Paxar 676 User Manual

Users Manual

Model 676

PAXAR Systems Group

Manual Edition 7.1

15 November 2002

Manual Part Number 371398

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Users Manual Model 676

Contents

Scope 6

Introduction ...............................................................................................................................6

Safety Issues / Warnings 6

Caution ......................................................................................................................................6

Warranty Information 7

Description / Specifications 8

Printer Description..................................................................................................................... 8

Printer Specification ..................................................................................................................9

Personal Computer Specifications........................................................................................... 10

Customer Responsibility 11

Location of Printer...................................................................................................................11

AC Power Line ........................................................................................................................12

Printer Unpacking / Installation 12

Unpacking................................................................................................................................ 12

Inventory of Components ........................................................................................................13

Fuse Configuration .................................................................................................................. 14

Installing the Power Cord ........................................................................................................ 15

Installing the PC Interface Cable............................................................................................. 15

Installing the PC Software....................................................................................................... 15

TCB Dip Switch S2 Settings ...................................................................................................15

Printer Operation 16

Loading Stock.......................................................................................................................... 16

Butt Splice ...............................................................................................................................17

Web Guides .............................................................................................................................17

Print Head Operation ............................................................................................................... 18

Installing Ink Ribbon ............................................................................................................... 19

Control Panel Operation 20

Printer Controls........................................................................................................................20

Indicator Lights........................................................................................................................21

Display Modes......................................................................................................................... 23

Adjustments 36

Users Manual Model 676 Scope • 3

Feed Roller Pressure................................................................................................................ 36

Sensors..................................................................................................................................... 37

Sensor Adjustments:................................................................................................................ 38

Print Head................................................................................................................................ 39

Knife squarness........................................................................................................................40

Stacker ..................................................................................................................................... 40

Machine Set Up Sequence ....................................................................................................... 42

Maintenance 43

Cleaning................................................................................................................................... 43

Print Head Handling ................................................................................................................44

Print Head Replacement ..........................................................................................................45

Lubrication Procedure .............................................................................................................47

Electrical Trouble Shooting 48

Power Up / Sign On / Communications...................................................................................48

Stock / Ink Advance ................................................................................................................50

Print .........................................................................................................................................51

Cut / Stack ...............................................................................................................................53

Mechanical Trouble Shooting 54

Stock ........................................................................................................................................ 54

Ink............................................................................................................................................ 56

Print .........................................................................................................................................57

Knife ........................................................................................................................................ 58

Appendix A 60

Error Messages ........................................................................................................................ 60

Appendix B 61

Software Upgrade Chip Placement Positions ..........................................................................61

Front Panel Diagnostic Descriptions .......................................................................................63

Appendix C 64

Ink and Stock Transfer Types.................................................................................................. 64

Appendix D 67

Knife MFG Guideline.............................................................................................................. 67

Appendix E 70

Printhead Life Extension .........................................................................................................70

Printhead Fail Modes...............................................................................................................71

Printhead Cleaning Procedure .................................................................................................72

Printhead Installation and Removal Procedures ......................................................................73

Static Checks for 636/656 Printers .......................................................................................... 74

Print Quality Adjustment......................................................................................................... 76

Appendix F 77

4 • Scope

Platen Rollers for 6x6 and 676 Printers................................................................................... 77

Electrical Assembly Drawings 82

Machine Wiring....................................................................................................................... 82

Electrical System Schematic.................................................................................................... 83

Motherboard Power Connectors.............................................................................................. 84

Mechanical Assembly Drawings 85

Unwind Assembly Drawing ....................................................................................................86

Unwind Parts List ....................................................................................................................87

Web Guide / Light Bar Assembly Drawing.............................................................................88

Web Guide / Light Bar Parts List ............................................................................................ 89

Drive Assembly Drawing ........................................................................................................ 90

Drive Parts List........................................................................................................................ 91

Top - Printhead Assembly Drawing ........................................................................................ 92

Top - Printhead Parts List........................................................................................................ 93

