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Paxar 656 / 636 User's Manual

1. 1 Feed pressure setting is off 2 Print position is incorrect 3 Field s position incorrect in the format 4 Bound platen roller Corrective Action 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 Set print head position Refer to Print Head Tangent Point 3 Set print head pressure Refer to Print Head Pressure Setting 4 Power off the machine and reinsert the offending connector or replace cable 5 Replace print head 6 Check Head Driver Board AT board connection and or replace Head Driver Board 1 Adjust sensor position so that the sensor light on the front panel flashes as a sense slot or hole passes under the sensor 2 Using TP13 and R51 on the Thermal Control Board re calibrate the sensor Refer to Sensor Trim Pots 1 Set feed pressure Refer to Mechanical Adjustment Of Feed Roller Pressure 2 Enter the setup menu and readjust the print setting as needed 3 Using formatter check and readjust the field s position s as needed 4 Check that the platen roller turns freely on it s shaft If it does not replace it Electrical Trouble Shooting e 49 Problem Print registration is off in the web direction Print contrast is too light or dark Voids in print image in the feed direction Machine continually stops with an erroneous interlock condition 50 e Electrical Trouble Shoo
2. 44 e Electrical Connections Users Manual Model 656 636 Electrical Trouble Shooting Power Up Sign On Communications Problem Machine fails to power up with no light present in the AC power switch Machine fails to power up with light present in the AC power switch Front panel displays no text or nothing at all Users Manual Model 656 636 Probable Cause 1 Incorrect power amplitude 2 Lack of power to machine 3 Missing or blown fuse s 1 Unconnected cable connector inside machine 2 Thermal Control Board unplugged from the Mother Board 1 Front panel cable unplugged Corrective Action 1 Confirm that the AC entry is configured for the line voltage intended to be applied to the machine Failure to do so can damage the machine s internal power supply Refer to the Fuse Configuration 2 Check that both ends of the power cord are plugged in securely 2A Confirm that the outlet the machine is plugged into has power 3 Check that the fuse s located inside the AC entry are present and intact Replace as needed Refer to the Fuse Configuration 1 Power off and remove the power cord from the AC entry Remove the back cover and inspect the cables and connectors to and from the power supply Refer to the Electrical System Schematic 2 Power off and remove the power cord from the AC entry Remove the back cover and reseat the Thermal Control Board 1 Power off and remove th
3. CE PAXAR Systems Group Manual Edition 3 0 18 February 2002 Manual Part Number 351398 This page intentionally blank Users Manual Model 656 636 Contents Scope 1 Tinttoduicti Otis At A A eg ted ess eine aah gh 1 Safety Issues Warnings 1 Catador ia 1 Warranty Information 2 Customer Responsibility 3 Location of Printet sciare issllaelilab tieiL Rhee ee E E 3 AC Power Lido a deren 4 Ufipackme culatello 4 Inventory of Components nono nnonncon nono nono ron r nn nr n rn nn nn nn nn nr on nr an nran nan rinnnannnnns 5 Printer Setup 6 Installing the Stack aa 6 EUSse CONFIgUrationi L iii pe egies Pa rn inizi 7 P C Board Installation iii 7 TCB Dip Switch S2 Settings ao ROLE AREA Aladar 8 Installing the Power Cord cri A nia Aaa 8 Installing the PC Interface Cable ala 9 Installing the PC Software aa i 9 Product Description 10 Priritet Meseripion aura Seed ses ee BEA ee Uli ce eet 10 Personal Computer Specifications 11 Unit Specifications 3 2 ae 11 Printer Operation 13 Installing Ink Ribbons 2 224 A A A HE a 13 Loading Mori dci 14 Butt Splice ii adas 15 Web Guide Adjustment nono nono n ron ccoo a e ron ea r ran n rn RA ai aE eaaa 15 Print Head Open Close acicate estima ddalaiahe tien dluialesla 16 Control Panel Operation 17 Printer Control uni ita 17 Tindicator A E RIONI RIA 19 Fron
