Avery LOKPRINT II User Manual
Users Manual
LOKPRINT
II
Industrial Apparel
Label Station
Operation / Maintenance
And Parts List
AVERY DENNISON
Manual Edition 4.0
9 June 2010
Manual Part Number 561398
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ii •••• Users Manual LOKPRINT™ II
Contents
Scope 5
Introduction................................................................................................................................ 5
Safety Issues / Warnings 5
Caution....................................................................................................................................... 5
Heaters.........................................................................................................................5
Feed Roller .................................................................................................................. 5
Warranty Information 6
Location / Power Requirements 8
Location of LOKPRINT™ II System........................................................................................8
Recommended Work Station Layout........................................................................... 8
AC Power Line .......................................................................................................................... 8
LOKPRINT™ II Main Line Protection....................................................................... 9
LOKPRINT™ II Internal Fuse Configuration ...........................................................................9
Branch Circuit Protection ............................................................................................ 9
Unpacking / Inventory 10
Unpacking................................................................................................................................ 10
Inventory of Components......................................................................................................... 11
Recommended Spare Parts ...................................................................................................... 11
LOKPRINT™ II Assembly 12
Installation Setup Procedure .................................................................................................... 12
System Interface Cable Connections........................................................................................ 13
Installing the Power Cord ........................................................................................................13
Product Description 14
Theory of Operation................................................................................................................. 14
Description of Operation ......................................................................................................... 14
Hands free operation.................................................................................................. 14
Interlocks ................................................................................................................... 14
LOKPRINT™ II Specification ................................................................................................ 15
LOKPRINT™ II Operation / Adjustments 16
Jam Sensor................................................................................................................. 16
Ventilation ................................................................................................................. 17
Feed Roller ................................................................................................................ 18
Web Threading ........................................................................................................................ 18
Heat Chamber Care.................................................................................................................. 19
Feed Roller Care ...................................................................................................................... 19
Users Manual LOKPRINT™ II •••• 3
Lamp Replacement Procedure 20
Drive Cable Replacement Procedure 22
Installing the Drive Cable at the Capstan ................................................................................. 22
Troubleshooting 23
Interlock Trouble Shooting Guide ...........................................................................................24
Electrical Schematic 27
115 / 230 Volt Schematic......................................................................................................... 28
Mechanical Assembly Drawings 29
Cover Assembly.......................................................................................................................30
Cover Parts List........................................................................................................................31
Baffle Assembly.......................................................................................................................32
Baffle Parts List .......................................................................................................................33
Air Filter Assembly..................................................................................................................34
Air Filter Parts List ..................................................................................................................35
Web Guide Assembly ..............................................................................................................36
Web Guide Parts List ............................................................................................................... 37
Drive Assembly........................................................................................................................ 38
Drive Parts List ........................................................................................................................39
Feed Assembly.........................................................................................................................40
Feed Parts List .........................................................................................................................41
Controller Assembly ................................................................................................................ 42
Controller Parts List .................................................................................................................43
Heat Chamber Assembly..........................................................................................................44
Heat Chamber Parts List .......................................................................................................... 45
Slide Mechanism Assembly ..................................................................................................... 46
Slide Mechanism Parts List...................................................................................................... 47
Cable Routing Diagram............................................................................................................48
Home Sensor Assembly ...........................................................................................................50
Home Sensor Parts List............................................................................................................ 51
4 •••• Users Manual LOKPRINT™ II
Scope
Introduction
This user manual was arranged for the person who is going to operate the system.
The information is arranged in the order that is needed to install, and then operate the
system. It starts with general information, then to unpacking the carton, setup,
installing the supplies, machine operation, and then finally care and maintenance.
We at AVERY DENNISON hope that you will come to appreciate the efforts and
quality that have gone into producing your AVERY DENNISON LOKPRINT™ II
System 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
products in the industry for years to come.
Safety Issues / Warnings
Caution
This system has some pinch points and hot surfaces. All of these areas have been
well guarded and it is recommended that the safety features of this system are never
altered or defeated.
Heaters
The heat chamber has been designed to prevent the operator from coming into
contact with areas that will cause burns during normal operation. Some surfaces are
very warm to the touch. The IR lamps and internal lamp guards are extremely hot.
Extra care should be taken when threading the machine while the machine is turned
on. Any maintenance or cleaning should be done after the machine has been turned
off and allowed to cool.
Feed Roller
The feed rollers will absorb heat from the web as the machine runs. These rollers
have a self-closing cover to avoid contact during operation. The feed system is also
equipped with an operator knob to advance the fabric forward and backwards as
needed to avoid touching the hot rollers.
