY DENNISON Corporation
One Wilcox Street
Sayre, PA 18840
Call: 1-800-967-2927 or (570) 888-6641
Fax: (570) 888-5230
For spare parts, requests for service or technical support, contact
AVERY DENNISON Corporation
One Wilcox Street
Sayre, PA 18840
Call: 1-800-967-2927 or (570) 888-6641
Fax: (570) 888-5230
For parts and service in other countries, please contact your local AVERY DENNISON supplier.
8 •••• Warranty Information
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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. The printer can generate a
complete label printed on two sides, with up to two colors on the top and a third on
the bottom.
• Design your own labels on a PC
• Computer interface = IBM Compatible
• Mainframe direct interface
• RS232 9 Pin D shell female Serial interface connector
Figure 1 - AVERY DENNISON MODEL 676 LABEL
PRINTER
Users Manual Model 676 Description / Specifications •••• 9
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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 (standard stacker)
1" (25.4mm) web x 5/8” (15.8mm) feed (optional 4 ¼” stacker)
Max: 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" (355.6mm) feed
No stacker – optional rewind unit or cut without stacking
Print Area Min: None
Max: up to 5" (127mm) web x up to 13.875" (352.4 mm) feed -
Except station #2 web reduced to 4.875” (123.8mm) for trap printing and electronic adjustment
Resolution 300 DPI x 300 DPI
Fonts Two scalable fonts resident: condensed, standard, and bold typefaces, upper and lower case
4pt up to 96pt (300 DPI),
All rotations 0°, 90°, 180°, 270°
Logos No restriction on number or size per tag (up to maximum image area)
All rotations 0°, 90°, 180°, 270°
Care Symbols Full Ginetex Care Symbol set and full NAFTA / ASTM Care Symbol Set
Fully Scaleable
All rotations 0°, 90°, 180°, 270°
Justification Left, Right, and Center field selectable
Stock Support for blank or pre-printed fabrics, blank or pre-printed card stock and die cut blank or
pre-printed pressure sensitive
Interface AVERY DENNISON PCL via RS232 serial port - 9 pin D-Shell
Control Panel Push-button printer function with 2 Line x 24 Character International LCD Backlit Display
Dimensions 17.0" (431.8mm) high x 35.75" (908.05mm) wide
Including stacker x 20.0" (508.0mm) deep
Weight 98 Lbs. (44.45Kg.)
Electrical 90-132 / 180-265 VAC 50-60Hz 10Amp 1 Ph User selectable
Temperature
Humidity 5% to 90% non-condensing
41°F (5°C) to 104°F (40°C)
10 •••• Description / Specifications
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Other Features - Downloading of information while machine is operating
- Sequenced Fields
- Time/Date Stamping (Both month/day/year and day/month/year format)
- Life Counts
- Operator adjustable: strobe, cut position, print position, baud rate, and buffer size
- Error Detection of: stock out, ink out, print head open, feed open, full stacker, stacker jam,
and print head over-temperature
- Display: labels left to be cut and stacked in a batch, batch ID, total life inches, total life
cuts
- Self Diagnostics
- Missed sense mark detection and correction
- Slot / Notches/ Hole
Ink Ribbon AVERY DENNISON standard thermal colors and widths
Options - SV-100 Barcode Verifier System
- 4 ½” Stacker
- Downstacker
- Rewind Unit (115V or 230V)
- Reflective registration detection (Back of web only)
- Optional Contrast registration detection
- PCMate Plus w/Formatter
- Spare Parts Kit
- International Hardware Kit
Users Manual Model 676 Description / Specifications •••• 11
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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.
“PcMate Plus / Formatter ” Requires the following;
• IBM® PC or compatible
• Microsoft Windows® 98 2nd edition or higher
(Including Win 2000, ME, NT, and XP)
• 64 Megabytes RAM
• 1 Gigabyte Hard Drive
• Pentium or Pentium Type processor - 400 Mhz or higher
• 3-1/2" floppy drive and CD Rom
DISK DRIVES: You will need a hard disk with at least 100 megabytes of free disk
space to store the PCMate Plus program. Additional space will be required to store
formats, batches, etc.
Refer to your specific software package for proper installation procedures.
12 •••• Description / Specifications
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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. The printer should be located in an area that maintains optimum flow of your
product while providing for the operator’s comfort. AVERY DENNISON has taken
significant steps to ensure that the operator controls and operations are easily
accessible. This goal can only be met, however, if the printer is also located with
human factors in mind. These include the height of the printer, the space around the
printer, and the accessibility to the printer.
The AVERY DENNISON 676 printer is a high-resolution thermal printer. While
AVERY DENNISON has designed the printer to be reasonably quiet, it is
recommended to locate the printer in an area where printing and cutting repetitious
noise is acceptable.
The unit should always be operated with the cover closed to minimize the amount of
dust and dirt in the machine.
Users Manual Model 676 Customer Responsibility •••• 13
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AC Power Line
AVERY DENNISON requires that the electric service be 10 Amps @ 115VAC or 10
Amps @ 230VAC. This will allow the computer and any additional support or
service equipment to be plugged into the same service.
Any electrical service 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.
The AVERY DENNISON printer was designed to operate in an industrial setting for
extended periods of time; however, the printer is controlled by a microprocessor that
is very sensitive to brownouts or power spikes. For this reason as well as the
minimum recommended current supply, AVERY DENNISON recommends that a
separate “clean” service be installed or reserved for the exclusive use of the AVERY
DENNISON printer and it’s peripherals.
Printer Unpacking / Installation
Unpacking
The AVERY DENNISON printer is shipped in a large plywood crate that may be
difficult to move by hand.
DO NOT REMOVE THE PRINTER FROM THE CRATE OR UNPACK IN
THE SHIPPING / RECEIVING DEPARTMENT.
NOTE: Unpacking in the shipping/receiving department is not recommended for the
following reasons. First: The plywood crate in which your AVERY DENNISON
printer was shipped allows the printer to be moved with a forklift, forkcart or hand
cart. Because of the weight of the printer, it is easier and safer to use one of these
devices to move the printer to its intended installation location. Second: Leaving the
printer in the crate while it is being moved within your facility will help to protect the
printer during the movements to this new location. Once the printer has reached its
intended location you should begin the unpacking process.
Open the crate from the bottom by removing the six screws along the bottom of the
cover near the floor (See Figure 3).
Remove the plastic over the printer.
Remove all the smaller loss items from in and around the printer.
Unbolt the shipping bracket from the crate bottom.
Lift the printer onto the table.
Remove the shipping brackets from the machine.
14 •••• Printer Unpacking / Installation
Page 15
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. If anything is missing, notify AVERY
DENNISON immediately - in the U.S.A. at (570) 888-6641. In countries other than
the U.S.A. please contact your local AVERY DENNISON supplier.
- AVERY DENNISON 676 "User's Manual" (See tool kit below)
- Stacker assembly
- A quick-disconnect power cord
- A serial communications cable with converter
- Optional software ordered to drive the printer.
- Tool kit
NOTE: Some of the above parts may be inside of the envelope that contains the tool
kit.
AVERY DENNISON 676 TOOL KIT (#371390)
241149 Anti-Static Gloves (2)
241132 Anti-Static Wrist Strap
921309 Hex Key Set
181301 2.5mm Ball Driver
101330 9/64” Ball Driver
921304 5/32” Ball Driver
921364 3/16" Long Ball Driver
351156 Chip Removal Tool
371398 676 Users Manual
921353 Phillips Head Screwdriver
Users Manual Model 676 Printer Unpacking / Installation •••• 15
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Fuse Configuration
Location of 115V Text
Location of 230V Text
Two 5 x 20MM Fuses One Each Side
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.
WARNING: Attempting to open the AC entry with the AC power cord inserted into
2) Remove the red fuse drawer.
3) Remove all fuses and the fuse jumper if it is present.
4) Insert into the fuse drawer the correct number and style of fuses and fuse jumper
for your application.
Configuration Number One: Line voltage between the range of
90 - 132VAC @ 50 - 60Hz 1 Ph
1) Install one 921167 - 10.0A 250V Fast Acting 1/4 x 1 1/4"
2) Install one Fuse Jumper
See Figure FUSE1
Configuration Number Two: Line voltage between the range of
1) Install two 921168 10.0A 250V Fast Acting 5 x 20MM
it will cause damage to the AC entry.
180 - 265VAC @ 50 - 60Hz 1 Ph
NOTE: The fuse jumper must be removed to install both 5 x
20mm fuses.
The fuses must be between points A and B as shown not B and C.
See Figure FUSE2
FIGURE FUSE1
Fuse Jumper
FRONT FRONT
Location of 115V Text
Location of 230V Text
One 1/4 x 1 1/4" Fuse Far Side
5) Reinsert the fuse drawer into the AC entry with the desired voltage up.
6) Close the AC entry and verify the correct voltage is now visible.
FIGURE FUSE2
5 x 20 mm fuse
A
C
B
16 •••• Printer Unpacking / Installation
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Installing the Power Cord
A power cord is shipped with each printer. The cord for 115-volt printers will use
the standard three-prong plug used in the U.S.A. A 230-volt printer and some other
115-volt configurations must have the receptacle end of the connector removed and
the proper plug installed. It is the customers’ responsibility to have the plug and
alteration work done by a certified electrician. AVERY DENNISON supplies
printers to many countries with many variations. Therefore we leave this to the
customer to make the proper selection for their country.
Installing the PC Interface Cable
The 676 requires a 9-pin RS232 cable. This cable is provided with the printer. If the
cable was not found it can be ordered from AVERY DENNISON (Part no. 351124).
The male end of the cable should be connected to the 9-pin D-shell female connector
that is located on the right side of the printer. The female end of the cable is made to
fit a 9-pin male RS232 connector on the back of the PC.
Installing the PC Software
The software to drive the AVERY DENNISON family of printers is covered in
separate documentation. The "Formatter" software to create formats for the AVERY
DENNISON 676 printer is a Windows application. The original software "Selfform"
will not create formats for the 676. The new "Formatter" package is capable of
making formats for all AVERY DENNISON control printers.
The DOS version of "PCMate" has been updated to drive the 676 printer. PCMate
DOS version 3.10 or higher is needed for its use.
The printer is also capable of operating directly from a mainframe when using the
RS232 interface and AVERY DENNISON's PCL command language.
TCB Dip Switch S2 Settings
DIP SWITCH # DEFINITION 676
8 DOWNSTACKER /
LOKPRINT
7 UNUSED OFF
6 UNUSED OFF
5 STACKER JAM ENABLE ON
4 MACHINE TYPE ON
3 MACHINE TYPE ON
2 UNUSED OFF
1 DPI N/A OFF
DOWNSTACKER ON
LOKPRINT® OFF
DISABLE OFF
300 ON
Users Manual Model 676 Printer Unpacking / Installation •••• 17
Page 18
Printer Operation
Loading Stock
WEB
TURN BAR
INK
DECURLER
WEB GUIDE / KNOB
KNIFE
SENSOR /
KNOB
HEAD 1
HEAD 3HEAD 2
DRIVE / AUX
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.
2) Adjust the web guides on the decurler bar to a width wider than the stock.
3) Remove the tape or pull the glued end of the stock loose from the supply roll of
stock. Pull off about 2 feet (.5 m) of stock to thread it through the printer.
NOTE: If the material was glued to the core, cut off all material that has glue on any
surface.
4) Open the hinged cover to the machine.
5) Open all the print heads by pulling the release knob and then rotating the print
head into the open latched position. The top two print stations have a pin in the
rear to hold them open. The bottom print station has a hole in the rear to hold
the print head slightly open to act as a bridge for the stock to pass over.
6) Open the feed rollers by rotating the feed pressure knob fully clockwise.
7) After looping the leading edge of the stock over the decurler slide it through the
funnel containing the registration sensor system. Adjuste the web guide knob to
the width of the stock. Do Not Pinch the edges of the material.
18 •••• Printer Operation
Page 19
Butt Splice
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.
12) Rewind any loose stock back onto the supply roll.
13) Adjust the web guides on the decurler down to the edges of the stock without
deforming the stock.
NOTE: DO NOT RUN BUTT SPLICES THROUGH THE PRINT STATIONS
The AVERY DENNISON 676 has been designed keeping the operators need to
change supplies quickly and often in mind. Re-threading the stock is quicker than
butt splicing. If however you have determined a butt splice is necessary, after
loading a new roll of stock onto the unwind tape the free ends together. Remove all
slack by rotating the supply roll counterclockwise. To prolong print head life it is
highly recommended that all hand splices be advanced beyond all three print stations
before printing is resumes. This can best be accomplished by using the stock
presently in the print stations to manually pull the new stock through and into the
stacker. Once the butt splice is in the stacker close the feed rollers and those print
stations needed for the format.