4. Part Qty Description Number 6 351160 1 Full Stacker Switch Harness 8 358001 1 Stacker Support _ 9 358091 1 StackerBase Assembly _____ 358012 Plate Stacker Locator not shown 358013 18 358015 2 Roller Support 358016 1 Shaft Roller 358017 Spring Trip Rod 358018 Asp 407 Timing Bak 7 Part Qty Description Number 38 999044 2 313x 437 x 375 Flanged Bushing 999100 3 16 x 5 16 x 1 8 Flanged Bearing 40 990102 2 10 SAE Washer 41 1351125 1 StackerHamess 990533 Tie Down 990513 is Tie 44 358005 2 Pressure Roller 22 358021 15 O Ring long X 3 1875 358019 15 O Ring short X 2 1875 A AAA Users Manual Model 656 636 358020 Label Side Support Assembly Drawings 93 Rewind Assembly Drawing 94 e Assembly Drawings Users Manual Model 656 636 Rewind Parts List Part Qty Description Number 6 111029 1 Base S 8 112028 1 Drivendisc 9 112032 1 Frictiondisc 10 112030 1 Drivedise _________ 11 999118 1 1 2x5 8 x 1 1 4 bushing 112005 28t 1 5p timing belt pulley 10 1 11 1 990091 10 32 x 1 2 btn hd screw 15 15 990465 1 comp spring 18 999121 1 1 2x3 4 x 1 2 bushing Users Manual Model 656 636 Part Qty Description Number 3 8 snap ring 989974 8 32 x 3 8 cap screw 30 351183 1 6x6 rewind motor harness not shown 10 r
5. my AS LA 76 e Assembly Drawings Users Manual Model 656 636 Drive Parts List Users Manual Model 656 636 Item Part Description 6 354009A Gear Driven 8 354017 Shaft IdlerGear 9 354021 Eccentric Shaft 6 32 x 14 Flat Head Screw Y4 20 x V2 Cap Screw 4 20 x 2 Flat Head Screw Assembly Drawings e 77 Printhead Assembly Drawing 21 23 16 i lw O 2O 25 ae 78 e Assembly Drawings Users Manual Model 656 636 Printhead Parts List Item Part Description Qty 355032 Plate Printhead Mount 1 357011 Static Brush tC 355031 Holder Printhead 355034 Shaft Adjustment 1 1 6 8 9 Users Manual Model 656 636 Item Part Description Qty 23 990037 6 Washer 2 26 990492 3MX8MDowelPin 1 1 2A X Fata ES Desa 2 1 2 990444 3M X14 Cap Screw 2 999051 3 16 X 5 16 X 5 16 Bushing 351101 Printhead 240DPI WI 00 A E fo rari Assembly Drawings e 79 Ink Unwind Rewind Assembly O QA 80 e Assembly Drawings Users Manual Model 656 636 Ink Unwind Rewind Parts List Item Part Description 6 376087 ArborAssembly 9 376088 Arbor Unwind Assembly Shaft Foil Bracket 1 8 516113 Ink Guide 1 1 1 1 1 Qty Ee 1 EA Em 1 EH Users Manual Model 656 636 Descriptio
6. 10 Zero is the middle of the range Use the Enter key to save the new value CUTTER IS DISABLED This screen allows the operator to turn the cutter ON or OFF Press the Enter J key this will toggle between the enable disable mode The screen will display the cutter status on the first line The knife motor will continue to run If the printer is used in the rewind mode only the knife motor plug may be disconnected CHANGE STROBE STROBE 0 NEW STROBE 2 0 Recommended center position adjustable to 7 settings Use the lt YES key to decrease the number and the gt NO key to increase the number Use the Enter key to save the value and move to the next number Recommend cleaning the head adjusting head tangent and setting head pressure before changing this strobe setting EMULATION MODE 630 NEW EMULATION MODE 650 This screen follows the STROBE ADJUST screen This screen allows the selection of an emulation mode The 656 636 is capable of emulating other PAXAR printers When in this mode the 656 636 will produce PCL tags as close as possible to the tags produced by the printer being emulated Formats designed for the 656 636 can not be printed on the older printers but formats designed for the older printers emulated by the 656 636 can be printed on the 656 636 printer Compatibility Notes e If the dpi of the 656 636 printer does not match the emulating printers dpi then certain field
