Paxar 676 User Manual Download

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Control Panel Operation

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.

Summary of Contents for 676

Page 1: ...Users Manual Model 676 PAXAR Systems Group Manual Edition 7 1 15 November 2002 Manual Part Number 371398 ...

Page 2: ...Users Manual Model 676 This page intentionally blank ...

Page 3: ... 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 Pri...

Page 4: ...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 Pr...

Page 5: ...arts 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 S...

Page 6: ...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 machin...

Page 7: ...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 570 888 6641 Fax 570 888 5230 For spare parts requests for service or technical support Paxar Service Group 170 Monarch Lane Miamisburg ...

Page 8: ... 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 i...

Page 9: ...ent 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 b...

Page 10: ...tration 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 ...

Page 11: ...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 PAX...

Page 12: ...d 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 w...

Page 13: ... 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 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 ...

Page 14: ...ry 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 L...

Page 15: ...ed 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 origi...

Page 16: ...ine 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 A...

Page 17: ...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 fo...

Page 18: ...int 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 ANTI STATIC GLOVES AND THE ANTI STATIC WRIST STRAP To open the print heads for threading supplies or cleaning pulling the release knob and then rotating the print head into the op...

Page 19: ...ated 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 rol...

Page 20: ...TART 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 ...

Page 21: ... 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 Indicator Lights 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 On Line OFF Has not been powered on I...

Page 22: ...er 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 ...

Page 23: ... HOME SCREEN 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 Q U A N T I T Y P C L 0 0 1 1 0 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...

Page 24: ...link 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 ENT...

Page 25: ...ys 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 res...

Page 26: ...g 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 N...

Page 27: ...ll 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 directio...

Page 28: ...xt 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 a...

Page 29: ...ll 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 a...

Page 30: ...ks 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...

Page 31: ... 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 ...

Page 32: ...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 T C B 1 0 9 3 4 This screen fo...

Page 33: ...on 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 ...

Page 34: ...ANSFER 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 TYPE3 screen This screen allows the front panel display language to be changed Use the YES and NO keys to mo...

Page 35: ...git 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 wit...

Page 36: ...th the stock feed lever closed fully counter clockwise 4 Add 1 2 turn to each of the 9 64 cap screws from the previous adjustment 5 Reload the production stock through the feed module 6 Run the checkout format found in the Printer Adjust Mode on the front panel and further adjust the two 9 64 cap screws an equal amount based on the results as follows Using the scribe marks on the front of the mach...

Page 37: ...ck 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 bar 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 n...

Page 38: ...urns on with the registration sensor over the media in the vicinity of the hole slot and stays on the sensor is over the registration hole or slot 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 scree...

Page 39: ...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 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 ap...

Page 40: ...r 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 squarness 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 e...

Page 41: ...ed 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 s...

Page 42: ...he 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 first check and adjust as needed the unwind and the collars on the decurler then if needed adjust the feed pressure from side to side until it is Re verify that the label is 11 0 in length If the print quality is inadequate refer back to step num...

Page 43: ...asive to the head NEVER use anything metallic on or near the printhead Alcohol and a cotton swab are the recommended items to use when cleaning the printhead RECOMMEND PAXAR 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 mu...

Page 44: ...ght 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 Paxa...

Page 45: ...elp 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 screw driver 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 end play If there is end play...

Page 46: ...TEGORY 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 th...

Page 47: ...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 Compositi...

Page 48: ... s located inside the AC entry are present and intact Replace as needed Refer to the Fuse Configuration Machine fails to power up with light present in the AC power switch 1 Unconnected cable connector inside machine 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 Schemat...

Page 49: ...o that the ejector button pops out Machine does not receive batches 1 Serial communications cable loose or unconnected 1 Check and secure both ends of the serial cable with the thumb screws 2 Machine not powered on or has not completed diagnostics tests 2 Power machine on and wait until machine displays Ready for batches Re download data 3 Data sent to wrong printer 3 In PCMate change to the print...

Page 50: ...sure 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 stock will pull through the printer with little to no resistance 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 s...