Web Guides
NOTE: Whenever stock of a different type or width is put on the printer, a sample
run should be performed. If the print quality / position is acceptable, you
can immediately begin your production run. If the print quality / position
needs to be optimized, refer to the Adjustments section and perform the
procedure needed to make the necessary improvement.
The AVERY DENNISON 676 printer has been designed with the operators needs in
mind. Therefore there are only three sets of web guides in the printer that need to be
changed as the width of the rolls change for various width stocks. Neither of these
adjustments requires a tool.
The first guide is on the unwind itself. A knob located on the front of the unwind
adjusts the width of the guides on the unwind while maintaining center justification.
To increase the width - turn the knob counter clockwise. To decrease the width - turn
the knob clockwise. Adjust the unwind width wider than the roll of stock to be
loaded. Set the stock roll on the unwind between the guides with the stock
unwinding from the top clockwise. Adjust the unwind width down to the stock size
without clamping the core.
The second set of guides are located on the decurler just to the left of the stock
registration funnel. Once a stock is loaded and tracking straight through the machine
adjust this set of web guides down to the edges of the stock without deforming the
Users Manual Model 676 Printer Operation •••• 19
Page 20
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. Later
in the manual, under separate headings, cleaning and replacement will be covered.
For clarity the print stations have been assigned numbers one through three from left
to right. The far-left print station prints the back; it is print station number one. The
center and right print stations print on the top; they are stations two and three. Each
print station has an interlock switch that prevents the printer from running with any or
all print stations in the open position if that print station is assigned in the format
being printed. If a print station is open, the display will read HEAD OPEN
STATION X.
WARNING: DO NOT TOUCH THE PRINT HEAD WITHOUT WEARING THE
To open the print heads for threading supplies or cleaning pulling the release knob
and then rotating the print head into the open latched position (see figure x). The top
two print stations have a pin in the rear to hold them open. The bottom print station
will remain open via gravity however it has a hole in the rear to hold the print head in
a slightly open position to act as a bridge when one is threading stock.
ANTI-STATIC GLOVES AND THE ANTI-STATIC WRIST STRAP.
Figure 5 - Print Head Open / Closed
To close the head again pull the release knob and then rotating the print head into the
closed latched position (See figure 5).
20 •••• Printer Operation
Page 21
Users Manual Model 676 Printer Operation •••• 21
Page 22
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.
WEB
TURN BAR
DECURLER
INK
WEB GUIDE / KNOB
HEAD 3HEAD 2
SENSOR /
KNOB
HEAD 1
DRIVE / AUX
KNIFE
Figure 6
1) Unwrap the ink ribbon and put it on the ink-ribbon supply arbor for the print
station to be loaded (Figure 6) by pressing it on to the arbor when the three slots
are lined up.
2) Make sure the ink ribbon comes off the roll in the direction shown and is threaded
as illustrated (Figure 6).
NOTE: A new ink ribbon has a leader that makes it easier to use when threading the
ribbon through the print area.
3) Place an empty ink-ribbon take-up core on the ink-ribbon take-up arbor for the
print station to be loaded. The ink take-up core must be at least as wide as the ink
supply.
4) Open the print head to the print station being loaded.
5) After starting the leader off the supply roll pull enough ink off to thread though
the print station and onto the take up core. The adhesive on the supply roll of ink
will be used to fasten the leader to the take up core.
NOTE: Make sure that the ink-ribbon take-up core and the ink-ribbon supply roll
are both against the ink backer plate so that the ink ribbon tracks straight
through the print station.
22 •••• Printer Operation
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Control Panel Operation
Printer Controls
Start
- Starts the printer
- ON LINE light must be GREEN
(Batches downloaded to be printed)
Feed
- FEED and START must both be used
- Feed will stop when the buttons are released
- Labels between print station one and the knife will be cut and stacked as
finished labels
- Stock moves through in one continuous strip
- Stock moves through without printing
- Ink will advance, ink save on print station two will automatically be
activated.
- The print heads must be latched in the down position.
Users Manual Model 676 Control Panel Operation •••• 23
Page 24
Indicator Lights
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.
The AVERY DENNISON 676 has three Indicator lights. These lights are used along
with the LCD display to tell the operator the current status of the printer.
On Line
OFF
- Has not been powered on.
- Is in its power - up sequence.
- Failed the system test
After Power Up Sequence:
- Printer is running.
24 •••• Control Panel Operation
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ORANGE
- System is operational
- Ready for batches to be downloaded
GREEN
- Batches to print, ready to start
Sensor
GREEN = "C" SENSOR
- Printer is stopped, - light is on, - sensor is 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 LCD Display
The LCD display is a 2 line, 24 character, with back lighting feature for easy
readability. The first line of the display, in most cases, will be a prompt or question the second line is the response.
Users Manual Model 676 Control Panel Operation •••• 25
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Display Modes
R E A D Y F O R B A T C H E S
6 7 6 / 3 0 0
B A T C H I D
P C L 0 0 1 1 0
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
OR
Q U A N T I T Y
Press the MODE/Down arrow button will cycle the panel through the following main
screens.
PRINTER ADJUSTMENTS
P R E S S E N T E R F O R
P R I N T / C U T P O S I T I O N S
PRINTHEAD ADJUSTMENTS
P R E S S E N T E R F O R
P R I N T H E A D S E T U P
CALIBRATE SENSORS
P R E S S E N T E R F O R
C A L I B R A T I N G S E N S O R S
LIFE COUNTS / VERSIONS
P R E S S E N T E R F O R
L I F E C O U N T S / V E R S I O N S
26 •••• Control Panel Operation
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SETUP SCREEN
P R E S S E N T E R F O R
F E A T U R E S E T U P
VERIFIER SETUP SCREEN
P R E S S 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). The LCD is checked by writing a character to
the display, checking for communications and then reading the character back and
comparing with the code. If an error occurs, the code will halt the diagnostic test and
blink the ERROR LED.
The keypad is also checked during DIAGNOSTIC TEST 1. Each key is tested to see
if it is stuck on. If a fault condition is detected, the test is halted and the screen will
display the first error key found with the following display:
( B U T T O N N A M E ) K E Y S T U C K
The (BUTTON NAME) will be one of the push button names on the front panel START, FEED, TEST, STOP, EXIT, MODE, <YES, NO>, OR ENTER.
When the code has finished the above tests, the code will attempt to communicate
with the Control Board (TCB).
D I A G N O S T I C T E S T # # #
T C B V E R S I O N 0 0 . 0 0
This screen will be updated with diagnostic numbers as the TCB and AT go through
different stages of PowerPC initialization.
The diagnostic test screen will also be displayed when the Diagnostic tests that are
runable from the front panel are being executed.
Once the diagnostic tests are complete, the Front Panel should display the HOME
screen.
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HOME SCREEN
T P A T T E R N
R E A D Y F O R B A T C H E S
6 7 6 / 3 0 0
OR
B A T C H I D
P C L 0 0 1 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. Note: Look into
suppressing leading zeros on batch quantity.
When the Batch Id/Qty screen is the home screen and the user presses the EXIT
button the Model and DPI are displayed briefly before the Batch Id/Qty screen is
shown.
If the printer is performing a FEED or a TEST pattern, the screen will show
"FEEDING" or "PRINTING TEST PATTERN" respectively on line two, the top line
will be blank
F E E D I N G
P R I N T I N G T E S
Q U A N T I T Y
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.
28 •••• Control Panel Operation
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PRINT/CUT POSITIONS
P R E S S E N T E R F O R
P R I N T / C U T P O S I T I O N S
This screen follows the Batch ID/Batch Qty screen if there are batches to print,
otherwise it follows the “Ready for batches”/ Model DPI “HOME” screen.
Pressing ENTER will take the user to the PRINTER ADJUSTMENTS screens.
Pressing the MODE/Down Arrow key will take the user to the "PRINTHEAD
SETUP" screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
PRINTER ADJUSTMENTS
P R E S S E N T E R T O
P R I N T C H E C K O U T F O R M A T
This screen is the first screen under PRINTER ADJUSTMENTS. Pressing ENTER
will cause the printer to print the checkout format. The printer will setup to do the
checkout format and start printing. The front panel will remain on this screen so the
user can use the MODE/Down Arrow key to get to the printer adjustments. When the
EXIT/Up Arrow key is pressed the printer stops printing the checkout format and
goes back to what it was doing before the checkout was requested.
Pressing the MODE/Down Arrow key will take the user to the first screen of this
group. Pressing the EXIT/Up Arrow key will take the user back to the "HOME"
screen.
P R I N T P O S I T I O N 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 follows the PRINT CHECKOUT FORMAT screen. This screen allows
the print position of station 1 to be adjusted.
The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive/negative format. The value ranges for XX and
YY can be from a -9 to a +9
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME.
P R I N T P O S I T I O N 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 the first screen under PRINTER ADJUSTMENTS. This screen
allows the print position of station 2 to be adjusted.
The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive/negative format. The value ranges for XX and
YY can be from a -9 to a +9
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME.
Users Manual Model 676 Control Panel Operation •••• 29
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P R I N T P O S I T I O N S T A T I O N 3
V A L U E : ± X X N E W V A L U E : ± Y Y
This screen follows the second screen under PRINTER ADJUSTMENTS. This
screen allows the print position of station 3 to be adjusted.
The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive/negative format. The value ranges for XX and
YY can be from a -9 to a +9
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME.
C H A N G E C U T P O S I T I O N
V A L U E : ± X X N E W V A L U E : ± Y Y
This screen follows the print adjust screens. This screen allows the cut position to be
adjusted. The <YES / NO> buttons are used to change the cut 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 ENTER will change the CURRENT CUT value to the
NEW CUT value. Pressing the MODE/Down Arrow key will take the user to the
next screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.
S T A T I O N 2 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 of station 2 to be adjusted in the WEB direction.
The <YES / NO> buttons are used to change the shift value.
The value is displayed in a positive/negative format. The value ranges for XX and
YY can be from a -16 to a +16 dots. (A dot is 1/300)
Pressing the MODE/Down Arrow key will take the user to the first screen under
PRINTER ADJUSTMENTS.
Pressing the EXIT/Up Arrow key will take the user back to the HOME.
PRINTHEAD SETUP
P R E S S E N T E R F O R
P R I N T H E A D S E T U P
This screen follows the PRINT/CUT POSITIONS screen.
Pressing ENTER will take the user to the PRINTHEAD SETUP screens.
Pressing the MODE/Down Arrow key will take the user to the "LIFE
COUNTS/VERSIONS" screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
30 •••• Control Panel Operation
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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 <YES / NO> buttons are used
to change the print value. The value is displayed in a positive/negative format. The
value ranges for X and Y can be from a -7 to a +7. Pressing ENTER will change the
CURRENT STROBE value to the NEW STROBE value.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
C H A N G E S T R O B E 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 strobe adjust for station 1. This screen allows the user to adjust
the strobe for station 2. The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive/negative format. The value ranges for X and Y
can be from a -7 to a +7. Pressing ENTER will change the CURRENT STROBE
value to the NEW STROBE value.
Pressing the MODE/Down Arrow key will take the user to the next screen. Pressing
the EXIT/Up Arrow key will take the user back to the HOME screen.
C H A N G E S T R O B E S T A T I O N 3
V A L U E : ± X X N E W V A L U E : ± Y Y
This screen follows strobe adjust for station 2. This screen allows the user to adjust
the strobe for station 3. The <YES / NO> buttons are used to change the print value.
The value is displayed in a positive/negative format. The value ranges for X and Y
can be from a -7 to a +7. Pressing ENTER will change the CURRENT STROBE
value to the NEW STROBE value.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
H E A D C A T E G O R Y 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 follows strobe adjust for station 3. The screen allows the user to enter
the head category for station 1. The <YES / NO> buttons are used to change the
head category value. The value ranges from 1 to 8. Pressing ENTER will change the
head category value to the new value. This value should be changed only if the
printhead is changed. See the section “PRINTHEAD REPLACEMENT” for
instructions on setting the head category.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
Users Manual Model 676 Control Panel Operation •••• 31
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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 <YES / NO> buttons are used to change
the head category value. The value ranges from 1 to 8. Pressing ENTER will change
the head category value to the new value. See the section “PRINTHEAD
REPLACEMENT” for instructions on setting the head category.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
H E A D C A T E G O R Y S T A T I O N 3
V A L U E : ± X X N E W V A L U E : ± Y Y
This screen follows HEAD CATEGORY STATION 2. The screen allows the user to
enter the head category for station 3. The <YES / NO> buttons are used to change
the head category value. The value ranges from 1 to 8. Pressing ENTER will change
the head category value to the new value. See the section “PRINTHEAD
REPLACEMENT” for instructions on setting the head category.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
S T A T I O N A C T I V A T I O N 1 2 3
C L O S E H E A D S P R E S S E N T E R
This screen follows HEAD CATEGORY STATION3. The screen allows the user to
configure the printer for the number of heads in the system. The numbers ‘1’,’2’,’3’
stand for stations 1, 2, and 3. If the number appears on the screen then it means that
station is activated. If the number doesn’t appear on the screen then that station is
not activated and the printer will not print, look for ink out, or look for head open on
that print station.