7. the data is intended to be sent 4 Re configure PCMate for Paxar PCL printer as per your PCMate manual 5 Replace Thermal Control Board 6 Contact Paxar Service Users Manual Model 656 636 Stock Ink Advance Problem Stock does not advance when the start button is depressed Users Manual Model 656 636 Probable Cause 1 No batches to be printed 2 An interlock condition exists 3 Feed motor unplugged or faulty 4 Thermal Control Board unplugged or faulty 5 Feed roller not gripping stock 6 Feed rollers bound 7 Stock bound Corrective Action 1 Download batch if batch downloaded uses the same format as a previously downloaded batch the machine with start automatically 2 Determine the number and type of interlock s by reading the front panel display As each is corrected the number of errors will decrease Example Error 910 Stock Out reload stock 3 Check feed motor cable and or replace feed motor 4 Check Thermal Control Board AT board connection and or replace Thermal Control Board 5 Adjust the feed pressure Refer to Mechanical Adjustment Of Feed Roller Pressure 6 With power off check that all rollers turn freely 7 With the print head and feed open check that the stock will pull through the printer with little to no resistance Electrical Trouble Shooting e 47 Problem Ink does not advance when the start button is depressed 48 e Electrica
8. 3 Clutch total failure 3 Unlikely but change if necessary 4 Solenoid Drive circuit failure 4 Replace Cable or TCB 5 Knife motor not cycling 5 Replace Cable or TCB Continuous Knife cycling 1 Solenoid stuck in 1 Clean and adjust solenoid 2 Circuit stuck on 2 Unplug solenoid wires from knife module connector and should stop cutting If it does stop cutting replace TCB 3 Very bad trip arm to stop pin on 3 Unusual but file roll pin and replace trip clutch arm 58 e Mechanical Trouble Shooting Users Manual Model 656 636 Mechanical Trouble Shooting Sequence If the printer is electrically operable proceed as follows 1 Open printhead and drive pressure roller and remove stock 2 Adjust unwind inner web guide to 31 32 24 6mm per instructions See Printer Operation Web Guide Adjustment 3 Take a short 2 3 50 75mm piece of stock you wish to run and adjust the drive module pressure per instructions See Maintenance Adjustments Stock Feed Adjustments 4 Rethread machine close drive module pressure handle Close print module Release pressure on printhead adjustment knobs Operate printer and fine tune drive module pressure until web tracks at 31 32 24 6mm from back edge to center frame 5 Open drive pressure module remove stock and ink and readjust print module pressure per instructions See Maintenance Adjustments Print Head Adjustments 6 Reinstall stock and ink operate and make any furt
9. Arm on Clutch 2 Replace Actuator actuator 3 Worn Stop roll pin on clutch 3 Replace Clutch if not solved above Skips cut double length label 1 Solenoid did not pull in 1 Check gap on the trip arm to clutch body must be about 040 inches If too large solenoid has less force Check assembly of spring and washers Use latest engineering assembly procedure Clean Solenoid 2 Trip arm sticking on clutch roll 2 Check for burr on trip arm catching on pin clutch 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 1 Packman not visibly homing 1 Adjust Packman to center the home motor turning location of the packman to the quiet location Ifthe knife still does not home clean knife cams and lubricate If still does not home replace blades If still does not home replace clutch 2 Packman homing ok but noisy 2 Adjust Packman to center the home location of the packman to the quiet location 3 Dirty Clutch 3 Clean clutch and one drop of light oil 4 Packman slipping 4 Order improved set screws with multiple points that bite better to shaft 5 Bad Motor Gear Box 5 Replace Knife Motor Users Manual Model 656 636 Mechanical Trouble Shooting e 57 Problem P
10. List Part 2 Item Part Description Qty 990072 8 32 Flat Hd Screw 990090 10 32 Button Hd Screw 990067 8 Flat Washer 4 12 990065 8 32 Button Hd Screw 4 4 6 8 9 Users Manual Model 656 636 Item Part Description Qty Nylon Washer Label Platform 1 Y Not Shown PA SN E Optional Stackers e 107 Optional Down Stacker Assembly Drawing Part 3 108 e Optional Stackers Za Pa 23 gt S 6 09 D 22 A 2 24 gt A O 15 16 Users Manual Model 656 636 Optional Down Stacker Parts List Part 3 item Part Description Qty 3 168012 TamperSupport 1 4 168034 Tamper Mount Bracket 1 5 168028 Tamper ooo J2 6 168036 StaticBrush____ 1 8 168085 Mounting BracketAssy 1 9 168016 Solenoid Mtg Bracket 1 11 168038 BracketLabel Stop 1 12 168057 Rod Label Stop_ 1 Tamper Pivot Pin a 168008 Pr Nut 15 197315 Solenoid Actuator Arm________ 1 Users Manual Model 656 636 item Part Description Qty 8 32 Cap Screw EA 27 990050 8 32 Cap Screw____ 2 28 880315 10 Thumb Screw Gap _ 2 ae 6 Snap Ring 30 99009 10 32 Button Hd Serew 2 31 990066 8 32 Button Hd Screw 5 Optional Stackers e 109