Ink-Save Printhead Assembly Drawing................................................................................... 94

Ink - Save Printhead Parts List ................................................................................................95

Bottom - Printhead Assembly Drawing................................................................................... 96

Bottom - Printhead Parts List ..................................................................................................97

Ink Unwind Assembly Drawing .............................................................................................. 98

Ink Unwind Parts List.............................................................................................................. 99

Ink Rewind Assembly Drawing.............................................................................................100

Ink Rewind Parts List ............................................................................................................ 101

Ink Rewind w/Head-Lift Assembly Drawing........................................................................ 102

Ink Rewind w/Head-Lift Parts List........................................................................................ 103

Ink Rewind - Station 3 - 1 over 1 - Assembly Drawing ........................................................104

Ink Rewind - Station 3 – 1 over 1 - Parts List ....................................................................... 105

Knife Assembly Drawing ...................................................................................................... 106

Knife Parts List...................................................................................................................... 107

Stacker Assembly Drawing (Part 1) ...................................................................................... 108

Stacker Parts List (Part 1)...................................................................................................... 109

Stacker Assembly Drawing (Part 2) ...................................................................................... 110

Stacker Parts List (Part 2)...................................................................................................... 111

Rewind Assembly Drawing................................................................................................... 112

Rewind Parts List................................................................................................................... 113

Optional 4 1/4” Stacker Specifications.................................................................................. 115

Optional 4 1/4” Pick-up Assembly ........................................................................................ 116

Optional 4 1/4” Pick-up Parts List......................................................................................... 117

Optional 4 1/4” Stacker Assembly.........................................................................................118

Optional 4 1/4” Stacker Parts List ......................................................................................... 119

Drive Belt Routing (2 over 1) Drawing................................................................................. 120

Drive Belt Routing (2 over 1) Parts List................................................................................ 121

Drive Belt Routing (1 over 1) Drawing................................................................................. 122

Drive Belt Routing (1 over 1) Parts List................................................................................ 123

Users Manual Model 676 Scope • 5

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 PAXAR hope that you will come to appreciate the efforts and quality which
have gone into producing your PAXAR 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

Warranty Information

Limited Warranty

PAXAR Systems Group, Division of PAXAR Corporation, extends the following
warranties to the original purchaser of a PAXAR 676 which has been installed and
operated using recommended procedures and operating conditions.

Parts

Parts found defective in material or workmanship will be replaced at no charge for a
period of six months following the machine's shipment date. Parts damaged by
negligence, abuse, or normal wear are not covered. PAXAR 676 parts classed as
normal wear items include print heads, feed and platen rollers, and knife blades.

Service

Service to replace defective parts as defined above, shall be provided at no charge
for a period of six months following the shipment date.

When ordering machines and supplies in the U.S.A., reference all correspondence to
the address below.

PAXAR Corporation

One Wilcox Street

Sayre, Pa. 18840

Call: 1-800-96PAXAR or [phone]

Fax: [phone]

For spare parts, requests for service or technical support

Paxar Service Group

170 Monarch Lane

Miamisburg, OH 45342

Call: [phone]

Fax: [phone] for Warranty Parts

Fax: [phone] or [phone] for Customer Parts Orders

For parts and service in other countries please contact your local PAXAR supplier.

PAXAR Apparel Identification Systems Group reserves the right to incorporate any
modifications or improvements in the machine system and machine specifications
which it considers necessary and does not assume any obligation to make said
changes in equipment previously sold.

Users Manual Model 676 Warranty Information • 7

Description / Specifications

Printer Description

The PAXAR 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 PAXAR’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

8 • Description / Specifications

Figure 1 - PAXAR MODEL 676 LABEL PRINTER

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 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 PAXAR 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)

Users Manual Model 676 Description / Specifications • 9

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 PAXAR standard thermal colors and widths

Options - VL70 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

Personal Computer Specifications

This specification describes the hardware and application software requirements for
the Personal Computer that is connected to the PAXAR 676 Printer.