The printer determines if a head is in the system by checking the head open switch
when the ‘Enter’ button is pressed. If the user would like to disable a station that is
in the machine for reasons of convenience then they can just open the head for that
station and press enter.
If the operating system has been changed or TCBSETUP has been used to reinitialize the machine it will show all print stations active as the default. If it is a 1/1
printer that doesn’t have station 3 installed then the user will have to come to this
screen and press ‘Enter’ to deactivate station 3, otherwise the printer will show INK
OUT STATION 3 errors when it is run.
Pressing the MODE/Down Arrow key will take the user to the first screen under
PRINTHEAD SETUP.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
32 •••• Control Panel Operation
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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 I N S E N S O R
V A L U E : 0 0 0 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. Slowly move stock under sensor until NEW VALUE
reads its smallest value then 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.
H O L E / S L O T N O T I N S E N S O R
V A L U E : 0 0 0 N E W V A L U E : 0 0 0
This screen follows HOLE/SLOT IN SENSOR under CALIBRATE SENSORS.
Place stock under the sensor so that it blocks 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.
T O P R E F L 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 HOLE/SLOT NOT IN SENSOR under CALIBRATE
SENSORS. Place stock under the sensor so that the reflective mark is under 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.
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 TOP REFL OVER MARK under CALIBRATE SENSORS.
Place 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 next screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
Users Manual Model 676 Control Panel Operation •••• 33
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B O T R E F L 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 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.
B O T 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 BOT REFL OVER MARK under CALIBRATE SENSORS.
Place stock over the sensor so that the stock is over the sensor but the reflective mark
is not over 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 next screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
S T A C K E R B L O C K E D
V A L U E : 0 0 0 N E W V A L U E : 0 0 0
This screen follows BOT REFL NOT OVER MARK under CALIBRATE
SENSORS. Place stock in the stacker jam sensor so that the stock is within the
sensor site path and when NEW VALUE is at is highest 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.
S T A C K E R N O T B L O C K E D
V A L U E : 0 0 0 N E W V A L U E : 0 0 0
This screen follows STACKER BLOCKED under CALIBRATE SENSORS.
Remove any stock from the stacker jam sensor so that no stock is within the sensor
site path and when NEW VALUE is at is lowest 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.
LIFE COUNTS / VERSIONS
P R E S S E N T E R F O R
L I F E C O U N T S / V E R S I O N S
This screen follows the CALIBRATE SENSORS screen.
Pressing ENTER will take the user to the Life Count and Operating system version
number Screens.
Pressing the MODE/Down Arrow key will take the user to the SETUP screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
34 •••• Control Panel Operation
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L A B E L C O U N T E R : 0 0 0 0 0 0
P R E S S E N T E R T O R E S E T
This screen is the first screen under LIFE COUNTS/VERSIONS.
This screen shows total labels since last counter reset.
Pressing the ENTER key will reset the counter.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
T O T A L L A B E L S P R O D U C E D
0 0 0 0 0 0 0 0 0 0
This screen follows the LABEL COUNTER screen. This screen displays the total
labels since the factory. This counter is NOT resettable by the user.
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
T O T A L I N C H E S O F S T O C K
0 0 0 0 0 0 0 0 0 0
This screen follows the TOTAL LABELS SINCE FACTORY screen. This screen
displays the total inches since the factory. This value is NOT resettable by the user.
Pressing the MODE/Down Arrow key will take the user to the next screen. Pressing
the EXIT/Up Arrow key will take the user back to the HOME screen.
C O N T R O L L E R V E R S I O N
2 . 1 6
This screen follows the FRONT PANEL VERSION screen.
This screen shows operating system version for the controller (TCB).
Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
I M A G E R V E R S I O N
2 . 1 6
This screen follows the controller version number screen.
This screen shows operating system version for the imager (AT).
Pressing the MODE/Down Arrow key will take the user to the first screen under
Counts \ Version.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
Users Manual Model 676 Control Panel Operation •••• 35
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FEATURE SETUP SCREEN
P R E S S E N T E R F O R
F E A T U R E S E T U P
This screen follows the LIFE COUNT\VERSIONS screen.
Pressing ENTER shows the first screen under setup.
Pressing the MODE/Down Arrow key will take the user to the PRINT/CUT
POSITIONS screen.
Pressing the EXIT/Up Arrow key will take the user back to the HOME screen.
C U T T E R I S E N A B L E D
P R E S S E N T E R T O D I S A B L E
OR
C U T T E R I S D I S A B L E D
P R E S S E N T E R T O E N A B L E
This screen is the first screen of SETUP. This screen allows the cutter to be enabled
or disabled. Pressing ENTER will toggle from ENABLED to DISABLED and vice
versa. Pressing the MODE/Down Arrow key will take the user to the next screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
E M U L A T I O N M O D E : N O N E
N E W E M U L A T I O N M O D E : 6 3 0
This screen follows the CUTTER ENABLE/DISABLE screen. This screen allows
the EMULATION MODE to be changed. Use the <YES and NO> keys to move
between NONE, 630, and 650 modes. Pressing ENTER will update the emulation
mode with the selection after new emulation mode. Pressing the MODE/Down
Arrow key will take the user to the next screen. Pressing the EXIT/Up Arrow key
will take the user back to the "HOME" screen.
D E F A U L T T R A N S F E R T Y P E 1
V A L U E : X X X N E W V A L U E : Y Y Y
This screen follows the EMULATION screen IF emulation mode is something other
than none. This screen allows the DEFAULT TRANSFER TYPE to be changed.
This transfer type is used when the printer is in 630 or 650 emulation mode for print
station 1. The 630 and 650 do not send valid 676 transfer types in their PCL code.
This default is used for those formats. Use the <YES and NO> keys change the
number value at the cursor position. Pressing ENTER will update the current
position with the selection and move the cursor to the next position. All three
positions must be entered. (I.e. 053 for type 53). After ENTER is pressed on the last
digit the TRANSFER TYPE on the top line will be updated. Pressing the
MODE/Down Arrow key will take the user to the next screen. Pressing the EXIT/Up
Arrow key will take the user back to the "HOME" screen.
D E F A U L T T R A N S F E R T Y P E 2
V A L U E : X X X N E W V A L U E : Y Y Y
This screen follows the DEFAULT TRANSFER TYPE1 screen IF emulation mode is
something other than none. This screen allows the DEFAULT TRANSFER TYPE to
be changed. This transfer type is used when the printer is in 630 or 650 emulation
36 •••• Control Panel Operation
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mode for print station 2. The 630 and 650 do not send valid 676 transfer types in
their PCL code. This default is used for those formats. Use the <YES and NO> keys
change the number value at the cursor position. Pressing ENTER will update the
current position with the selection and move the cursor to the next position. All three
positions must be entered. (i.e. 053 for type 53). After ENTER is pressed on the last
digit the TRANSFER TYPE on the top line will be updated. Pressing the
MODE/Down Arrow key will take the user to the next screen. Pressing the EXIT/Up
Arrow key will take the user back to the "HOME" screen.
D E F A U L T T R A N S F E R T Y P E 3
V A L U E : X X X N E W V A L U E : Y Y Y
This screen follows the DEFAULT TRANSFER TYPE2 screen IF emulation mode is
something other than none. This screen allows the DEFAULT TRANSFER TYPE to
be changed. This transfer type is used when the printer is in 630 or 650 emulation
mode for print station 3. The 630 and 650 do not send valid 676 transfer types in
their PCL code. This default is used for those formats. Use the <YES and NO> keys
change the number value at the cursor position. Pressing ENTER will update the
current position with the selection and move the cursor to the next position. All three
positions must be entered. (i.e. 053 for type 53). After ENTER is pressed on the last
digit the TRANSFER TYPE on the top line will be updated. Pressing the
MODE/Down Arrow key will take the user to the next screen. Pressing the EXIT/Up
Arrow key will take the user back to the "HOME" screen.
L A N G U A G E : X X X X X X
N E W L A N G U A G E : 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 <YES and NO> keys to
move between the supported languages on the printer. Any number of front panel
languages can be stored on the Flash Disk Module (dependent on available space). If
no additional languages other than the default are available on the printer XXXXXX
and YYYYYY will be the same value. Pressing ENTER will update the display
language with the selection. Pressing the MODE / Down Arrow key will take the
user to the "PROTOCOL" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.
Warning: Mis-matched communication protocols may result in the inability to
communicate with the printer and / or loss of data.
P R O T O C O L : X X X X X X
N E W P R O T O C O L : Y Y Y Y Y Y
This screen follows the LANGUAGE screen. This screen allows the
communications protocol to be changed between the supported types. Use the <YES
and NO> keys to move between the supported protocols – RTS/CTS is considered
hardware handshaking and XON/XOFF is considered to be software. Pressing
ENTER will update the communications protocol with the selection. Pressing the
MODE/Down Arrow key will take the user to the next screen. Pressing the EXIT/Up
Arrow key will take the user back to the "HOME" screen.
Users Manual Model 676 Control Panel Operation •••• 37
Page 38
B A U D R A T E : X X X X X X
N E W B A U D 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 <YES and NO> keys to move
between the supported speeds – typical is 9600 dependent on serial communication
cable length. Pressing ENTER will update the communications speed with the
selection. Pressing the MODE/Down Arrow key will take the user to the “CHANGE
DATE AND TIME" screen. Pressing the EXIT/Up Arrow key will take the user
back to the "HOME" screen.
C H A N G E D A T E A N D T I M E
0 3 / 1 4 / 0 0 1 2 : 0 5 P M
This screen follows the “BAUD RATE” screen. This screen allows the system date
and time to be changed. When this screen appears, the first digit of the month will be
blinking. (The date is shown in US format, MM/DD/YY.) Pressing the <YES and
NO> keys will change the digit up and down respectively. Pressing ENTER will
move to the next digit. Only the digits and the A or P in AM or PM can be changed.
When all changes are complete, pressing the MODE/Down Arrow key will take the
user to the “INSAVE ENABLE/DISABLE” screen, and pressing the EXIT/Up
Arrow key will take the user back to the “HOME” screen. If an illegal date or time is
entered, this screen will be re-displayed with the original date or time. A valid date
and time must be entered before the user can go on.
I N K S A V E I S E N A B L E D
P R E S S E N T E R T O D I S A B L E
OR
I N K S A V E I S D I S A B L E D
P R E S S E N T E R T 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. Pressing the MODE/Down
Arrow key will take the user to the "CUTTER ENABLE/DISABLE" screen.
Pressing the EXIT/Up Arrow key will take the user back to the "HOME" screen.
38 •••• Control Panel Operation
Page 39
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.
Note: This screen for SV-70 Verifier only
P R E S S E N T E R T O
P R I N T V E R I F I E R H I S T O R Y
This screen is the first screen under "VERIFIER SETUP". Pressing ENTER will
cause the printer to print a verifier history report containing bar code information for
all the problem scans since the scan memory was last cleared.
Pressing the MODE/Down Arrow key will take the user to the "PRINT VERIFIER
SETUP" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.
Note: This screen for SV-70 Verifier only
P R E S S E N T E R T O
P R I N T V E R I F I E R S E T U P
This screen follows the "PRINT VERIFIER HISITORY" screen. Pressing ENTER
will cause the printer to print a report containing the present verifier setup.
Pressing the MODE/Down Arrow key will take the user to the "CLEAR SCAN
HISTORY" screen. Pressing the EXIT/Up Arrow key will take the user back to the
"HOME" screen.
Note: This screen for SV-70 Verifier only
P R E S S E N T E R T O
C L E A R 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
V E R I F I E R I S E N A B L E D
P R E S S E N T E R T O D I S A B L E
V E R I F I E R I S D I S A B L E
P R E S S E N T E R T O E N A B L E
"HOME" screen.
OR
This screen follows the "CLEAR SCAN HISTORY" screen. This screen allows the
verification process to be enabled or disabled. Pressing ENTER will toggle from
ENABLED to DISABLED and vice versa.
Pressing the MODE/Down Arrow key will take the user back to the "PRINT
VERIFIER HISTORY" screen. Pressing the EXIT/Up Arrow key will take the user
back to the "HOME" screen.
Users Manual Model 676 Control Panel Operation •••• 39
Page 40
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.