11. Parts List io A A a 91 Stacker Assembly Drawing nono nnonnronn ron rrnn ron ron rra n ran naeta asa iiiar 92 Stacker Parts Dist A A A A A Is 93 Rewind Assembly Drawing na a aA a aare e TE EEA SESS 94 Rewind Patts List rn aeee E a EEEE 95 Stock Out Sensor Assembly Drawing 96 Stock Out Sensor Parts List iaia od a 97 Optional Stackers 98 ADS Stackers pec Cath ons sat 99 Optional 4 25 Pick up Assembly 100 Optional 4 25 Pick up Parts Distinciones 101 Optional 4 25 Stacker ASsemblY ii 102 Optional 4 25 Stacker Parts List a a e iN 103 Optional Down Stacker Assembly Drawing Part 1 i 104 Optional Down Stacker Parts List Part 1 i 105 Optional Down Stacker Assembly Drawing Part 2 i 106 Optional Down Stacker Parts List Part 2 107 Optional Down Stacker Assembly Drawing Part 3 108 Optional Down Stacker Parts List Part 3 i 109 Users Manual Model 656 636 ev Scope Introduction This user manual was arranged for the person who is going to operate this 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 carton installing the ink ribbon and stock printer operation control panel operation and finally ca
12. The same pot is used for both adjustments and a compromise value must be achieved Stock out Adjustment The stock out sensor has been set at the factory however for some stocks it may be necessary to adjust the sensor to detect stock out With a full roll of stock loaded in the machine run the printer and observe how far behind the stock to the left of the stock the stock out wire rod is located This should be between 1 4 and 1 2 inch 6 to 12mm behind the running stock If not loosen the set screw and rotate the wire to the acceptable distance and re tighten Knife Square Adjustment Users Manual Model 656 636 The knife has an adjustment to square the cut to the stock To make the adjustment loosen the two cap screws one on top of the knife and one below the knife using the 3 16 ball driver in the tool kit Move the knife in the direction desired to square the cut and re tighten Maintenance Adjustments e 37 Stacker Adjustments The stacker has four adjustments which can be made without a tool to accommodate different types of stocks Stock Length Adjustment Loosen the two thumb screws at the base of the stacker uprights and slide the uprights to a position that allows the cut tag or label to hang over the last belt roller approximately 1 4 6mm Re tighten Stock Width Adjustment Loosen the two thumb screws behind the stacker uprights and adjust the stacker upright nearest to the operator to the desired stock wid
13. Trouble Shooting Sequence en 59 Lubrication Procedure stas 59 Appendix A 60 Error Messages scan A a a dit 60 Appendix B 61 Software Upgrade Chip Placement Positions 61 Appendix C 64 Trik and Stock Transfer Types nia an nana 64 Appendix D 67 Knife MEG Guidelines ii ltda 67 Users Manual Model 656 636 Assembly Drawings 71 Unwind Assembly Drawing i 72 Unwind Parts Listia deere Asse Aliante e ends dedo en dde e heated ion Shei O tat na 73 Web Guide Light Bar Assembly DraWing ii 74 Web Guide Light Bar Parts List iii aaa 75 Drive Assembly Drawing 76 Drive Parts sti a ge se ssa ons to a o dao i 77 Printhead Assembly Drawing neiere e O a E EE N E ees 78 Pritithead Parts Listin a Thee Be E E E Aa 79 Ink Unwind Rewind Assembly 80 Ink Unwind Rewind Parts List iiini eiiis ieii isea iiie iii i ins 81 Ink Rewind Arbor Assembly ii 82 Ink Rewind Arbor Parts List nooo nconnronnrnnnrnnnonn ron rra rra rr nr rana nas 83 Feed amp Ink Drive Amb ca 84 Fe d amp Ink Drive Parts MT 85 Timing Belt Threading Diagram 86 Timing Belt Parts List AT A EORA E 87 Ink Turn Roller Assembly ci a na Oi ia 88 Ink Turn Roller Parts Listin urna ani nio Leal E 89 Knife Assembly DE WINE ii A ea oR 90 Knife