Page 51: ...ck Head Driver Board AT board connection and or replace Head Driver Board Machine stops after ever third label 1 Stock registration sensor miss aligned 1 Adjust sensor position so that the sensor light on the front panel flashes as a sense slot or hole passes under the sensor 2 Stock registration sensor uncalibrated 2 Recalibrate the sensor from the front panel using the Calibrate Sensors mode Ref...

Page 52: ...ad pressure 4 Set print head pressure Refer to Print Head Pressure Setting Voids in print image in the feed direction 1 Ink misaligned with format 1 Adjust ink position on the arbors to achieve full ink coverage over all fields on the format 2 Print head dirty 2 Power off the machine clean the print head and platen Refer to Print Head Cleaning 3 Faulty print head 3 After cleaning head and running ...

Page 53: ...ammed causing auto resetting fuse to trip on the Thermal Control Board 3 Remove cause of jam at the knife 4 Faulty knife motor 4 Replace the knife motor 5 Faulty knife motor drive circuit on the Thermal Control Board 5 Replace the Thermal Control Board The stacker fails to run 1 The stacker cable is unconnected 1 Power off and insert the stacker cable in the stacker port on the Thermal Control Boa...

Page 54: ...eb guides on unwind arm too tight 1 Adjust web guides to touch outer edges of stock with minimum pressure required to keep stock out switch closed 2 Web guides on decurler arm too tight 2 Adjust collars on decurler bar to touch edge of stock 3 Stock is slipping in drive or drive pressure is uneven 3 Remove stock from drive rollers Using a piece of stock the same thickness as the stock being run as...

Page 55: ...and moves easily in the bearing slots Will not stack 1 Stacker not operating 1 See step 3 above 2 Stacker position on machine too far forward so labels go under rear stacker rail 2 Loosen stacker mounting knob and move stacker toward rear of machine tighten 3 Incorrect rail position or stacker bed angle 3 Using a cut label position stacker rails so that approximately 3 8 9 5mm overhangs the second...

Page 56: ...t until it touches rear of ink roll on unwind arbor Lock slide rewind core toward rear of printer until it just contacts plate 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 printed This is especially critical when using a narrow web with cut down rollers Ink rolls loosely on take up roller 1 Take up roller not turning 1 Assure r...

Page 57: ...e Action Poor print uneven or no print mechanical Also see electrical trouble shooting 1 Incorrect tangent position 1 Refer to tangent adjust procedure in Print Head section 2 Broken ink 2 Replace ink and readjust see INK trouble shooting 3 Ink not rewinding 3 Readjust see INK trouble shooting ...

Page 58: ...ch stop roll pin File off burr on clutch roll pin and or replace trip arm 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 Packman not visibly homing 1 Adjust Packman to center the home location of the...

Page 59: ...an clutch and replace if not solved Stock popping in front of knife 1 Slow knife rotation 1 Worn out blades create too much load for motor and knife slows down too much during cut Replace Blades 2 Clutch has trouble engaging and stock runs into 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...

Page 60: ...ENS 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 X X E R R O R S I N K O U T 9 0 4 X X E R R O R S H E A D O R F E E D O P E N 9 1 0 X X E R R O R S M I S S E D S E N S E M A R K 7 O 1 X X E R R ...

Page 61: ...1 Appendix B Software Upgrade Chip Placement Positions Thermal Control Board P N 371105TT U36 U 23 U 21 U 4 U 3 U 18 U 19 U 20 U 22 THERMAL CONTROL BOARD Align angled corners of chip with socket and arrow denotes pin 1 or dimple on chip ...

Page 62: ...nual Model 676 Head Driver Board P N 371106TT U 30 U 9 U 10 U 20 U 5 U 8 Use chip removal tool p n 351156 for square I C s HEAD DRIVER BOARD Align angled corners of chip with socket and arrow denotes pin 1 or dimple on chip ...

Page 63: ...rotected Mode Imaging Code 8 Attempting to read PCMCIA Card if installed 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 Prot...

Page 64: ...ve 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 Fabr...

Page 65: ...ock 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 311...