Hole / Slot Index Registration
The hole / slot registration is via an optical sensor used in conjunction with an LED
located in the stock funnel which allows the printer to register to pre-punched
possible preprinted stock.
Reflective Index Registration
The same optical sensor used for hole / slot registration, allows the printer to register
to preprinted stock by detecting a black mark when the LED light is turned off via the
format.
Ink Out
Optical sensors located on each print station’s ink unwind arbor allow the printer to
monitor the availability of ink.
Roller Drop
An optical sensor on back of print station number two 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.
40 •••• Adjustments
Page 41
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.
Sensor Adjustments:
All the micro switches and optical sensors in your 676 printer were calibrated at the
time your printer was manufactured, however from time to time it may become
necessary to readjust / recalibrate due to the large variety of stocks and inks that can
be run on the machine.
Stock Out
With a full roll of stock loaded on the unwind with the unwind web guides properly
adjusted you should heard the switch click as you raise and lower the roll. If not the
switch bale is adjusted by carefully bending it as needed.
Print Registration Sensor Web Position
Adjustment
If you are running sense mark media with a hole or slot for registration the
registration sensor web position must be adjusted for the sense mark media being run:
1) Open the feed roller and print stations.
2) Move the sensor in line with the registration hloes.
3) Move the stock by hand in the feed direction until the registration hole or slot
desired is in under the sensor. The front panel LED with come on and off as the
hole or slot moves under the sensor. Position the stock just before the sensor mark
and the front panel LED is off.
4) Close the feed and those print stations needed for the format.
If your machine stops, for no apparent reason, while it is in the middle of printing a
batch, you may be missing sense marks (three consecutive tickets in a row in which a
sense mark was not found). Check for the following:
- The front panel will display a screen indicating that there has been a missed
sensor error.
1) Check that the web guides have been positioned properly on the unwind,
decurler bar and the web guide funnels.
2) Check that the feed roller pressure has been set equally across the roller.
3) Check that the feed roller pressure has been set to pull 11 inches of media
properly.
Users Manual Model 676 Adjustments •••• 41
Page 42
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.
Optical Sensor Electrical Calibration
Re calibration times are indicated in the troubleshooting section.
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 effect their performance.
There are three basic steps to calibrating each optical sensor.
1) Select the sensor to be calibrated in the Calibrate Sensors mode on the front panel.
2) Place media or ink as the case maybe in the appropriate sensor and press the enter
button on the front panel.
Print Head
3) In the case of stock registration sensing reposition the media so that a hole / slot or
black reflective mark is in the sight path of the appropriate registration sensor and
press the enter button on the front panel. In the case of stacker jam sensor
reposition the media so the media is not in the sight path of the jam sensor and
press the enter button on the front panel.
Tangent
Proper print head tangent is perhaps the most important adjustment to make on a
thermal transfer printer. A printhead which is not properly adjusted will result in
poor print quality, poor heat dissipation which can reduce print head life, and
possible ink wrinkling problems. When the machine was manufactured, the print
head was adjusted to the proper tangent point on the platen roller, however, with
print head replacements the tangent point for the new print head may change. It is
therefore necessary to understand when and how to properly adjust the printhead
tangent. Before making any adjustment to any of the three print station tangent
points confirm the following:
- Is the ink and stock loaded in the printer correctly?
- Is the proper ink and stock loaded in the printer for the format downloaded?
- Is the strobe setting(s) on the front panel set according to the ink and stock loaded
in the printer?
- Is the ink and stock of known types?
42 •••• Adjustments
Page 43
- 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. Since this adjustment is very precise, do not turn the thumbscrew
more than 1/4 turn before evaluating the results of your adjustment. (See Note)
4) Continue adjusting the thumbscrew until obtaining optimum print quality. Most
stocks and inks print the best with the tangent adjusted to just before top dead
center.
5) Rerun some label to determine if any further adjustment is required, if so repeat
steps three through seven.
NOTE: The print head mounting block is spring mounted so that tangent adjustment
can be performed without loosening mounting screws.
Squareness
If the test pattern, printed on a wide web (4" (100mm) plus), is lighter on one edge
than the other, it is possible that the printhead is out of square. This can also be
detected by looking at the front edge of the print head in reference to the printhead
holder. To remedy this problem, power off the machine and remove the print head as
outlined in the print head installation information. The printhead adjustment plate
has been manufactured so when properly adjusted the head will be square. The
printhead holder has a locator plate that must be slide up snug against the printhead
mount plate. Reinstall the head and it should be square to the web.
Knife Squareness
The knife has an adjustment to square the cut to the stock. To make the adjustment,
loosen the two cap screws, one on top of the knife and one below the knife, using the
3/16" ball driver in the tool kit. Move the knife in the direction desired to square the
cut and retighten the screws.
Stacker
The stacker has four adjustments that can be made without a tool to accommodate
different types of stocks.
Stock Length Adjustment
Loosen the two thumb screws 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.
Users Manual Model 676 Adjustments •••• 43
Page 44
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.
Stacker Full Adjustment
The switch on the inboard stacker up right is used to stop the printer when the stack
is full. A thumbscrew adjustment is provided to set the stack height.
Warning: Some stock materials cannot be stacked to the full height of the
stacker because of excessive weight.
44 •••• Adjustments
Page 45
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.
4) Arrow down to the PRINT / CUT POSITIONS mode and press enter. Cycle
through all the prints, cut, and station two-dot shift values to get a feel for their
present settings.
5) Cycle back to the beginning of the Printer Adjustment and press enter at Print
Checkout Format.
6) Adjust as needed the print head tangent for optimum print quality on all print
stations present. Refer to the Print Head Tangent adjustment section in the manual.
If the machine will not pull stock for this step refer to step number seven.
7) Check the feed pull is 11.0" +- .032" of media. If the feed length is short check
for tight unwind and web guides. After the machine is pulling the correct amount
of media, make sure that the tracking line on the back of the label is at the center of
the stock +- .032" through out the label. If it is not, adjust the outer webguide
postion by loosening the thumb screw under the outer mount block. Rotate the
adjustment nut in or out as needed and tighten the thumb screw. Re-verify that the
label is 11.0" in length. If the print quality is inadequate refer back to step number
six.
8) Using two consecutive labels back-to-back check the squarness of the cut. Adjust
the knife module, as needed referring to the Knife Square adjustment section in the
manual.
9) Using the front panel adjust the print positions so that the print lines for each print
station present is 1.0" +- .032" from the leading edge of the label.
10) If both stations two and three are present, adjust station number two-dot shift on
the front panel so that the tracking line on the front of the label becomes one
continuous line.
NOTE: Once a production sense mark format is loaded, the cut position may be
adjusted which will cause the print to move accordingly.
The machine is now ready for production formats at which time the operator should
need only to fine-tune the prints, cut, and strobes via the front panel.
NOTE: If the machine is used to print on multiple media types the print heads may
need to be adjusted for optimum print quality on each media as they are ran.
Users Manual Model 676 Adjustments •••• 45
Page 46
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.
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.
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.
- Alcohol and a foam swab are the recommended items to use when cleaning the
printhead.
RECOMMEND AVERY DENNISON "MASTER CLEANING KIT" # 921338
Procedure:
-The Printhead should be cleaned every two to four hours of continuous usage. A
good cleaning of the print head after eight to twelve hours of continuous usage
should be done. This cleaning must be done with the print head in the printer.
- Apply a liberal amount of alcohol to a swab.
- Rub the swab across the print line of the printhead to remove the build-up.
- The platen roller and feed rollers should also be cleaned with alcohol to remove ink
and card dust build-up.
46 •••• Maintenance
Page 47
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. Clean the
platen roller located immediately beneath the print head with a clean cloth and a
small amount of alcohol. Be careful not to damage the platen roller while cleaning.
If the roller is worn, replace the roller.
Cleaning Print Sensor
When print registration, in reference to sense mark, becomes inconsistent or erratic
the Sensor and Light Bar may need to be cleaned.
Supplies:
- Always use clean supplies when cleaning the sensor and light bar.
- Never use anything abrasive to the sensor and light bar.
- NEVER use an alcohol based solution when cleaning the sensor or light bar.
- Dry air or a foam swab are the AVERY DENNISON recommended items to use
when cleaning the sensor and light bar.
Print Head Handling
Warning
Print heads can be damaged easily, and are subject to premature failure if not cleaned
on a regular basis. Please follow the procedures carefully to help ensure print head
life and print quality.
Thermal print heads are very sensitive and must be handled with care to help ensure
longer print head life. Because print heads may be damaged through a number of
ways, AVERY DENNISON has developed the following procedures;
Handling
Static discharge is very detrimental to thermal print heads. To avoid contacting print
heads with a static charge, follow these simple procedures:
- All print heads should be kept in original anti-static bags until they are
placed in the machine.
- The 676 printer is supplied with an anti-static wrist strap. Locate the strap
- it must be worn at all times when handling the print heads.
- Do not touch any terminals extending from the print head or the print line.
- Anti-static gloves are provided with your machine upon installation and
extras may be ordered from AVERY DENNISON. These gloves must
be worn at all times when handling the print head. If an anti-static glove
is not available, make absolutely certain to thoroughly wash and dry your
Users Manual Model 676 Maintenance •••• 47
Page 48
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.
1) Review the Printhead Handling Procedure Sheet packaged with each print head to
determine if any procedures have changed before beginning this procedure.
2) Remove the media and ink from the machine for easy print head removal.
3) Unplug the cables that connect to the print head. Unplug the cable by firmly, but
gently pulling it out.
4) Loosen the two 6-32 screws on the rear of the print head holder and slide the
mounting pins inward.
5) Place your hand (with static gloves on) underneath the print line of the print head
and push up to release the locator pins on the heat sink, while pulling the print
head to the right of the machine. This will remove the print head assembly from
the mount plate. You may need to "help" the print head out by pushing on the
heat sink with your left hand.
6) Remove the two print head mount screws located on the top of the print head with
a Phillips head screwdriver.
7) Remove the old printhead carefully from the heat sink.
8) Place the new print head onto the heat sink. Check to see that the new printhead
sits square on the heat sink and that there is no endplay. If there is endplay, or the
head does not seat properly, the heat sink guide will need adjustment.
9) Replace the two print head mount screws. Be sure that the head is resting flat on
the heat sink before tightening these screws.
10) Replace the print head assembly in the printer, sliding the pins (Paragraph 4) into
the holes in the mount plate. Make sure that the guide pins insert into both the
front and back grooves. Secure the 6-32 screws.
11) Reconnect the print head cable connectors, making sure that the connectors are
seated tightly.
NOTE: If the cable is not connected correctly, the print head will be destroyed when
the machine is powered on. Check to see that the cable is tight by observing
from underneath the print head. The cable’s connectors should be inside of
the connectors located on the print head.
12) Replace the media and ink and double-check your work. Power the machine on
and make sure that no adverse effects are noted.
48 •••• Maintenance
Page 49
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 (<YES) or right (NO>) arrow key set the HEAD
CATEGORY as called out in the PRINTHEAD CATEGORY
CHART below.
D) Press the ENTER key to enter the value. The printer must be turned
off and back on for the change to take effect.
PRINTHEAD CATEGORY CHART
MEAN
RESISTANCE
Obtained from
printhead label
PRINTHEAD
CATEGORY
Entered in front
panel for print station
containing head
1190 – 1243 1
1244 – 1295 2
1296 – 1348 3
1349 – 1400 4
1401 – 1453 5
1454 – 1505 6
1506 – 1558 7
1559 – 1610 8
13) As a final test of the print head installation, run a test pattern to check the print
quality. You should observe an even grid of chevrons. If you do not see such a
grid, you may wish to reference the topic of print head tangent adjustment.
Users Manual Model 676 Maintenance •••• 49
Page 50
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.
Cam - Lubrication Procedure
1) Clean dust and residue from cams (using alcohol or other suitable solvent) daily,
or approximately every 100K cuts. Use any good quality general-purpose grease
(not oil). Apply with foam swab or other non-metallic device.
2) If lubrication is omitted, knife will squeak and draw attention to required
lubrication.
3) Some machines are equipped with a self-lubricating oiler system built into the
knife protector. This is an oil-wick system and will require 2-3 drops of SAE 30
weight oil weekly. Be sure wick is in contact with cam. If not, press wick
downward with any suitable blunt device that will fit through the oil cap.
Composition (Iglide) Bearings
1) If field replacement of an assembly fitted with an Iglide bearing is performed, a
single drop of spindle oil should be applied to assist in bearing break-in.
2) If, after long use, an Iglide bearing starts to "squeak", disassemble the component
containing the bearing and lightly abrade the shaft surface. Clean the bearing
(dust or old oil) with alcohol, re lubricate with 1 drop of light oil and reassemble.
No other printer lubrication should be required in normal use.