CAUTION: TURN OFF THE POWER AND ALLOW THE MACHINE TO COOL
BEFORE CLEANING.
Users Manual LOKPRINT™ II Scope •••• 5
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.
6 •••• Warranty Information Users Manual LOKPRINT™ II
− 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.
Users Manual LOKPRINT™ II Warranty Information •••• 7
Location / Power Requirements
Location of LOKPRINT™ II System
AC Power Line
Recommended Work Station Layout.
The LOKPRINT™ II requires a workstation with a minimum worktable of 30”
(76.2cm) deep x 96” (243.8cm) long x 30” high (adjustable height may be desired
depending on if the operator will be standing or seating). The worktable does not
include a space for the computer. The table must be capable of supporting 300 Lbs.
(136.1Kg).
The LOKPRINT™ II should be installed with the alignment template included to
ensure the fabric tracks properly from the printer into the LOKPRINT™ II. Locate
the Finishing Station or Cold Knife Cutter as close to the exit of the LOKPRINT™ II
as possible without restricting its dancer arm travel.
The LOKPRINT™ II requires an electrical service of 20A @ 115V or 10A @ 230V
and must be purchased as a 115 or 230 volt electrical configuration. Check the
machine’s serial number plate to make sure the machine is the desired electrical line
voltage. Power consumption is 18 amps @ 115 volts and 9 amps @ 230 volt.
Connect the power cord to a grounded 115 or 230 volt AC electric outlet of sufficient
8 •••• Location / Power Requirements Users Manual LOKPRINT™ II
power. Because of the higher current draw of the LOKPRINT™ II, the printer /
Finishing Station or Cold Knife should be on a separate electrical service of 15A.
Refer to the Printer and Finishing Station or Cold Knife serial number plates for their
line requirements. Please check with your local electrical code and have the system
wired by a qualified electrician.
LOKPRINT™ II Main Line Protection
The LOKPRINT™ II main AC power switch also serves as a resettable circuit
breaker. The 115V machine incorporates a 20A breaker while the 230V machine
uses a 10A breaker.
LOKPRINT™ II Internal Fuse Configuration
Branch Circuit Protection
Both controllers and the feed motor drive circuit have a 5x 20mm fuse as per the
following chart.
Device Fuse
Designator
U1 F3 990754 1.0A 250V FA
U2 F4 990754 1.0A 250V FA
Web
F6 990915 1.6A 250V TL
Feed
Motor
AVERY
DENNISON Part #
115 VAC &
230VAC
5x20mm
5x20mm
5x20mm
Users Manual LOKPRINT™ II Location / Power Requirements •••• 9
Unpacking / Inventory
Unpacking
The AVERY DENNISON equipment is shipped in a large cardboard box, which may
be difficult to move by hand.
DO NOT REMOVE THE MACHINE FROM THE BOX OR UNPACK IN
THE SHIPPING / RECEIVING DEPARTMENT.
NOTE: Unpacking in the shipping/receiving department is not recommended for the
following reasons.
First: The cardboard carton in which your AVERY DENNISON equipment was
shipped allows the machine to be moved with a forklift, forkcart or
handcart. Because of the weight of the machine, it is easier and safer to
use one of these devices to move the equipment to its intended
installation location.
Second: Leaving the machine in the carton while it is being moved within your
facility will help to protect the equipment during any movements to this
location. Once the equipment has reached its intended location you
should begin the unpacking process.
Open the carton from the top. Do not cut deep into the carton, as there are items
located just under the top. Remove the items located on the top insert. Remove the
top insert. Lift the machine onto the table with the two banding straps. Remove the
two straps and the plastic from the machine. Inspect the machine for shipping
damage. If damage is discovered, contact AVERY DENNISON for further
instructions - in the U.S.A. at (570) 888-6641. In other countries please contact your
local AVERY DENNISON supplier. Once you are satisfied that there was no
obvious shipping damage, the machine can now be moved to its intended location. In
some cases, a double box has been used to ship your machine.
Shipping Carton.
Save the shipping materials to relocate the equipment or return to factory for service.
10 •••• Unpacking / Inventory Users Manual LOKPRINT™ II
Inventory of Components
The following is a list of additional parts (pieces) that should be included in your
LOKPRINT™ II shipping container. If anything is missing notify AVERY
DENNISON immediately – in the U.S.A. at (570) 888-6641. In other countries
contact your local AVERY DENNISON supplier.
– AVERY DENNISON LOKPRINT™ II “User’s Manual”.
– Quick-disconnect power cord.
– Printer / LOKPRINT™ II positioning template.
Recommended Spare Parts
The following spare parts are recommended for each facility that has a
LOKPRINT™ II
Spare Parts Kit 560010 120V / 230V contains the following parts.