Page 66: ...rics 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 ...

Page 67: ...st 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 mou...

Page 68: ...re 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 c clip Now the Small nylon washer and spring can be p...

Page 69: ...ing 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 ...

Page 70: ...ems 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 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 fu...

Page 71: ...o 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 Symptom 3 While printing along fine early in the printheads life 300 000 inches a dot suddenly appears missing The verifier will halt the machine if the missing dot is in a barcode Cause Most likely the printhead failed from...

Page 72: ... loosing data 2 Turn the machine off 3 Open the printhead carriage assembly 4 Soak a small amount of rubbing alcohol on a cotton 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...

Page 73: ...e 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 maintai...

Page 74: ...installed Make sure to 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 m...

Page 75: ...s again select Strobe If not 0 return the strobe setting to zero using the arrow keys and then the Enter key 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 you...

Page 76: ...ad 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 4 Ink Use ink unwind and take up tensions adjustments to eliminate any ink wrinkles or skid marks Printhead Stock Platten roller Specialty Brand 23456 78901 Style Fall Color Rose Ink Tangent too far left Printhead Stock Platten roller Specialty Bran...

Page 77: ...nd 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 355009 Standard Full Width Tag Stock Red wo Ink Save Back Justified Web Path 355096 Standard Full Width Tag Stock Red w Ink Save 656 355029 Standard Full Widt...

Page 78: ... 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 ...

Page 79: ...ler 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 ...

Page 80: ...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 ...

Page 81: ... 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 ...

Page 82: ...ssembly Drawings Machine Wiring SYSTEM HARNESS NOT USED INK SAVE TWO ROLLER DROP BROWN BROWN KNIFE RED PH3 GRAY GRAY ORANGE ORANGE PH2 GRAY ORANGE FEED POWER SUPPLY PH1 BROWN RED HEAD DRIVER BOARD FRONT 371106TT VERIFIER THERMAL CONTROL BOARD REAR 371105TT FRONT PANEL ...

Page 83: ...OR 510014 SICK OR 510012 OMRON OPTIONS HARNESS 371142 SWITCH 191120 FEED MOTOR HARNESSED 371111 J3 J4 J1 CABLE TCB TO FP 371119 FRONT PANEL 511108 J1 351181 OPTIONAL PCMCIA BOARD POWER GOOD TOP 2 INK OUT 371140 FEED MOTOR CROSSOVER SYSTEM HARNESS ASSEMBLY 371126 J13 J8 CONN 4 CONN 3 CONN 4 CONN 4 CONN 4 CONN 2 SENSOR 371128 OPTION TOP CONTRAST SENSOR ROLLER DROP SENSOR 371130 TOP REGISTRATION SENS...

Page 84: ...e 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 pow...

Page 85: ...Users Manual Model 676 Mechanical Assembly Drawings 85 Mechanical Assembly Drawings ...

Page 86: ...86 Mechanical Assembly Drawings Users Manual Model 676 Unwind Assembly Drawing ...

Page 87: ...de 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 Cap screw 2 11 990069 8 32 Hex nut 1 12 990000 2 56 x 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 NS Not Shown ...

Page 88: ...88 Mechanical Assembly Drawings Users Manual Model 676 Web Guide Light Bar Assembly Drawing ...

Page 89: ... 990268 Dowel pin 2 8 351139 Bar Sensor mount 1 9 354023 Sensor block 1 10 989974 8 32 x 5 8 Cap screw 1 11 990314 8 Thumb screw knob 1 12 371128 Sensor assembly 1 13 990448 Washer 1 14 989973 4 40 x Cap screw 1 15 990053 8 32 x Cap screw 2 16 353004 Roller Unwind 1 17 990133 20 x Flat head screw 1 18 990120 20 x Cap screw 1 19 990121 20 x 5 8 Cap screw 2 20 354025 Bracket Fabric weave 1 21 194020...

Page 90: ...90 Mechanical Assembly Drawings Users Manual Model 676 Drive Assembly Drawing 5 13 4 17 2 1 19 14 4 12 15 9 19 6 8 11 16 18 3 7 ...