50 •••• Maintenance
Page 51
Electrical Trouble Shooting
Power Up / Sign On / Communications
Problem Probable Cause Corrective Action
Machine fails to power up
with no light present in
the AC power switch.
2) Lack of power to machine. 2) Check that both ends of the power cord are
3) Missing or blown fuse(s) 3) Check that the fuse(s) located inside the AC
Machine fails to power up
with light present in the
AC power switch.
2) Thermal Control Board
Front panel displays no text
or nothing at all.
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".
plugged in securely.
2A) Confirm that the outlet the machine is plugged
into has power.
entry are present and intact. Replace as needed.
Refer to the "Fuse Configuration".
1) Unconnected cable / connector
inside machine.
unplugged from the Mother Board
1) Front panel cable unplugged. 1) Power off and remove the power cord from the
1) Power off and remove the power cord from the
AC entry. Remove the back cover and inspect
the cables and connectors to and from the power
supply. Refer to the "Electrical System
Schematic".
2) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat the
Thermal Control Board.
AC entry. Remove the back cover and inspect
the cable and connectors to and from the front
panel. Refer to the "Electrical System
Schematic".
Users Manual Model 676 Electrical Trouble Shooting •••• 51
Page 52
Problem Probable Cause Corrective Action
Front panel does not
complete diagnostics test
2.
Machine does not receive
batches.
2) Machine not powered on or has
3) Data sent to wrong printer. 3) In PCMate change to the printer the data is
4) Configuration incorrect in
5) Faulty Thermal Control Board. 5) Replace Thermal Control Board.
6) Jumpers not configured correctly. 6) Contact AVERY DENNISON Service.
1) One or more PC board(s)
unplugged from the Mother
Board.
1) Serial communications cable
loose or unconnected.
not completed diagnostics tests.
PCMate.
1) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat the
offending board.
1) Check and secure both ends of the serial cable
with the thumbscrews.
2) Power machine on and wait until machine
displays "Ready for batches". Re download data.
intended to be sent.
4) Re configure PCMate for AVERY DENNISON
PCL printer as per your PCMate manual.
52 •••• Electrical Trouble Shooting
Page 53
Stock / Ink Advance
Problem Probable Cause Corrective Action
Stock does not advance
when the start button is
depressed.
2) An interlock condition exists. 2) Determine the number and type of interlock(s)
3) Feed motor unplugged or faulty. 3) Check feed motor cable and or replace feed
4) Thermal Control Board
5) Feed roller not gripping stock. 5) Adjust the feed pressure. Refer to "Mechanical
6) Feed rollers bound. 6) With power off check that all rollers turn freely.
7) Stock bound. 7) With the print head and feed open check that the
Ink does not advance when
the start button is
depressed.
1) No batches to be printed. 1) Download batch (If batch downloaded uses the
same format as a previously downloaded batch
the machine with start automatically).
by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 901 Stock Out" reload stock).
motor.
4) Check Thermal Control Board / AT board
unplugged or faulty.
1) No batches to be printed. 1) Download batch (if batch downloaded uses the
connection and or replace Thermal Control
Board.
Adjustment Of Feed Roller Pressure".
stock will pull through the printer with little to
no resistance.
same format as a previously downloaded batch
the machine with start automatically).
2) An interlock condition exists. 2) Determine the number and type of interlock(s)
by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 901 Stock Out" reload stock).
3) Ink motor unplugged or faulty. 3) Check ink motor cable and or replace ink motor.
4) Thermal Control Board
unplugged or faulty.
5) Ink roller bound. 5) With power off check that all rollers and arbors
6) Ink bound. 6) With the print head open check that the ink will
4) Check Thermal Control Board / AT board
connection and or replace Thermal Control
Board.
turn freely.
pull through the printer with little to no
resistance.
Users Manual Model 676 Electrical Trouble Shooting •••• 53
Page 54
Print
Problem Probable Cause Corrective Action
Machine advances stock
but does not print.
2) Miss adjusted print head position. 2) Set print head position. Refer to "Print Head
3) Miss adjusted print head pressure. 3) Set print head pressure. Refer to "Print Head
4) Print head cable unconnected or
5) Print head faulty. 5) Replace print head.
6) Head Driver Board unplugged or
Machine stops after ever
third label.
2) Stock registration sensor
Print registration is off in
the feed direction.
1) Stock registration sensor miss
aligned.
faulty.
faulty.
1) Stock registration sensor miss
aligned.
uncalibrated.
1) Feed pressure setting is off. 1) Set feed pressure. Refer to "Mechanical
1) Adjust sensor position so that the sensor light on
the front panel flashes as a sense slot or hole
passes under the sensor.
Tangent Point".
Pressure Setting".
4) Power off the machine and reinsert the
offending connector or replace cable.
6) Check Head Driver Board / AT board
connection and or replace Head Driver Board.
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) Recalibrate the sensor from the front panel using
the “Calibrate Sensors” mode. Refer to
"Optical Sensor Electrical Calibration".
Adjustment Of Feed Roller Pressure".
2) Print position is incorrect. 2) Enter the setup menu and readjust the print
setting as needed.
3) Field(s) position incorrect in the
format.
4) Bound platen roller. 4) Check that the platen roller turns freely on it's
3) Using formatter check and readjust the field(s)
position(s) as needed.
shaft. If it does not replace it.
54 •••• Electrical Trouble Shooting
Page 55
Problem Probable Cause Corrective Action
Print registration is off in
the web direction.
2) Web guides incorrectly adjusted. 2) Check and adjust as needed. Refer to "Web
3) Unwind incorrectly adjusted. 3) Check and adjust as needed. Refer to "Web
4) Incorrect DIP switch settings on
Print contrast is too light or
dark.
2) Incorrect strobe setting in the
3) Misadjusted print head position. 3) Set print head position. Refer to "Print Head
4) Misadjusted print head pressure. 4) Set print head pressure. Refer to "Print Head
Voids in print image in the
feed direction.
2) Print head dirty. 2) Power off the machine clean the print head and
1) Machine incorrectly threaded. 1) Check and rethread the media as needed. Refer
to "Loading Stock".
Guide Adjustment".
Guide Adjustment".
4) Check and reset DIP switches as needed. Refer
the Thermal Control Board.
1) Incorrect strobe setting selected
in the format.
machine setup.
1) Ink misaligned with format. 1) Adjust ink position on the arbors to achieve full
to "TCB Dip Switch S2 Settings".
1) Using Formatter check and adjust the strobe
setting according to the media and ink being
used.
2) Enter the setup menu and readjust the strobe as
needed.
Tangent Point".
Pressure Setting".
ink coverage over all fields on the format.
platen. Refer to "Print Head Cleaning".
3) Faulty print head. 3) After cleaning head and running the test pattern
to confirm that a void still exists, replace the
print head.
4) Misadjusted print head position. 4) Set print head position. Refer to "Print Head
Tangent Point".
5) Misadjusted print head pressure. 5) Set print head pressure. Refer to "Print Head
Pressure Setting".
6) Worn platen roller. 6) Replace platen roller.
Machine continually stops
with an erroneous
interlock condition.
2) Sensor position misadjusted. 2) Determine which sensor and relocate
3) Ink sensor type (light / dark)
1) Sensor uncalibrated. 1) Recalibrate the sensor from the front panel using
the “Calibrate Sensors” mode. Refer to
"Optical Sensor Electrical Calibration".
accordingly.
3) Either change the ink or the ink type in the
incorrect in the format for the ink
type being used.
format.
Users Manual Model 676 Electrical Trouble Shooting •••• 55
Page 56
Cut / Stack
Problem Probable Cause Corrective Action
Machine fails to cut labels
(the rotary knife does
not rotate).
2) Knife cable unconnected. 2) Power off and remove the power cord from the
3) Knife jammed causing auto
4) Faulty knife motor. 4) Replace the knife motor.
5) Faulty knife motor drive circuit
The stacker fails to run. 1) The stacker cable is unconnected. 1) Power off and insert the stacker cable in the
2) Faulty stacker motor. 2) Replace the stacker motor.
3) Stacker jammed causing auto
4) Faulty stacker motor drive circuit
1) The cut is disabled in the setup
menu.
resetting fuse to trip on the
Thermal Control Board.
on the Thermal Control Board.
resetting fuse to trip on the
Thermal Control Board.
on the Thermal Control Board.
1) Enable the knife in the setup menu via the front
panel.
AC entry. Remove the back cover and inspect
the cable and connector to the knife module.
Refer to the "Electrical System Schematic".
3) Remove cause of jam at the knife.
5) Replace the Thermal Control Board.
stacker port on the Thermal Control Board.
3) Remove cause of jam at the stacker.
4) Replace the Thermal Control Board.
56 •••• Electrical Trouble Shooting
Page 57
Mechanical Trouble Shooting
Stock
Problem Probable Cause Corrective Action
Stock will not roll or jumps 1) Incorrect adjustment of unwind
web guides
2) Adjust web guides to touch stock roll but not
Machine fails to stop at end
of roll.
Stock does not pull
smoothly through
printhead module.
2) Web guides on decurler arm too
3Web guide funnels to tight . 3) Open the funnels slightly. Do Not Pinch the
1) Incorrect adjustment of stock-out
sensor.
1) Web guides on unwind arm too
tight.
tight
1) Be sure stock roll is as flat as possible and does
not extend over core.
pinch the roll.
1) Adjust contact strip so that a “click” will be
heard when supply roll is lifted.
1) Adjust web guides to touch outer edges of stock
with minimum pressure required to keep stockout switch closed.
2) Adjust collars on decurler bar to touch edge of
stock.
web with the funnels
Users Manual Model 676 Mechanical Trouble Shooting •••• 57
Page 58
Problem Probable Cause Corrective Action
Stock jams in bridge blade
rollers or knife area.
2) Knife not cutting full width of
3) Stacker not operating or nip
Will not stack. 1) Stacker not operating. 1) See step 3 above.
2) Stacker position on machine too
3) Incorrect rail position or stacker
Knife will not cut or partial
cut
1) Knife mounted bridge blade too
close to stationary bridge blade.
stock.
rollers not turning.
far forward so labels go under rear
stacker rail.
bed angle.
1) Incorrect pre-load on clutch pawl. 1) With back cover removed and power off -
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) Loosen knife shear adjustment screws and move
outer end of knife until full cut is accomplished.
3) Check stacker connection to access port. Be
sure nip roller is free to rotate and moves easily
in the bearing slots.
2) Loosen stacker mounting knob and move
stacker toward rear of machine - tighten.
3) Using a cut label, position stacker rails so that
approximately 3/8" (9.5mm) overhangs the
second grooved roller. Loosen quick-turn
handle on stacker clamp and raise or lower
stacker bed until opening between 1st label
overhang and belt surface will allow entry of
next label.
operate solenoid by hand. When lever is moved,
clutch pawl should move counter-clockwise
about 1/32" (0.79mm) with the "pac-man" in
home position. If not - loosen "pac-man" set
screws and readjust "pac-man" to stop with
spring in detent.
2) Partial cut 2) Loosen shear adjustment screws and move outer
end of knife until full cut is obtained.
58 •••• Mechanical Trouble Shooting
Page 59
Ink
Problem Probable Cause Corrective Action
Ink wrinkles or will not pull
smoothly.
2) Unwind roller and ink take-up
3) Ink buildup on turn bar(s). 3) Clean with alcohol.
4) Incorrect ink width. 4) Use an ink width no wider than stock being
Ink rolls loosely on take-up
roller.
2) Take-up core binding on locator
3) Ink unwind adjuster too tight. 3) Loosen knurled knob to a point flush with
1) Incorrect adjustment of unwind
roller brake resistance.
roller misaligned.
1) Take-up roller not turning. 1) Assure roller does not bind and is clean. Adjust
plate.
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) Align rear edge of ink with rear of print area
(allow approximately 1/8" (3mm) overlap).
Loosen thumb cap screw on ink out sensor
mount plate and adjust until it touches rear of
ink roll on unwind arbor. Lock slide rewind
core toward rear of printer until it just contacts
plate.
printed. This is especially critical when using a
narrow web with cut down rollers.
pressure knob to higher detent position if
required.
2) Move core .015" - .030" (.38mm - .76mm) away
from plate.
surface of mounting shaft.
4) Take-up roller too full. 4) Remove used ink roll. It is designed to hold
only 1 full roll.
Users Manual Model 676 Mechanical Trouble Shooting •••• 59
Page 60
Print
Problem Probable Cause Corrective Action
Poor print - uneven or no
print (mechanical).
Also see electrical
trouble shooting.
2) Broken ink. 2) Replace ink and readjust (see INK trouble
3) Ink not rewinding. 3) Readjust (see INK trouble shooting).