Part # Description Qty
224045 Timing belt 1/5P 72T 1
561120 Elec, Quartz lamp, Harnessed 4
564010 Spring, Feed, Right 2
564011 Spring, Feed, Left 2
564030 Assembly, Grit roller, Upper 1
564031 Assembly, Grit roller 1
990754 Fuse, 1.0A 250V F.A. 5 X 20mm 2
991113 Drive, Timing belt, 54T X ¼” 1
Users Manual LOKPRINT™ II Unpacking / Inventory •••• 11
LOKPRINT™ II Assembly
Installation Setup Procedure
1) Assemble the system components and connect all the interface cables between
the three components.
2) Check / set the Printer TCB DIP switches for a 676 with stacker jam disabled (1,
3, and 4 ON / all others OFF).
3) Power on the Printer, Lokprint II, and Finishing Station for warm up.
4) While the Lokprint II Ready light is still off close the Lokprint II and Finishing
Station guards, raise the Finishing Station stacker platform, and check / enter the
value for Calibrate Sensor “Stacker Not Blocked” on the 676. This value should
be somewhere around “40”. Once the ready light comes on check / enter the
value for “Stacker Blocked”. This value should be somewhere around “225”.
5) Load fabric and ink on the Printer, advance the fabric though the Lokprint II.
6) Once all interlocks are satisfied press the start button on the printer to clear any
remaining errors, the front panel should now read “Ready For Batches / Lokprint
II”.
7) Download data to the Printer, this format should include a printed sense mark for
the Finishing Station to register.
8) Press start again and allow the system to run until there are sufficient printed
labels to thread and register in the Finishing Station.
9) Thread the Finishing Station and align the sensor / sense mark for registration.
The sense mark must be the first thing the sensor sees when you start the
Finishing Station.
10) Set the Finishing Station settings on its front panel as needed for the format and
start the Finishing Station in order to remove the slack between the Lokprint II
and the Finishing Station. The Speed adjustment should be set to provide
constant tension on the fabric between the Lokprint II and the Finishing Station
with the least Finishing Station stopping and starting.
11) Start the system, while running take note of the Lokprint II oven position in
relation to the oven insulation strip secured to the Plexiglas guard. The oven
should fully engage the strip squarely from one end of the oven to the other. The
oven position is controlled by a C sensor sensing a metal flag bolted to the back
of the outer oven. Check / adjust the sensor position as needed to cause the oven
to travel to the desired position. The guard insulator strip can be adjusted up or
down as needed by loosening it’s mounting hardware and relocating it
accordingly.
The Lokprint II back cover will need to be removed to make the sensor
adjustment. Do not attempt to run the system with the cover removed, as the
process will over heat for lack of controlled airflow around the oven.
12) Check / adjust both guard switch bales as needed to cause both switches to
trigger only when the guard is closed.
12 •••• LOKPRINT™ II Assembly Users Manual LOKPRINT™ II
13) Once the oven position has been checked / adjusted - run the system and take
note of the fabric position in relation to the oven as it enters the oven. Adjust the
Lokprint II box forward or backwards on the bench in relation to the printer
using the template / mount knob. The web position collars on the 676 are more
for a reference then position. Do not use them to deflect the web, as wrinkling
will occur. Do set them to the web edges after the Lokprint II position has been
adjusted to cause the fabric to flow into the oven centered front to back.
14) Once the Lokprint II position has been checked / adjusted - run the system and
adjust the Finishing Station on the bench forward or backwards in relation to the
Lokprint II box so that the fabric flows straight into the Finishing Station’s web
guides.
15) Using the CALIBRATION PROCEDURE section of IS 561301 Rev 2 or higher
check / adjust U1 and U2 offsets as needed to produce and monitor the exit
temperature at 400° while running stabilized.
Note: Requires AVERY DENNISON Service
16) Using the SP2 ADJUSTMENT PROCEDURE section of IS 561301 Rev 2 or
higher check / adjust U1 SP2 as needed to transition from idle to running without
deforming the fabric or dipping in process temperature.
Note: Requires AVERY DENNISON Service
System Interface Cable Connections
Connect both the 7 and 15 pin cable connectors located on the left side of the
LOKPRINT™ II to the host printer. Connect the 7-pin cable connector located on
the Finishing Station or Cold Knife to the 7-pin receptacle located on the right side of
the LOKPRINT™ II.
Installing the Power Cord
Both the 115V and 230V machines incorporate a quick disconnect power cord. The
115V cord requires a NEMA 5-20R receptacle while the 230V cord requires a
NEMA 6-15R receptacle. Install the receptacle end of the power cord in the plug on
the back of the machine then insert the plug end of the cord in the appropriate wall
outlet.