Page 91: ...screw knob 2 6 354017 Shaft Idler gear 1 7 990023 6 32 x 1 2 Flat head screw 1 8 354008A Gear Idler 1 9 354014 Driven roller Molded 1 10 354009A Gear Driven 1 11 990057 8 32 x 1 8 Knurled cup point 1 12 374017 Bridge blade Short 1 13 354094 Roller Drive assy 1 14 374016 Bridge blade Lower 1 15 354021 Shaft Eccentric Drive 1 16 354095 Tape roller Molded Assy 1 17 244024 Feed knob 1 18 990416 1 4 20...

Page 92: ...92 Mechanical Assembly Drawings Users Manual Model 676 Top Printhead Assembly Drawing ...

Page 93: ... 990122 1 4 20 x 75 Cap screw 1 8 375085 Support beam Print assembly 1 26 990135 1 4 20 x 75 Button head screw 1 9 375087 Support rear Print module assy 1 27 990325 3 16 E Snap ring 1 10 375088 Support front Print module assy 1 28 990328 1 2 E Snap ring 1 11 375013 Knob Shaft lock 1 29 990496 Spring Head lock 1 12 375014 Shaft Head mount 1 30 990497 1 2 Wave washer 1 13 375015 Pin lock Printhead 1...

Page 94: ...94 Mechanical Assembly Drawings Users Manual Model 676 Ink Save Printhead Assembly Drawing ...

Page 95: ... 1 8 375085 Support beam Print assembly 1 27 990325 3 16 E Snap ring 1 9 375087 Support Rear print module assy 1 28 990328 1 2 E Snap ring 1 10 375088 Support Front print module assy 1 29 990496 Spring Head lock 1 11 375013 Knob Shaft lock 1 30 990497 1 2 Wave washer 1 12 375014 Shaft Head mount 1 31 990729 3 16 x 7 16 Nylon washer 2 13 375015 Pin lock Printhead 1 32 991014 Spring Head mount 2 14 ...

Page 96: ...96 Mechanical Assembly Drawings Users Manual Model 676 Bottom Printhead Assembly Drawing ...

Page 97: ...rinthead 1 25 990122 20 x Cap Screw 1 8 375085 Support Beam Print Assembly 1 26 990135 20 x Button Head Screw 1 9 375084 Support Rear Assy Bottom Part 1 27 990325 3 16 E Snap Ring 1 10 375083 Support Front Assy Bottom Part 1 28 990328 E Snap Ring 1 11 375013 Knob Shaft Lock 1 29 990496 Spring Head Lock 1 12 375014 Shaft Head Mount 1 30 990497 Wave Washer 1 13 375015 Pin Lock Printhead 1 31 990729 ...

Page 98: ...98 Mechanical Assembly Drawings Users Manual Model 676 Ink Unwind Assembly Drawing ...

Page 99: ...t Item Part Description Qty 1 356010 Shaft lock 1 2 990042 8 32 x 3 16 Knurled Cup Point 1 3 990490 Spring Comp 1 4 999009 5 16 Thrust Bearing 1 5 356053 Shaft Unwind 1 6 376088 Arbor Unwind Assembly 1 7 990133 20 x Flat Head Screw 1 8 376026 Unwind Fiber Spacer 1 NS Not Shown ...

Page 100: ...100 Mechanical Assembly Drawings Users Manual Model 676 Ink Rewind Assembly Drawing ...

Page 101: ... Collar Foil Guide 2 13 376025 Bearing Spacer 1 4 376002 Ink Guide 1 14 991018 Internal Snap Ring 1 5 990080 10 32 x 3 8 Cap Screw 1 15 376022 Sprocket Altered 1 6 990313 10 Thumb Cap 1 16 991086 6 32 x 1 Cap Screw 4 7 356204K Arbor Rewind Assembly 1 17 356201 Magnetic Clutch 1 8 990058 8 32 x Set Screw 1 18 990355 O Ring 5 9 356203 Shaft Rewind 1 19 991089 Retaining Ring 2 10 376016 Bearing Housi...