1) Incorrect tangent position. 1) Refer to tangent adjust procedure in Print Head
section.
shooting).
60 •••• Mechanical Trouble Shooting
Page 61
Knife
Problem Probable Cause Corrective Action
Double Cuts, extra knife
cycle
2) Worn Trip Arm on Clutch
3) Worn Stop roll pin on clutch 3) Replace Clutch if not solved above.
Skips cut, double length
label
2) Trip arm sticking on clutch roll
3) Low voltage to solenoid 3) Check power supply voltage for 12 and 24 volts
4) Weak solenoid driver 4) Substitute TCB. Change back if not solved.
5) Bad Solenoid 5) Unusual, but replace Solenoid and adjust.
Noisy Rattle when not
cutting but motor
turning
1) Solenoid sticking in 1) Check proper assembly of washers. Clean
plunger with alcohol and completely dry.
2) Replace Actuator
actuator.
1) Solenoid did not pull in 1) Check gap on the trip arm to clutch body must
be about .040 inches. If too large, solenoid has
less force. Check assembly of spring and
washers. Use latest engineering assembly
procedure. Clean Solenoid.
2) Check for burr on trip arm catching on clutch
pin.
1) Packman not visibly homing 1) Adjust Packman to center the home location of
stop roll pin. File off burr on clutch roll pin
and/or replace trip arm.
the packman to the quiet location. If the knife
still does not home, clean knife cams and
lubricate.
If still does not home, replace blades. If still does
not home, replace clutch.
2) Packman homing ok but noisy. 2) Adjust Packman to center the home location of
the packman to the quiet location .
3) Dirty Clutch 3) Clean clutch and one drop of light oil.
4) Packman slipping 4) Order improved set screws with multiple points
that bite better to shaft.
5) Bad Motor Gear Box 5) Replace Knife Motor
Users Manual Model 676 Mechanical Trouble Shooting •••• 61
Page 62
Problem Probable Cause Corrective Action
Knife stops during cut in
stock
2) Clean cams and lubricate 2) Make sure oiler is on knife. Instruct Operator to
3) Clutch worn out and can’t stay
Slight Long and Short Tags 1) Sticking Solenoid 1) Check gap on the trip arm to clutch body must
2) Sticking Trip Arm to Clutch Roll
3) Clutch has trouble picking up 3) Clean clutch and replace if not solved
Stock popping in front of
knife
2) Clutch has trouble engaging and
1) Check life of blades 1) If warn and dull, may stall in stock. If life is
greater than 2 million, replace blades.
oil weekly. Make sure oil is available.
3) Replace Clutch
engaged
be about .040 inches. If too large, solenoid has
less force. Check assembly of spring and
washers. Use latest engineering assembly
procedure. Clean Solenoid.
2) Check for burr on trip arm catching on clutch
Pin
1) Slow knife rotation 1) Worn out blades create too much load for motor
stock runs into blades
stop roll pin. File off burr on clutch roll pin
and/or replace trip arm.
and knife slows down too much during cut.
Replace Blades.
2) Clean clutch and replace if not solved.
Knife does not cycle 1) Solenoid not engaging 1) Trip knife solenoid by hand to see if knife
cycles. If cycles and cuts, check cable to
solenoid, check solenoid adjustments and
assembly, check gap and replace solenoid if
necessary.
2) Knife Motor Broken 2) Replace Knife Motor, good for 10 million labels
by spec
3) Clutch total failure 3) Unlikely, but change if necessary
4) Solenoid Drive circuit failure 4) Replace Cable or TCB
5) Knife motor not cycling 5) Replace Cable or TCB
Continuous Knife cycling 1) Solenoid stuck in 1) Clean and adjust solenoid.
2) Circuit stuck on 2) Unplug solenoid wires from knife module
connector and should stop cutting. If it does
stop cutting, replace TCB.
3) Very bad trip arm to stop pin on
clutch
3) Unusual, but file roll pin and replace trip arm.
62 •••• Mechanical Trouble Shooting
Page 63
Appendix A
Error Messages
On the Machine's detection of errors/error, the displays will show the first error encountered and allow the
displaying of any other errors with the <YES / NO> keys, which will "Scroll" through additional errors if any.
XX is the total number of errors at the time of error detection.
ERROR SCREENS:
The screen advances to next error with each depression of the "NO>" key
The screen retreats to prior error with each depression of the "<YES" key
The screen reverts back to the first error when the “EXIT” key is pressed.
X X E R R O R ( S )
S T O C K O U T 9 0 1
Error Message Error
HEAD 1 OVER TEMP 404
HEAD 2 OVER TEMP 405
HEAD 3 OVER TEMP 406
STOCK OUT 901
CHECK STACKER 902
INK OUT STATION 1 904
INK OUT STATION 2 905
INK OUT STATION 3 906
MISSED SENSE MARK 908
FEED OPEN 910
VERIFIER HALT 1 912
VERIFIER HALT 2 913
IMAGER ERROR 919
HEAD OPEN STATION 1 920
HEAD OPEN STATION 2 921
HEAD OPEN STATION 3 922
Users Manual Model 676 Appendix A •••• 63
Page 64
Appendix B
U 36
U 23
U 21
U 4
U 3
U 18
U 19
U 20
U 22
Software Upgrade Chip Placement Positions
Thermal Control Board P/N 371105TT
THERMAL CONTROL BOARD
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.
64 •••• Appendix B Users Manual Model 676
Page 65
Head Driver Board P/N 371106TT
U - 30
U - 9
U - 10
U - 20
U - 5
(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.
Users Manual Model 676 Appendix B •••• 65
U - 8
Page 66
Front Panel Board P/N 351108
(Use chip removal tool p/n. 351156 for square I.C.'s)
FRONT PANEL BOARD, Upgradeable software I.C.'s include U1.
Align angled corners of chip with socket and arrow denotes pin #1 or dimple on chip.
Front Panel Diagnostic Descriptions
Diagnostic Numbers Descriptions
1 Front panel initialization
2 TCB Opsys initialization * See note below
5 Attempting Serial Host Initialization
6 Initializing Verifier
7 Executing Protected Mode Imaging Code
8 Checking Flash Disk Module
9 Attempting to read in scalable fonts.
10 Initializing Font Scaler
11 Attempting to load code pages
12 Attempting to read in logos
13 Attempting to read in care symbols
14 Waiting for Machine Definition from TCB
15 Attempting to create test pattern
16 Attempting to create strobe tables
17 Attempting to read in formats
18 Protected Mode Imaging Code initialization complete
19 Serial Communications Activated
0 Power up complete
Note: There must be a PCMCIA card installed in the slot if the PCMCIA option board is installed. If the
PCMCIA card is not present – the front panel will stop at Diagnostic 2.
66 •••• Appendix B
Page 67
Appendix C
Ink and Stock Transfer Types
Transfer Type values associated with the XT commands.
Value Transfer Type
51 Heat Seal & SD-1111 Ink
52 Topcoated card stock & TT-3111 Ink
53 Topcoated card stock & TT-1111 Ink
54 Topcoated card stock & HR-3111 Ink
55 Topcoated card stock & HR-1111 Ink
56 Topcoated Card Stock & TW-1111 Ink
57 Topcoated card stock & TW-1151 Ink
58 Pressure Sensitive & TT-3111 Ink
59 Pressure Sensitive Thermal Receptive & TT-1111 Ink
60 Pressure Sensitive Thermal Receptive & TW-1111 Ink
61 Pressure Sensitive & TW-1151 Ink
62 Pressure Sensitive & HR-3111 Ink
63 Uncoated Tag Stock & TT-3111 Ink
64 Uncoated Tag Stock & TT-1111 Ink
65 Uncoated Tag Stock & HR-3111 Ink
66 Uncoated Tag Stock & HR-1111 Ink
67 Uncoated Tag Stock & TW-1111 Ink
68 Uncoated Tag Stock & TW-1151 Ink
69 Fabric 2800 & TT-1111 Ink
70 Fabric 2800 & HR-3111 Ink
71 Fabric 2800 & TT-3111 Ink
72 Fabric 2800 & HC-3111 Ink
73 Fabric 2800 & HR-1111 Ink
74 Fabric 2795 & TT-1111 Ink
75 Fabric 2795 & HR-3111 Ink
76 Fabric 2795 & TT-3111 Ink
77 Fabric 2795 & HC-3111 Ink
78 Fabric 2795 & HR-1111 Ink
79 Coated Tag Stock & HR-4111 Ink
Users Manual Model 676 Appendix C •••• 67
Page 68
Value Transfer Type
80 Pressure Sensitive & HR-4111 Ink
81 Uncoated Tag Stock & HR-4111 Ink
82 Fabric 2800 & HR-4111 Ink
83 Fabric 2795 & HR-4111 Ink
84 New Pressure Sensitive (no xfer) & TT-3111 Ink
85 New Pressure Sensitive (no xfer) & TT-1111 Ink
86 New Pressure Sensitive (no xfer) & TW-1111 Ink
87 New Pressure Sensitive (no xfer) & TW-1151 Ink
88 New Pressure Sensitive (no xfer) & HR-1111 Ink
89 New Pressure Sensitive (no xfer) & HR-3111 Ink
90 New Pressure Sensitive (no xfer) & HR-4111 Ink
91 Coated Tag Stock & GP-1111 Ink
92 Uncoated Tag Stock & GP-1111 Ink
93 New Pressure Sensitive (no xfer) & GP-1111 Ink
94 2800 Fabric & GP-1111 Ink
95 2795 Fabric & GP-1111 Ink
96 2795 Fabric & CT-1111 Ink
97 4800 Fabric & CT-1111 Ink
98 4800 Fabric & CT-1114 (Blue)
99 4800 Fabric & GP-1111
100 2395NWT Fabric & CL-1111 (UK)
101 2395NWT Fabric & XC-3111 (UK)
102 2395NWT Fabric & HR-1111 (UK)
103 2495NWT Fabric & CL-1111 (UK)
104 2495NWT Fabric & XC-3111 (UK)
105 2495NWT Fabric & HR-1111 (UK)
106 4000NWT Fabric & CL-1111 (UK)
107 4000NWT Fabric & XC-3111 (UK)
108 4000NWT Fabric & HR-1111 (UK)
109 4002NWT Fabric & CL-1111 (UK)
110 4002NWT Fabric & XC-3111 (UK)
111 4002NWT Fabric & HR-1111 (UK)
112 G.S. Satin & XC-3111 (UK)
113 2012T Fabric & XC-3111 (UK)
114 1021T Fabric & XC-3111 (UK)
115 2800 Fabric & CT-1111
116 591SST Fabric & CT-1111 Ink
68 •••• Appendix C
Page 69
Value Transfer Type
117 591SST/601SST Fabrics & CT-1114 Ink
118 601SST Fabric & CT-1111 Ink
119 591SST/601SST Fabrics & CT-1115 Ink
120 591SST/601SST Fabrics & CT-1117 Ink
121 591SST Fabric & CT-1112 Ink
122 601SST Fabric & CT-1112 Ink
155 4900NWT / 4900HSA & HS1111
156 1800FRA & TW1111
157 1800FRA & GP1111
158 2085NWT / 2495NWT / 2360NWT & HS1111
159 2360NWT / 2800NWT & XC3111
160 2895NWT / 2800NWT & HS1111
161 2895NWT & XC3111
162 2895NWT & HC3111
163 1800MWA & GP1111
164 1800MWA & TW1111
165 604LKP / 601LKP & DS7501 / 7502 / 7504
166 604LKP / 601 LKP & DS7503
167 4800NBC Fabric & HS1011
168 2012T Fabric & HS1111/1112
169 4360NBT Fabric & SD1011
170 4041THS Fabric & HS1111
171 4700TWT Fabric & PL1111
172 4800TST Fabric & CT1111
173 4800TST Fabric & CT1112
174 4800TST Fabric & CT1114
175 4800TST Fabric & CT1115
176 4800TST Fabric & CT5137
177 4800TST Fabric & HS1111
178 770SWT Fabric & CT1112
179 770SWT Fabric & CT1114
180 770SWT Fabric & CT1115
181 770SWT Fabric & CT5137
182 772SWT Fabric & CT1112
183 772SWT Fabric & CT1114
184 772SWT Fabric & CT1115
185 772SWT Fabric & CT5137
Users Manual Model 676 Appendix C •••• 69
Page 70
Appendix D
+.000
Knife MFG Guideline
Solenoid Trigger Setting
-.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.
Other hints if there is still a problem:
• If the gap is greater then .047”, an old solenoid bracket is being used. Replace (P/N 357003) or
slot the bracket.
• If plunger binds, the solenoid is not parallel with the base of the bracket that mounts to the knife
support, and/or the actuator slot is bottoming out on the roll pins that are on the plunger. Make
adjustment or replace the bracket.