14. allows the printer to register to preprinted media by detecting a black mark Begin by placing the stock so that the black mark is not in the sensor s sight path and adjust the pot until the high value is achieved Then place the stock so that the black mark is directly in front of the sensor s sight path and adjust until the low level is met The low level is the more crucial of the two adjustments NOTE The same pot is used for both adjustments and a compromise value must be achieved Film Out Sensor Top Ink Sensor AAA OS Sensor Blocked Sensor Not Blocked TP12 TP12 Adjustment Pot RSO R50_ 1 Light Status On off Desired Voltage gt 3 50 VDC lt 0 75 VDC The Film Out Sensor allows the printer to monitor the availability of ink Begin by blocking the sensor with the ink intended for use and adjust the pot until the high value is achieved Then remove the ink from the sensor and adjust until the low level is met The low level is the more crucial of the two adjustments NOTE The same pot is used for both adjustments and a compromise value must be achieved Bottom Ink Sensor ee Sensor Blocked Sensor Not Blocked TP16 TP16 Adjustment Pot RAD 2 Light Status On of Desired Voltage gt 3 50 VDC lt 0 75 VDC The Bottom Ink Sensor is not available at this time and is reserved for future expansion 36 e Maintenance Adjustments Users Manual Model 656 636 Headlift Sensor A Sensor Blocke
15. away from plate 3 Assure that take up roll is not binding on locator plate and swing arm moves freely 4 Remove used ink roll It is designed to hold only 1 full roll Mechanical Trouble Shooting e 55 Print Problem Probable Cause Poor print uneven or no print 1 Incorrect printhead pressure mechanical Also see electrical adjustment trouble shooting 2 Broken ink 3 Ink not rewinding 56 e Mechanical Trouble Shooting Corrective Action 1 Remove stock and ink Close printhead Release pressure 2 knurled knobs Readjust pressure by turning knob s clockwise until they just contact printhead plate Reinstall stock and ink Turn adjusters clockwise approximately 1 8 turn 5 clicks of knob As machine operates increase pressure 2 3 clicks at a time until best print is obtained Narrow webs will require less pressure on front adjuster If print is still poor loosen 2 M3 cap screws visible on outer edges of printhead carrier Adjust tangent point to optimum print by rotating M3 screw in top center of printhead plate Lock in place with 2 outer M3 cap screws 2 Replace ink and readjust see INK trouble shooting 3 Readjust see INK trouble shooting Users Manual Model 656 636 Knife Problem Probable Cause Corrective Action Double Cuts extra knife cycle 1 Solenoid sticking in 1 Check proper assembly of washers Clean plunger with alcohol and completely dry 2 Worn Trip
16. print quality should be acceptable if the pressure screw is properly positioned Once the print quality is acceptable start to back off the screw until the print begins to fail Once the print is starting to fail increase the pressure by 4 clicks Minimum pressure should be used when running narrow webs wide webs require slightly greater pressure Additional print quality will be obtained by adjustments of the Tangent point see Print Head Tangent Point If you are unable to correctly adjust the screw for good print call for service 32 e Maintenance Adjustments Users Manual Model 656 636 Squaring the Print Head 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 be detected by looking at the front edge of the print head in reference to the printhead holder To remedy this problem power off the machine and remove the print head as outlined in the print head installation information The printhead adjustment plate has been manufactured so when properly adjusted the head will be square The printhead holder has a locator plate that must be slide up snug against the printhead mount plate Install the head and it should be square to the web Print Head Tangent Point The print head pressure adjustment must be done with the head pressure set light Turn the pressure screw counterclockwise Run a test pattern to determine the adjus