The PAXAR 676 Printer uses a DOS Version of PCMate or a Windows version of
“PcMate Plus / Formatter ”. These applications 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® 95 or higher (Including Win 2000, ME, and NT)

- 16 Megabytes RAM (minimum) - 32 Megabytes recommended

- 50 Megabytes (minimum) free disk space

- Pentium or Pentium Type processor - 200 Mhz or higher

- 3-1/2" floppy drive

Refer to your specific software package for proper installation procedures.

10 • Description / Specifications

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. PAXAR
recommends an industrial type work table 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 PAXAR 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. PAXAR 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 PAXAR 676 printer is a high-resolution thermal printer. While PAXAR 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 • 11

AC Power Line

PAXAR 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 which is supplying a PAXAR printer or peripheral equipment
connected to a PAXAR printer should follow standard electrical code practices
including proper grounding and neutral requirements.

The PAXAR printer was designed to operate in an industrial setting for extended
periods of time; however, the printer is controlled by a microprocessor which is very
sensitive to brownouts or power spikes. For this reason as well as the minimum
recommended current supply, PAXAR recommends that a separate “clean” service
be installed or reserved for the exclusive use of the PAXAR printer and it’s
peripherals.

Printer Unpacking / Installation

Unpacking

The PAXAR printer is shipped in a large plywood crate which 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 PAXAR 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.

12 • Printer Unpacking / Installation

Inspect the machine for shipping damage. If obvious damage is discovered, contact
PAXAR for further instructions - in the U.S.A. at (570)-888-9116. In countries
other than the U.S.A. please contact your local PAXAR supplier.

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) which should be included in
your PAXAR 676 shipping crate. If anything is missing, notify PAXAR
immediately - in the U.S.A. at (570)-888-9116. In countries other than the U.S.A.
please contact your local PAXAR supplier.

- PAXAR 676 "User's Manual" (See tool kit below)

Figure 3 Shipping Crate.

- Stacker assembly

- A quick-disconnect power cord

- A serial communications cable with converter

- Optional IC card for custom Logos or additional fonts that were special ordered.
(in the back of the manual)

- Optional software ordered to drive the printer.

- Tool kit

NOTE: Some of the above parts may be inside of the envelope which contains the

tool kit.

PAXAR 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 • 13

Fuse Configuration

The main fuse(s) on the Paxar 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

it will cause damage to the AC entry.

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

180 - 265VAC @ 50 - 60Hz 1 Ph

1) Install two 921168 10.0A 250V Fast Acting 5 x 20MM

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

4) Reinsert the fuse drawer into the AC entry with the desired voltage up.

5) Close the AC entry and verify the correct voltage is now visible.

14 • Printer Unpacking / Installation

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. Paxar 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 order from PAXAR (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 Paxar family of printers is covered in separate
documentation. The "Formatter" software to create formats for the Paxar 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
Paxar 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 Paxar'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

DISABLE OFF

® OFF

300 ON

Users Manual Model 676 Printer Unpacking / Installation • 15

Printer Operation

Loading Stock

LOADING STOCK FOR THE FIRST TIME

Figure 4 - Stock Threading

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. Keep the stock in the center,
as the printer is center justified.

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 maybe 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.

16 • Printer Operation

Butt Splice

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 PAXAR 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.

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.

Web Guides

The Paxar 676 printer has been designed with the operators needs in mind.
Therefore there are only two 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
stock. If a large distance is to be covered loosen the plastic thumb screw and slid the
collar into the new position then retighten the thumbscrew. Fine adjustments of the
stocks web position can be made by simply moving the collar as a set in or out. If
the guides are too tight, the stock will have rolled up edges.

Users Manual Model 676 Printer Operation • 17

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.

18 • Printer Operation

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).

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.

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.

Users Manual Model 676 Printer Operation • 19

Control Panel Operation

Printer Controls

20 • Control Panel Operation

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.

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 Paxar 676 has three Indicator lights. These lights are used along with the LCD
display to tell the operator the current status of the printer.