70 •••• Appendix D
Page 71
• 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. To install, the c-clip has to be removed, then put the large washer on the
plunger and push it down against the coil pin. While holding it in that location, re-install the cclip. Now the Small nylon washer and spring can be put on the plunger and inserted into the
solenoid.
- 989513
Users Manual Model 676 Appendix D •••• 71
Page 72
• There should be a .010-.020 gap (for roller clutch onl
y) 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.)
• (Rev 1) Pre-load setting adjustment. While motor is running, not while cutting, loosen set
screws on “pac-man” and rotate the rotary blade clockwise, mark the stopping position on the
“pac-man”, rotate counterclockwise, mark the “pac-man”, then rotate the blade to the middle of
the two marks and tighten the set screws.
• (Rev 2) All new knife assemblies have a blue clutch. The clutch outer race bushing has an I.D.
of .500 and the 2 extension springs are .012 dia wire.
• (Rev 2) The 2 extension springs on all rebuilt clutches must have the .009 dia. wire springs
replaced with .012 wire springs.
• (Rev 5) Replace Knife Actuator 357020, if it is worn or if there is a “bulge” at the 90-degree
bend.
• (Rev 6) Changed feeler gauge tolerance from .047 MIN
72 •••• Appendix D
Page 73
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. However, we run into printhead
problems when customers combine both these features.
The edge of the narrower stock not covered by the ink will gouge the printhead and cause dots to be
out.
Here, the customer will have
much shorter printhead life
because of the edge of the
narrower, uncovered stock.
Printhead
WRONG!
The solution is to make sure
that the narrower stocks
have at least 1/8” of ink
coverage over the edge.
The widest stock does not
need full ink coverage.
RIGHT!
This edge which is
not covered by ink
will erode the
printhead.
Must have 1/8" inch
overlap to protect the
printhead from the
stock edges
Will have missing dots from
the eroded printhead when
this prints out.
Printhead
Overlap unneccessary because
this is the widest stock being
printed
Users Manual Model 676 Appendix E •••• 73
Page 74
Printhead Fail Modes
Symptoms, Causes, Solutions
Symptom #1:
sometimes in the print area, and sometimes not. If in a barcode, the verifier will halt the printer.
Cause: Paper dust or dirt on the printhead
causing the ink to print without printhead firing.
The dot is NOT failed on. The printhead is
DIRTY.
If not addressed immediately: the line will go
from black or gray to white and the dot will fail.
The printhead will be damaged.
Solution: Immediately stop the printer and clean the printhead in the machine.
If problem continues: Remove the printhead and clean with hard pressure.
A dot is leaving a line in the print direction. The dot appears to be dragging or failed on,
Lines of
print from
a dragging
dot
Specialty
Style: Fall
Color: Rose
23456 78901
Brand
$5.95
Specialty
Brand
Style: Fall
Color: Rose
23456 78901
$5.95
Specialty
Brand
Style: Fall
Color: Rose
23456 78901
$5.95
Specialty
Brand
Style: Fall
Color: Rose
23456 78901
$5.95
Specialty
Brand
Style: Fall
Color: Rose
23456 78901
$5.95
Symptom #2:
Edges of barcode and text do not appear
crisp and sharp.
23456 78901
Cause: Strobe is too high. Printhead is dirty.
Solution: Reduce front panel strobe one increment at a time until
fuzzy printing goes away.
If problem continues: Clean the printhead as described below.
Fuzzy edges
Symptom #3:
appears missing. The verifier will halt the machine if the missing dot is in a barcode.
While printing along fine early in the printheads life (< 300,000 inches), a dot suddenly
Cause: Most likely, the printhead failed from static.
Solution: Replace the printhead.
If problem continues: Check that the machine has all the static upgrades. Double-check the connections
and wires.
74 •••• Appendix E
Page 75
Printhead Cleaning Procedure
Printhead performance and life are influenced by proper handling and cleaning.
• Dirt on the printhead that causes problems is often too small to see.
• Exercise care in handling printheads as they are very susceptible to static. Use the wrist grounding strap
and anti-static gloves when handling.
• It is OK to scrub the printhead HARD to clean it. Use rubbing alcohol and the “loop side” or “wool side” of
Velcro, followed by drying with rough, brown paper towels.
• If the printhead doesn’t work, take it out and clean it again.
• For maximum printhead life, clean the printhead after every roll change of ink or every 20,000 inches.
In Machine Cleaning Procedure
1. Stop the machine after the last batch has printed to
avoid loosing data.
2. Turn the machine off.
3. Open the printhead carriage assembly.
4. Soak a small amount of rubbing alcohol on a foam
swab and apply to the printhead.
5. Scrub the printhead several times with hard force
using the “wool side” of Velcro.
6. Dry the printhead with a dry, brown paper towel.
7. Shut the printhead carriage assembly and resume
printing.
8. If a problem continues, remove the printhead and
clean it.
Dirt along the
print line.
Printhead cleaning when removed from the printer
1. Remove the printhead.
2. Place the printhead upside down on the edge of a
clean table with the connector pug over the edge of
the table.
3. Soak a small amount of rubbing alcohol a foam swab
and apply to the print line.
4. Scrub the printhead several times using HARD
pressure with the “loop side” of Velcro.
5. Dry with a dry, brown paper towel.
6. Replace the printhead.
Heavy finger
pressure here
Thumb here to
hold against
the table
Scrub here,
hard pressure
Table edge
Users Manual Model 676 Appendix E •••• 75
Page 76
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.
Printhead installation procedure
1. Position the printhead loosely under the printhead
carriage assembly.
2. Connect the wire pack.
3. Position the printhead in the printhead carriage
assembly so that the alignment pegs match up and
the printhead fits snugly.
4. Shut the printhead while maintaining snug fit on the
printhead.
5. Tighten the tangent set screws.
Shield
Printhead carriage assembly
Printhead
alignment
pegs
Wire pack
Open printhead carriage
Tangent locking
screw locations
76 •••• Appendix E
Page 77
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
WRONG!
installed and making physical
contact with the main stacker
roller. Sometimes, the clip is
installed but moved off the
Grounding
clip
roller.
b) Check the stacker mounting knob has a
large washer installed. Make sure to
Washer
Stacker knob removed
tighten the knob all the way.
2. Ink arbors: With an ohmmeter, check
for continuity on the two ink arbors and
three ink turn rollers. Place one lead of
the ohmmeter on the arbor and the other
on the chassis ground screw.
3. Printhead static protections. Check for proper installation.
a) Static brushes. Make sure the brushes
are installed and just barely touching the
stock and ink. Too much dragging and
they wear; too little contact and they don’t
dissipate the static.
b) Static shield. Make sure the static shield
is installed and the screws are tight.
RIGHT!
Machine side of the
stacker
Ink arbors
Ink turn rollers
Static
brushes
Shield
Users Manual Model 676 Appendix E •••• 77
Page 78
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. Tangent: Set the tangent so that the locking screw is centered
when looking down on the printhead.
4. Strobe: Using the arrow keys, select “Setup” on the front
panel. Using the arrow keys again, select “Strobe”. If not 0,
return the strobe setting to zero using the arrow keys, and
then the “Enter” key.
Printhead Carriage Assembly
5. Ink tension: Back the tension on the ink unwind and take up to minimal. Turn the tension knobs left or
counter-clockwise.
6. Stock widths: The width of the ribbon must be greater than the supply width. Since some supplies are
more abrasive to printheads than others, using a ribbon wider than your supply helps protect the
printhead. Failure to do this may void your warranty. Replacement printheads are expensive.
Pressure
adjustment knob
Tangent locking
screw locations
Tangent
adjustment knob
7. Cleaning: Clean the printhead with an approved printhead cleaning method. Use rubbing alcohol on a lint
free cloth or the “Hook side” or Velcro. Always turnoff the machine and wear the wrist grounding strap.
Never touch the printhead with a metal object like a knife or screwdriver.
78 •••• Appendix E
Page 79
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.
Specialty
Brand
Style: Fall
Color: Rose
23456 78901
Printhead
Stock
Platten
roller
Ink
Printhead
Stock
Platten
roller
Ink
Tangent too far left
Tangent properly adjusted
2. Pressure - Adjust printhead pressure to get desired print definition. If the pressure seems like it is getting
too tight, readjust tangent. Don’t tighten the printhead to maximum or damage to the printhead could
occur.
3. Strobe - Adjust strobe for print darkness and bar code scanability. Adjust one increment at a time.
Specialty
Brand
Style: Fall
Color: Rose
23456 78901
$5.95
Printhead
Ink
Stock
Platten
roller
Tangent too far right
Specialty
Brand
4. Ink - Use ink unwind and take-up tensions adjustments to eliminate any ink wrinkles or skid marks.
Users Manual Model 676 Appendix E •••• 79
Page 80
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. The width of the fabric will determine the width of the cut down part
of the green platen roller. The ink should not extend beyond the edge of the cut
down part of the platen. The 1 3/8” roller can be used for fabric from the minimum
1” to 1 1/8” wide. The 3” cut down platen roller can be used from 1 1/8” to 2 ½” in
width. Fabric from 2 ½” wide up to the full 5” width of the printer should use the
regular full size platen rollers.
The following pages will show the platen rollers used in the 6x6 and 676 controlled
printers. They are approximately full size. Just compare the roller you are using to
one of the pictures and using the following chart – select the replacement part
number. The first 6x6 machines had beige colored covers and the web path was back
justified. The later model of 6x6 has gray colored covers and has a web path that is
centered on the platen rollers in the same way as the 676.