17. the head down while depressing the latch When the mount plate swings past the top of the latch release 16 e Printer Operation Users Manual Model 656 636 Control Panel Operation N Pa N ZI Y CO 4 O O O O O AL A Printer Controls a lt gt EEE 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 the head and knife will be cut and stacked as finished labels Stock moves through in one continuos strip Stock moves through without printing Ink will not advance ink save on the 656 636 will automatically be activated The print head must latched in the down position Test TEST and START must both be used Users Manual Model 656 636 Control Panel Operation e 17 Test will stop when the buttons are released Labels between the head and knife will be cut and stacked as finished labels Stock moves through in one continuos strip Stock moves through with test pattern printing The ink will advance with the stock The print head must be latched in the down position Stop The stop button will stop the printer at the end of the current label being printed 18 e Control Panel Operation Users Manual Model 656 636 Indicator Lights The Paxar 656 636 has three Indicator lights These lights are used along with the LC
18. 1 Stacker not operating 2 Stacker position on machine too far forward so labels go under rear stacker rail 3 Incorrect rail position or stacker bed angle 1 Incorrect pre load on clutch pawl 2 Partial cut Corrective Action 1 Move decurler turn bar toward unwind end of machine until cracks no longer appear NOTE Stock out switch rod may have to be readjusted after moving decurler 1 Loosen screws in upper knife securing bridge blade roller assembly and slide up holes in blade are slotted until rollers just contact stock Tighten screws 2 Loosen knife shear adjustment screws and move outer end of knife until full cut is accomplished 3 Check stacker connection to access port Be sure nip roller is free to rotate and moves easily in the bearing slots 1 See step 3 above 2 Loosen stacker mounting knob and move stacker toward rear of machine tighten 3 Using a cut label position stacker rails so that approximately 3 8 9 5mm overhangs the second grooved roller Loosen quick turn handle on stacker clamp and raise or lower stacker bed until opening between Ist label overhang and belt surface will allow entry of next label 1 With back cover removed and power off operate solenoid by hand When lever is moved clutch pawl should move counter clockwise about 1 32 0 79mm with the pac man in home position If not loosen pac man set screws and readjust pac man to stop with s
19. 12V P_ amp B KUHP 11D51 12 DESCRIPTION Users Manual Model 656 636 Electrical System Schematic AS ENTRY o POWER SWITCH HARNESSED 5V 212V 24V aS fee 351113 POWER SUPPLY 110V 220V y 351119 1A 1 HOT o gt LA STOCK OUT SWITCH sione HARNESS 351138 LINE CORD GRounp gt SNO O p finess A 191120 WEB PATH SENSOR ER i 110V HARNESS 351127 Ea OPEN NEUTRAL gt D o 7 110Y PCMCIA FEED OPEN Li SWITCH 191120 5 INK OUT SENSOR 12vD HARNESSED 351131 c HO m ROLLER DROP SENSOR HARNESSED 351130 110V OPERATION SOLO SIATE REGISTRATION SENSOR PHOTO DETECTOR ONE 10 0A 250V IT 424v HARNESSED 351128 1 4 X 1 1 4 FUSE 921167 281164 REGISTRATION SENSOR LIGHT BAR 220V OPERATION 5V HARNESSED 351120 TWO 10 0A 250V 5 X 20MM FUSES 921168 OPTIONAL BOTTOM REFLECTIVE FRONT PANEL REGISTRATION SENSOR RETURN 351108 HARNESSED 351129 J1 RELAY CONTROL HARNESS 351118 L TCB TO FP CABLE SYSTEM HARNESS ASSEMBLY 351126 II STEPPER MOTOR CABLE PLATEN DROP e490 351132 MOTOR 351157 UOOUULUULULU SI 7123466789 01112 STEPPER MOTOR CABLE INK MOTOR 351132 351141 PL2 PEA AT Di STEPPER MOTOR CABLE o FEED BUS 351132 MOTOR 245026 z js y KNIFE MOTOR MOTHER BOARD HARNESSED 351171 636 351172 LAL 656 351170 BUS THRMAL CONTROL KNIFE SOLENOID BOARD jgr STACKER Harness HARNESSED 3
20. 24A 356110 1 60T Timing Belt 300dpi 24B 356026 57T Timing Belt 240dpi Not Shown 356111 1 65T Timing Belt Double Sided 101 Et Users Manual Model 656 636 Assembly Drawings e 87 Ink Turn Roller Assembly 88 e Assembly Drawings Users Manual Model 656 636 Ink Turn Roller Parts List Part Qty Description Number 376086 Turn Bar Assembly 990416 Y4 20 x Va Flat Head 356105 Turn Bar Bracket 990121 4 20 x 5 8 Cap Screw 29 354090 1 636 656 Feed Assembly Only inner support bracket shown Users Manual Model 656 636 Assembly Drawings e 89 Knife Assembly Drawing Users Manual Model 656 636 90 e Assembly Drawings Knife Parts List Part Qty Description Number 10 Washer O 1 197003 1 10 Washer 2 3 4 5 7 10 11 12 13 14 15 16 1 Spring Torsion Front Natural Finish Static Brush Users Manual Model 656 636 41 Part Qty Description Number MEM 1 10 32 x 5 8 Cap Screw 1 4 20 x 1 2 Cap Screw 1 4 20 x 1 Cap Screw 989978 8 Star Washer 1 4 20 x 3 4 Flat Head 999097 1 Flanged Bushing Inc w 357021k Assembly Drawings e 91 Stacker Assembly Drawing ITEM 22 SHORT BELT FOR S N 173 amp B LONG BELT FOR S N 174 amp ABOVE xx ol 2 1875 FOR SHORT B 3 1875 FOR LONG BE ELTS LTS ELOW 27 37 92 e Assembly Drawings Users Manual Model 656 636 Stacker Parts List