Users Manual Model 676 Control Panel Operation • 21

On Line

OFF

- Has not been powered on.

- Is in it's power - up sequence.

- Failed the system test

After Power Up Sequence:

- Printer is running.

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.

22 • Control Panel Operation

Display Modes

READY FOR BATCHES

676 / 300

BATCH I D QUANT I TY
PCL001 10

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

Press the MODE/Down arrow button will cycle the panel through the following
main screens.

PRINTER ADJUSTMENTS

PRESS ENTER FOR
PR I NT / CUT POS I T I ONS

PRINTHEAD ADJUSTMENTS

PRESS ENTER FOR
PR I NT HEAD SETUP

CALIBRATE SENSORS

PRESS ENTER FOR
CAL I BRAT I NG SENSORS

LIFE COUNTS/VERSIONS

PRESS ENTER FOR
L I FE COUNTS /VERS IONS

Users Manual Model 676 Control Panel Operation • 23

SETUP SCREEN

PRESS ENTER FOR
FEATURE SETUP

VERIFIER SETUP SCREEN

PRESS ENTER FOR
VER I F I ER SETUP

POWER UP DIAGNOSTICS

D I AGNOST I C T ES 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:

(BUT TON NAME ) KEY STUCK

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 AGNOST I C T ES T # # #
TCB VERS ION 00 . 00

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.

24 • Control Panel Operation

HOME SCREEN

READY FOR BA TCHES

676 / 300

OR

BATCH I D QUANT I TY
PCL001 10

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

FEED I NG

PR I NT I NG TEST PAT TERN

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.

Users Manual Model 676 Control Panel Operation • 25

PRINT/CUT POSITIONS

PRESS ENTER FOR
PR I NT / CUT POS I T I ONS

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

PRESS ENTER TO
PR I NT CHECKOUT FORMAT

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.

PR I NT POS I T I ON STAT I ON 1
VALUE : ±XX NEW VALUE : ± YY

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.

PR I NT POS I T I ON STAT I ON 2
VALUE : ±XX NEW VALUE : ± YY

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.

26 • Control Panel Operation

PR I NT POS I T I ON STAT I ON 3
VALUE : ±XX NEW VALUE : ± YY

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.

CHANGE CUT POS I T I ON
VALUE : ±XX NEW VALUE : ±YY

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.

STAT ION 2 DOT SH I FT
VALUE : ±XX NEW VALUE : ± YY

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

PRESS ENTER FOR
PR I NTHEAD SE TUP

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.

Users Manual Model 676 Control Panel Operation • 27

CHANGE STROBE STA T I ON 1
VALUE : ±XX NEW VALUE : ± YY

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.

CHANGE STROBE STA T I ON 2
VALUE : ±XX NEW VALUE : ± YY

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.

CHANGE STROBE STA T I ON 3
VALUE : ±XX NEW VALUE : ± YY

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.

HEAD CAT EGORY STAT I ON 1
VALUE : ±XX NEW VALUE : ± YY

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.

28 • Control Panel Operation

HEAD CAT EGORY STAT I ON 2
VALUE : ±XX NEW VALUE : ± YY

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.

HEAD CAT EGORY STAT I ON 3
VALUE : ±XX NEW VALUE : ± YY

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.

STAT ION ACT I VAT I ON 12 3
CLOSE HEADS PRESS ENTER

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 STATION3 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.

Users Manual Model 676 Control Panel Operation • 29

CALIBRATE SENSORS

PRESS ENTER TO
CAL I BRAT E SENSORS

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.

HOL E / SLOT I N SENSOR
VALUE: 000 NEW VALUE:000

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.

HOL E / SLOT NOT I N S ENSOR
VALUE: 000 NEW VALUE:000

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.

TOP REF L OVER MARK
VALUE: 000 NEW VALUE:000

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.

TOP REF L NOT OVER MARK
VALUE: 000 NEW VALUE:000

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.

30 • Control Panel Operation