Machine Part Number Platen Roller Description and Use
636/656 Beige Covers
Back Justified Web Path 355096 Standard Full Width Tag Stock - Red – w / Ink Save (656)
355029 Standard Full Width Green - Fabric – wo / Ink Save
355083 Standard Full Width Green - Fabric – w / Ink Save (656)
355044 3” Cut Down Green - Fabric – wo / Ink Save
355082 3” Cut Down Green - Fabric – w / Ink Save (656)
636/656 Gray Covers
Center Justified Web Path 355096 Standard Full Width Tag Stock - Red – w / Ink Save (656)
355029 Standard Full Width Green - Fabric – wo / Ink Save
355083 Standard Full Width Green - Fabric – w / Ink Save (656)
375030 1 3/8” Cut Down Green - Fabric – wo / Ink Save
375031K 1 3/8” Cut Down Green - Fabric – Ink Save (656)
375026 3” Cut Down Green - Fabric – wo / Ink Save
375025K 3” Cut Down Green - Fabric – w / Ink Save (656)
676
Center Justified Web Path 355096 Standard Full Width Tag Stock - Red – w / Ink Save
355029 Standard Full Width Green - Fabric – wo / Ink Save
355083 Standard Full Width Green - Fabric – w / Ink Save
375030 1 3/8” Cut Down Green - Fabric – wo / Ink Save
375031K 1 3/8” Cut Down Green - Fabric – w / Ink Save
375026 3” Cut Down Green - Fabric – wo / Ink Save
375025K 3” Cut Down Green - Fabric – w / Ink Save
355009 Standard Full Width Tag Stock - Red – wo / Ink Save
355009 Standard Full Width Tag Stock - Red – wo / Ink Save
355009 Standard Full Width Tag Stock - Red – wo / Ink Save
80 •••• Appendix F
Page 81
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
Page 82
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
Page 83
Center Justified Platen Roller
1 3/8” C ut D own
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
Page 84
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
Page 85
Electrical Assembly Drawings
Machine Wiring
INK
FE ED
SA VE
(TW O)
SY ST EM H ARN ES S
FR ONT PAN EL
PH1
KN IFE
BRO WN
BRO WN
GRA YORA NGE O RAN GE
PH3
GRAY
RO LL ER
DR OP
RED
ORA NGE
PH2
GRA Y
(NOT USE D)
BRO WNRED
Users Manual Model 676 Electrical Assembly Drawings •••• 85
VE RIFIER
TH ERM A L
CO N TR O L
BO ARD ( REA R)
371105 TT
HE AD DR IV E R
BO ARD
(FRO N T)
371107 T3
PO W ER
SU PP LY
Page 86
Electrical System Schematic
AC ENTRY
115V
341111
371137
LINE CORD
181134
CONN 4
GROUND
NEUTRAL
LINE
115V OPERATION
ONE 10.0A 250V
1/4 X 1 1/4 FUSE 921167
230V OPERATION
TWO 10.0A 250V
5 X 20MM FUSES 921168
551149
OPTIONAL
10
ETHERNET
BASE T
TO SERIAL
CONVERTER
230V
A
B
C
D
DIODE
990998
CONN 4 CONN 4
370028
341147
CONN 3
A
HARNESSED +5V/+12V/+24V
POWER SUPPLY
371116
L
N
G
+24V
RETURN
MB POWER CONN 12
POWER GOOD
CONN 2
MACHINE COOLING
FAN 511120
371191A
MOTHER BOARD
371168
IDE 2 (J6)
CONN 4
NC
NC
CONN 4
SEE NOTE 3
OPTIONAL
PCMCIA
BOARD
351181
FRONT PANEL ASSY
511108
PCB 511110
OVERLAY 511111
CODE 800265
J1
TCB TO FP
CABLE
371119
J13
J1
THRMAL CONTROL
BOARD
371105TT
J2 J5
J8
J14
J11
J10
J12
J9
J6
J3/J4
AT
BUS
J7
TCB TO HDB
351121
CONN 4
CONN 4
CONN 4
CONN 2
CONN 4
CONN 4
CONN 3
CONN 4
SYSTEM HARNESS
ASSEMBLY 371126
371140 FEED MOTOR CROSSOVER
STEPPER MOTOR CABLE
STEPPER MOTOR CABLE
371132
KNIFE FUSE HARNESS 359007
(FUSE 990755)
STACKER HARNESS
351125
SERIAL CABLE
EXTERNAL 351124
551114
+12V
+5V
MODULE, FLASH DISK
16MB MEMORY 341146B
PROCESSOR
FAN
421142
351132
HARNESS 359006
(FUSE 990915)
CONN 9
551115
STOCKOUT SWITCH
HARNESS 371142 SWITCH 191120
FEED OPEN
SWITCH 191120
TOP 1 HEAD-OPEN
SWITCH 375018
TOP 2 HEAD-OPEN
SWITCH 375018
BOTTOM HEAD-OPEN
SWITCH 375018
TOP 1 INK-OUT
SENSOR 371118
TOP 2 INK-OUT
SENSOR 371118
BOTTOM INK-OUT
SENSOR 371118
TOP REGISTRATION
SENSOR 371128
BOTTOM REGISTRATION
SENSOR 371128 OPTION
ROLLER DROP
SENSOR 371130
TOP CONTRAST SENSOR
510014 SICK OR 510012 OMRON OPTIONS
FEED MOTOR
HARNESSED 421123
INK MOTOR
351141
KNIFE MOTOR
HARNESSED 351171
KNIFE SOLENOID
HARNESSED 351123
STACKER FUSE
CONN 3
CONN 3
CONN 3
FEED MOTOR
HARNESSED 371111
ROLLER DROP
MOTOR
CONN 2
PACIFIC
SCIENTIFIC
371165A
FULL STKR SWITCH
HARNESSED 351160
JAM SENSOR
HARNESSED 371133
REGISTRATION GAIN
SWITCH 551170
IR LED 551169
SUPERIOR
351157
STACKER MOTOR
HARNESSED 351161
VERIFIER
551144
OPTIONAL IN LINE
VERIFIER 550027
NOTES:
1. ALL AC WIRE 18AWG 600V INTERNATIONAL
COLOR CODE:
LINE BROWN
NEUTRAL LT. BLUE
EARTH GROUND GREEN W/ YELLOW STRIPE
2. DC OUTPUT OF POWER SUPPLY:
+5V RED
+12V YELLOW
+24V GRAY
RETURN BLACK
3. FLASH DISK REPLACED PCMCIA BOARD, REMOVE IF FLASH
DISK IS INSTALLED.
J4J1/J2
TOP PRINTHEAD 1
J9
J10
J7
CABLE 371123
TOP PRINTHEAD 2
CABLE 371123
BOTTOM PRINTHEAD
CABLE 371124
J5
HEAD
DRIVER
J6
BOARD
371107T3
PRINTHEAD
371102
PRINTHEAD
371102
PRINTHEAD
371102
86 •••• Electrical Assembly Drawings Users Manual Model 676
Page 87
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.
Ensure that all of the black wires are located next to each other in the center of the two connectors (as shown in the diagram
below), and that the clamps on the back side of the connectors ate secured along the PCB header. All pins should be covered.
Warning: Connecting the power supply incorrectly may cause irreversible (unwarranted) damage! Ensure that the power is
turned off before connecting the power supply. Make certain that the 115 / 230VAC fuse drawer is in the correct position
Users Manual Model 676 Electrical Assembly Drawings •••• 87
Page 88
Page 89
Mechanical Assembly Drawings
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Page 90
Unwind Assembly Drawing
90 •••• Mechanical Assembly Drawings Users Manual Model 676
Page 91
Unwind Parts List
(*NS) = Not Shown
Item Part # Description Qty
1 373012 Web Guide, Rear 1
2 373009 Lead screw, Tape unwind 1
3 373011 Adjuster, Outer web guide 1
4 373010 Rod, Web guide, Outer 1
5 353002 Bracket, Unwind 1
6 105023 Impression adj, Knob/SS Kit 1
7 373014 Bracket, Sensor mount 1
8 373013 Bracket, Stock out 1
9 191120 Micro switch 1
10 989973 4-40 x ½ Cap screw 2
11 990069 8-32 Hex nut 1
12 990000 2-56 x ¼ Cap screw 2
13 990065 8-32 x 3/8 Button head screw 1
14 371142 Stock out switch, Harness (*NS) 1
15 990513 Small wire tie (*NS) 1
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Page 92
Web Guide / Light Bar Assembly Drawing
36
33
32
31
35
13
5
2
24
5
1
12
9
4
21
30
34
8
14
28
15
29
21
9
1
22
20
26
27
9
3
16
37
21
23
19
7
25
17
18
6
1
10
11
1
9
92 •••• Mechanical Assembly Drawings Users Manual Model 676
Page 93
Web Guide / Light Bar Parts List
ITEM PART NO.
1 374059 SHAFT, SENSOR GUIDE 4
2 374060 SHAFT, WEB GUIDE ADJUST 1
3 374055 SENSOR GUIDE HOLDER 1
4 374061 WEB GUIDE ADJUST 1
5 374051 BRACKET, WEB GUIDE 2
6 374049 BRACKET, LED MOUNT 1
7 374050 BRACKET, SENSOR MOUNT 1
8 514102 ASSY.MOUNT 1
9 999100 BUSHING, FLANGE,3/16 X 5/16 X 1/8 6
10 554059 SHAFT, THEADED LOWER 1
11 554058 SHAFT, SENSOR ADJUST 1
12 554005 DRIVE, WEB GUIDE ADAPTOR 1
13 554004 BRACKET, WEB GUIDE MOUNT 1
14 374058 GEAR, 36T 1
15 554064A DRIVER, SENSOR ADJUS GEAR 2
16 105023K KNOB, IMPRESSION ADJUST 1
17 551169 SENSOR, LED WIRED 1
18 532015 CLAMP, SENSOR 1
19 371128 TOP&BOTTOM REFLECT SENSOR 1
DESCRIPTION QTY
ITEM PART NO.
20 554006 BRACKET, WEB MOUNT, FRONT 1
21 990091 #10-32 X 1/2B.H.C.SCREW 8
22 990424 #4-40 X 3/8 S.H.C. SCREW 1
23 990448 WASHER 1/8 1
24 990090 #10-32 X 3/8 B.H.C.SCREW 4
25 991279 4-40 X 1/8 B.H.C.SCREW 2
26 990016 #6-32 X 3/8 S.H.C.SCREW 1
27 990312 #6 THUMB KNOB 1
28 990262 1/4 SNAP RING 1
29 990007 #4-40 X 1/8 SET SCREW 4
30 990058 #8-32 X 1/4 SET SCREW 1
31 516001 BRACKET, STATIC BRUSH 1
32 989978 #8 STAR WASHER 2
33 355039 STATIC BRUSH 1
34 990066 8-32 X 1/4 BUTTON HEAD CAP SCREW 2
35 990069 #8 HEX NUT 2
36 990119 1/4-20 X 3/8 CAP SCREW 1
37 196028 KNOB, BLACK (GLOSS) 1
DESCRIPTION QTY
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Page 94
Drive Assembly Drawing
7
6
5
11
25
3
2
23
14
18
12
27
13
8
28
4
24
16
2
1
19
21
22
17
26
10
9
20
22
15
6
7
94 •••• Mechanical Assembly Drawings Users Manual Model 676
Page 95
Drive Parts List
Item Part # Description Qty Item Part # Description Qty
1 514009K Spring lever, Front 1
2 990261 Snap ring, 3/16 2
3 514010K Spring lever, Rear 1
4 514002 Slide, Idler shaft 1
5 374044 Bridge plate, Web 1
6 990080 10-32 x 3/8 Cap screw 4
7 990313 Thumb screw knob, #10 4
8 514003 Pin, Spring anchor 2
9 354008A Gear, Idler 1
10 354009A Gear, Driven 1
11 514094 Lift cam ass’y 1
12 374047 Feed knob / SS 1
13 991170A Extension spring 2
14 990023 6-32 x 1/2 Flat head screw 1
15 374016 Bridge blade, Lower 1
16 354094 Roller, Drive ass’y 1
17 991019 Bushing, 3/8 x 3/4 x 1/16 1
18 990416 1/4-20 x 1/2 Flat head screw 1
19 354014 Roller, Molded 1
20 354017 Shaft, Idler 1
21 374087 Ass’y, Outer drive support 1
22 990120 1/4-20 x 1/2 Cap screw 5
23 374088 Ass’y, Rear drive support 1
24 355018 Support, Knife / Drive / Print 1
25 514001 Shaft, Idler roller 1
26 990057 8-32 x 1/8 Knurled cup point 1
27 990058 8-32 x 1/4 Knurled cup point 2
28 514090 Tape roller molded, Ass’y 1
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Page 96
Top Auxiliary Feed Assembly Drawing
2
5
6
7
6
2
5
3
4
1
3
96 •••• Mechanical Assembly Drawings Users Manual Model 676
Page 97
Top Auxiliary Feed Parts List
Item Part # Description Qty
1 374025 Pre-feed plate 1
2 374026 Plate, Support 2
3 990003 4-40 x 1/4 Flat head screw 4
4 991051 4-40 Captive screw 1
5 354022 Spring, Eccentric lift 2
6 999070 Bushing, 3/16 x 5/16 x 5/16 Fl Oilite 2
7 354013 Idler roller, Molded 1
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Page 98
Top - Printhead Assembly Drawing
19
16
15
33
32
14
8
12
1
28
18
21
2
34
23
24
13
36
7
11
37
17
6
3
30
29
31
25
10
26
27
35
9
4
5
22
20
98 •••• Mechanical Assembly Drawings Users Manual Model 676
Page 99
Top - Printhead Parts List
Item Part # Description Qty Item
1 375087 Support rear ass’y 1
2 375085 Support beam print assembly 1
3 990135 1/4-20 x 3/4 Button head screw 1
4 355029 90 Durometer molded roller 636 1
5 356020 Roller, Molded (ink) 1
6 375088 Support front assembly 1
7 375014 Shaft, Head mount 1
8 990083 10-32 x 3/4 Cap screw 1
9 990122 1/4-20 x 3/4 Cap screw 1
10 375005 Plate, Print head mount 1
11 990497 Washer, 1/2" Wave 1
12 990328 Snap ring, 1/2 "e" Ring 1
13 355037 Pin, Pivot ns 2
14 376051 Bracket, Static brush, mount 1
15 376052 Electrical, Static brush bracket 1
16 990448 Washer, .125 x .313 x .031 FL 2
17 991081 Spring, Compression 2
18 991025 6-32 x 3/16 Cone point set screw 2
19 990006 4-40 x 1/4 Cap screw 2
(*NS) = Not Shown
20 371102 Printhead, 676, 300 DPI, LS5405 1
21 376032 Assembly, Ink turn roller 1
22 375016 Plate, Locator, Print head 1
23 375089K3 Printhead holder ass’y kit (sta 3) 1
24 375086 Plate printhead mount 1
25 375021 Block, Head adjust 1
26 375022 Knob, Head adjust 1
27 990325 Snap ring, 3/16 e-Ring 1
28 375043 Knob, Adjustment 2
29 375039 Shaft, Head lock 2
30 989976 Washer, #6 Star 2
31 990019 6-32 x 1/4 Button head screw 2
32 990037 Washer, #6 SAE 2
33 990016 6-32 x 3/8 Cap screw 2
34 375044 Holder, Spring 2
35 990028 6-32 3/8 Flat head screw 1
36 989543 3mm x 6mm Flat head screw 2
37 991124 Spring, Compression 2
Part # Description Qty
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Page 100
Ink-Save Printhead Assembly Drawing
25
24
28
32
18
15
33
12
30
29
5
4
3
35
34
23
20
38
4
19
30
29
37
2
8
1
31
13
10
14
6
7
9
11
21
22
17
36
27
26
16
100 •••• Mechanical Assembly Drawings Users Manual Model 676
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