21. 51123 STACKER MOTOR 351105 es HARNESSED 351161 FULL STKR SWITCH HARNESSED 351160 JAM SENSOR C4 J14 Jie 41203 SERIA OALE CONN 3 HARNESSED 241159 AE OPTIONAL_IN LINE VERIFIER 351144_____ E TCB TO VERIFIER PC BOARD e1144 RELAY TCR TOHDB 1 L E 351184 VERIFIER 351136 CABLE 351121 ee HARNESSED 351159 __ PRINT HEAD CABLE 361122 ASINI HEAD er 7 351102 300 DPI conn 8 24V MACHINE HARNESS 351117 HEAD DRIVER BOARD 351106 Di Users Manual Model 656 636 Electrical Connections e 43 Motherboard Power Connectors The power supply connector on any PC XT or PC AT compatible motherboard is made up of dual six pin male connectors Two female connectors from the power supply plug directly onto these male connectors The following diagrams illustrates the proper method of attaching the connectors Ensure that all of the black wires are located next to each other in the center of the two connectors as shown in the diagram below and that the clamps on the back side of the connectors ate secured along the PCB header All pins should be covered Warning Connecting the power supply incorrectly may cause irreversible unwarranted damage Ensure that the power is turned off before connecting the power supply Make certain that the 115 230VAC fuse drawer is in the correct position POWER CONNECTOR HOOKS SOCKET KEYBOARD CONNECTOR LEFT REAR CORNER OF MOTHER BOARD
22. D display to tell the operator the current status of the printer 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 Users Manual Model 656 636 Control Panel Operation e 19 Front Panel Menu Functions y y y y y y y y y y y y Cutter Enable Total Inches Disable y Adjust Strobe y Change Emulation Mode Verifier Setup y Clear Verifier Scan Memory Change Language y Verifier Enable Disable Change Ink Transfer Type y Checkout Format 20 e Control Panel Operation Users Manual Model 656 636 LCD Display Users Manual Model 656 636 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 Diagnostic Tests During power up the follow
23. E STARTING ANY CLEANING NEVER REMOVE THE HEAD FROM THE PRINTER EXCEPT FOR REPLACEMENT The Anti static wrist strap which must contact the skin and be tight and anti static gloves must be worn at all times when handling a print head to avoid damaging the print head Supplies Always use clean supplies when cleaning the head Never use anything abrasive to the head NEVER use anything metallic on or near the printhead 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 must be done with the print head in the printer Apply a liberal amount of alcohol to a swab Rub the swab across the print line of the printhead to remove the build up The platen roller and feed rollers should also be cleaned with alcohol to remove ink and card dust build up Users Manual Model 656 636 Print Head Replacement NEVER REMOVE THE PRINT HEAD FROM THE PRINTER EXCEPT FOR REPLACEMENT TURN OFF THE POWER TO THE PRINTER BEFORE STARTING ANY ELECTRONIC COMPONENT REPLACEMENT NOTE The Anti static wrist strap which must contact the skin and be tight and anti static gloves must be worn at all times when handling a print head to avoid damaging the prin