Users Manual LOKPRINT™ II LOKPRINT™ II Assembly •••• 13
Product Description
Theory of Operation
The LOKPRINT™ II was designed to receive labels printed on both sides from a
AVERY DENNISON 676 printer or one sided from a AVERY DENNISON 636
printer using dye sublimation inks. The LOKPRINT™ II dye sublimates the labels
and feeds a Finishing Station for ultrasonic or cold knife cutting. The LOKPRINT™
II is equipped with four infrared (IR) quartz heating bulbs and two non-contact IR
heat sensors with one PID controller controlling the process and a second monitoring
the fabric temperature. The PID controller controls an SCR that regulates the energy
provided to the quartz bulbs, which produces the heat. The PID control, IR sensor,
SCR, and quartz bulbs are all part of an automatic, “closed loop” system to ensure
fully sublimated labels.
Once connected, all components of the LOKPRINT™ II act as a system, including
the Printer, LOKPRINT™ II and the Finishing Station. Optimum dye sublimation
occurs between the temperatures of 400° - 420° F (205° - 215.5° C) inside the heat
chamber. The LOKPRINT™ II will shut the printer down if the web temperature
drops below 400° F (205° C). This closed loop system approach ensures maximum
sublimation and minimum label waste.
Description of Operation
Hands free operation
Once the LOKPRINT™ II has been threaded, very little operator input is needed. As
the fabric moves through the heat chamber - the PID controllers control and monitor
the web temperature according to web speed. The LOKPRINT™ II is threaded with
the heat chamber in a parked (back) position. When the printer’s start button is
pushed, the heat chamber will move forward to the operating position that covers the
web - heating it to the desired temperature.
If the “stop” button on the printer is pushed or if the system shuts down
automatically, the heat chamber will move back to the parked position.
Interlocks
During operation, the LOKPRINT™ II will shut down the system automatically, if
one or more of the following conditions exist. See the Printer and or Finishing
Station manuals for their interlocks.
(1) Power lost to the LOKPRINT™ II.
(2) LOKPRINT™ II power switchable circuit breaker exceeds safe
current or temperature levels.
(3) Oven didn’t reach the operating position in time at startup.
(4) No web in web sensor.
(5) Heat chamber thermostat temperature exceeds safe limit.
14 •••• Product Description Users Manual LOKPRINT™ II
(6) Web under temperature alarm.
(7) Oven over temperature alarm.
(8) Guard open.
The recommended room temperature for the system is 60°F (15.5°C) to 90°F
(32.2°C). If a cooling system is required it should not be pointed directly at the
system to create drafts that could affect the sublimation process.
LOKPRINT™ II Specification
Sublimation method: Non-contact
Narrow polyester web
Dye sublimation thermal transfer inks
Web speed: Speed – 5 IPS - (127mm/second)
Web Size: Min: 1.062" (27mm)
Max: 2.0" (50.8mm)
Feed length: No restrictions on the LOKPRINT™ II station
Cutting: No cutter included in LOKPRINT™ II station
Interface: AVERY DENNISON 636LKP (one sided)
AVERY DENNISON 676LKP (2 over 0, 1 over 1 and 2 over 1) thermal printers
Finishing method
interface:
Dimensions 13.5" (34.5cm) high x 26.5" (67.3cm) wide x 23.5" (59.7cm) deep
Weight 58 Lbs. (26.3Kg.) Shipping Weight = 81 Lbs. (36.7Kg.)
Electrical 115 volt system: 90-132 VAC 50-60Hz 20Amp 1 Phase.
Temperature
Humidity 5% to 90% non-condensing
SS Finisher (ultra sonic cutter with stacker)
Cold knife (cutter and stacker)
12” Rewind
230 volt system: 180-265 VAC 50-60Hz 10Amp 1 Phase.
60°F (15.5°C) to 90°F (32.2°C)
Patent pending
Users Manual LOKPRINT™ II Product Description •••• 15
LOKPRINT™ II Operation /
Adjustments
JAM SENSOR
Jam Sensor
The jam sensor (illustrated with the bridge removed) is looking for the presence of
the fabric for the printer to start and continue to operate. If the fabric in not present,
the system will not start and the printer front panel will display a message “Check
Stacker”. If the fabric breaks during operation and pulls out of the sensor, the system
will stop and printer front panel will again display “Check Stacker”. If the web sags
more than the feed can take up before the heat chamber moves to the run position, the
web may be pushed out of the jam sensor and stop the system.
16 •••• LOKPRINT™ II Operation / Adjustments Users Manual LOKPRINT™ II
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