Page 102: ...102 Mechanical Assembly Drawings Users Manual Model 676 Ink Rewind w Head Lift Assembly Drawing ...

Page 103: ...376023 Bearing Spacer 1 3 376003 Collar Foil Guide 2 13 376025 Bearing Spacer 1 4 376002 Ink Guide 1 14 991018 Internal Snap Ring 1 5 990080 10 32 x 3 8 Cap Screw 1 15 376022 Sprocket Altered 1 6 990313 10 Thumb Cap 1 16 990015 6 32 x Cap Screw 4 7 356204 Arbor 1 17 356201 Magnetic Clutch 1 8 990058 8 32 x Set Screw 1 18 990355 O Ring 5 9 356203 Shaft Rewind 1 19 991089 Retaining Ring 2 10 376016 ...

Page 104: ...104 Mechanical Assembly Drawings Users Manual Model 676 Ink Rewind Station 3 1 over 1 Assembly Drawing ...

Page 105: ...nk Rewind 1 8 990019 6 32 x Button Head Screw 4 2 376016 Bearing Housing 1 9 376022 Sprocket Altered 1 3 999002 Bearing 2 10 376014 Adapter Ink Sprocket 1 4 376025 Bearing Spacer 1 11 990102 Washer 10 SAE 1 5 376023 Bearing Spacer 1 12 990091 10 32 X Button Head Screw 1 6 376024 Bearing Spacer 1 13 991084 8 32 x Set Screw NS 1 7 991018 Snap Ring Internal 1 NS Not Shown ...

Page 106: ...106 Mechanical Assembly Drawings Users Manual Model 676 Knife Assembly Drawing 22 26 31 21 30 9 5 24 25 6 16 28 7 29 8 2 20 19 3 4 27 14 12 11 10 13 17 1 25 18 24 15 23 ...

Page 107: ...g cam 1 22 357020 Actuator Knife 1 7 197312 Spring Cam 1 23 990082 10 32 x 5 8 Cap screw 4 8 357094 Assy Ground rotary 1 24 990016 6 32 x 3 8 Cap screw 4 9 197311 Cam Knife homing 1 25 990120 1 4 20 x 1 2 Cap screw 2 10 990055 8 32 x 3 8 Flat head screw 1 26 990325 Snap ring 3 16 E Ring 1 11 989978 Washer 8 Star 1 27 197319 Torsion spring Right 1 12 990065 8 32 x 3 8 Button head screw 1 28 357029 ...

Page 108: ...108 Mechanical Assembly Drawings Users Manual Model 676 Stacker Assembly Drawing Part 1 ...

Page 109: ... 1 6 378054 Bracket Roller Mount 1 21 518001 Bracket Roller Clip 1 7 990403 Rivet 3 16 x 1 2 Flat Head 2 22 989976 Washer 6 Star 1 8 999014 1 4 x 5 8 FL Ball Bearing 2 23 989987 6 32 E S Nut 1 9 999100 Bushing FL 3 16 x 5 16 x 1 8 4 24 518002 Bracket Roller Mount 2 10 144034 Feed Lock Knob 1 25 358016 Shaft Roller 1 11 989979 10 32 x 1 Knurled Cup Point 1 26 378048 Assy Belt Tension Roller 1 12 99...

Page 110: ...110 Mechanical Assembly Drawings Users Manual Model 676 Stacker Assembly Drawing Part 2 ...

Page 111: ... Rail 1 10 358033 Bracket Stacker Support 1 32 990028 6 32 x 3 8 Flat Head Screw 2 11 358094 Roller Stacker Support Assy 2 33 378041 O Ring NS 19 12 378005 Rail Rear Stacker 1 34 558006 Bracket Roller Lock Front 1 13 378052 Shaft Tension Roller 1 35 558007 Bracket Roller Lock Rear 1 14 378056 Roller Idler Center 1 36 990056 8 32 x 1 2 Flat Head Screw 2 15 378058 Bracket Stacker Base 1 37 990272 Wa...

Page 112: ...112 Mechanical Assembly Drawings Users Manual Model 676 Rewind Assembly Drawing ...

Page 113: ...5 990054 8 32 x 1 Cap Screw 4 8 999017 Thrust Ball Bearing 1 26 989974 8 32 x 3 8 Cap Screw 3 9 112031 Timing Belt 67T 1 5P 1 27 112036 EAR Motor Insulation 1 10 112005 28T 1 5P Timing Belt Pulley 1 28 197078 12T 1 5P Timing Belt Pulley 1 11 999118 x 5 8 x 1 Bushing 1 29 351161 Motor 1 12 112030 Drive Disc 1 30 111034 Cover Drive Motor 1 13 112032 Friction Disc 1 31 990079 10 32 x Cap Screw 2 14 1...

Page 114: ......

Page 115: ...that has a mount hole Part number 355018 Fabric and heat seal only not for pressure sensitive or tags Stack height dependent on material size and weight may not reach full stacker height Jam sensor will require relocating the LED to the center position for the 676 545 and the back set of holes for the 636 656 If changing from standard stacker to 4 25 stacker the knife guard must be changed to matc...

Page 116: ...116 Mechanical Assembly Drawings Users Manual Model 676 Optional 4 1 4 Pick up Assembly ...

Page 117: ... Cap Sc 12 19 990019 6 32 x Button Head Screw 8 6 378126 Support Roller 2 20 378216 Sensor Mount Lower 1 7 990401 Rivet 3 16 x 3 8 F H 2 21 991029 Knob 3 Prong 10 32 Stud 1 8 378213 Roller Driven Pick Up 1 22 371133 Jam Sensor Harness 1 9 378208 Roller Center Drive 1 23 991032 O Ring NS 4 10 378201 Roller Pressure 1 24 378291 Oiler Mount Knife Protector Assy 1 11 378287 Pressure Roller Assembly 4 ...

Page 118: ...118 Mechanical Assembly Drawings Users Manual Model 676 Optional 4 1 4 Stacker Assembly ...

Page 119: ...x Cap Screw 2 10 991107 10 32 x 5 8 Button Head Screw 2 32 348009 Drive Pulley 10 Tooth 1 11 999012 x Flg Ball Bearing 2 33 348010 Drive Pulley 15 Tooth 1 12 378215 Rail Stacker Upright 1 34 358018 1 5P 40T Timing Belt 1 13 378035 Rail Stacker Upright Rear 1 35 990019 6 32 x Button Head Screw 2 14 990006 4 40 x Cap Screw 2 36 991067 8 32 x 5 16 Knurled Pt Set Screw 2 15 990466 Washer 1 8 Nylon 1 3...

Page 120: ...120 Mechanical Assembly Drawings Users Manual Model 676 Drive Belt Routing 2 over 1 Drawing 7 7 7 9 3 5 4 8 4 5 4 5 1 2 6 ...

Page 121: ...rt Description Qty 1 374006 Long Belt Double Sided 1 2 374020 Short Belt Double Sided 1 3 374005 Short Belt Single Sided 86T 1 4 376022 Sprocket Altered 3 5 356029 Pulley 26T 1 5P 3 6 284025 Pulley 14T DFL ID 1 7 244012 Pulley 14T SFL ID 3 8 374028 Pulley 14T DBL 3 8 ID 1 9 374007 Pulley Double Drive 1 ...

Page 122: ...122 Mechanical Assembly Drawings Users Manual Model 676 Drive Belt Routing 1 over 1 Drawing 3 9 7 7 1 5 4 2 5 4 8 4 7 6 ...

Page 123: ...rt Description Qty 1 374006 Long Belt Double Sided 1 2 374020 Short Belt Double Sided 1 3 374021 Short Belt Single Sided 84T 1 4 376022 Sprocket Altered 3 5 356029 Pulley 26T 1 5P 2 6 284025 Pulley 14T DFL ID 1 7 244012 Pulley 14T SFL ID 3 8 374028 Pulley 14T DBL 3 8 ID 1 9 374007 Pulley Double Drive 1 ...

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