24. System Schematic 3 Remove cause of jam at the knife 4 Replace the knife motor 5 Replace the Thermal Control Board 1 Power off and insert the stacker cable in the stacker port on the Thermal Control Board 2 Replace the stacker motor 3 Remove cause of jam at the stacker 3 Replace the Thermal Control Board Electrical Trouble Shooting e 51 Electrical Trouble Shooting Machine Set Up Sequence 52 e Electrical Trouble Shooting If the printer is mechanically operable proceed as follows 1 Power off the printer remove the media and ink and thoroughly clean it from the unwind to the stacker using alcohol and a clean soft cloth The print head should be cleaned as per the Print Head Cleaning instructions section in the manual 2 Load a full roll of an average width media and ink on the printer 3 Power on the printer After passing diagnostics test one and two the front panel will display READY FOR BATCHES 4 Arrow down to the setup mode and press enter Set the print cut and strobe to 0 5 From the host PC download a batch of 1000 labels using the 6X6 setup format 92 6 Adjust as needed the print head position and then pressure for optimum print quality Refer to the Print Head Adjustment section in the manual If the machine will not pull stock for this step refer to step number seven 7 Adjust the feed pressure to pull 11 0 032 of media Refer to the Stock Feed Adjustment section in the m
25. ake sure that the guide pins insert into both the front and back grooves 11 Reconnect the print head cable making sure that the connector is seated tightly NOTE If the cable is not connected correctly the print head will be destroyed when the machine is powered on Check to see that the cable is tight by observing from underneath the print head The ribbon cable connector should be inside of the black connector located on the print head 12 Replace the ink and double check your work Power the machine on and make sure that no adverse effects are noted As a final test of the print head installation run a test pattern to check the print quality You should observe an even grid of chevrons If you do not see such a grid you may wish to reference the topic of print head tangent adjustment Users Manual Model 656 636 Maintenance Adjustments e 31 Print Head Adjustment Tangent Proper print head tangent is perhaps the most important adjustment to make A printhead which is not properly adjusted will result in poor print quality poor heat dissipation and possible ink wrinkling problems When the machine was manufactured the print head was adjusted to the proper tangent point on the platen roller however with print head replacements the tangent point for the new print head may change It is necessary to understand how to properly adjust the printhead Clean Platen Roller You may determine if the printhead has been adjusted properl
26. andard three prong plug used in the U S A A 220 volt printer and other 110 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 8 e Printer Setup Users Manual Model 656 636 Installing the PC Interface Cable The 656 636 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 Users Manual Model 656 636 The software to drive the Paxar family of printers is covered in separate documentation The Formatter software to create formats by the customer for the Paxar 656 636 printer is a Windows application The original software Selfform will not create formats for the 656 636 The new Formatter package is capable of making formats for all Paxar control printers The original DOS version of PCMate has been updated to drive the 656 636 printer PCMate DOS version 3 05 or later needs to be use
27. anual After the machine is pulling the correct amount of media measure the distance between the top of the media and the tracking line This distance must be 5 032 through out the label If it is not first check and adjust as needed the unwind core guide and the web guide 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 number six 8 Using two consecutive labels back to back check the squareness of the cut Adjust the knife module as needed referring to the Knife Square Adjustment section in the manual 9 Using the front panel adjust the physical cut to be 1 0 032 from the cut line on the label The machine is now ready for production formats at which time the operator should need only to adjust the print cut and strobe via the front panel NOTE Ifthe machine is used to print on multiple media types the print head may need to be adjusted for optimum print quality on each media as they are ran Users Manual Model 656 636 Mechanical Trouble Shooting Stock Problem Probable Cause Stock will not roll or jumps 1 Incorrect adjustment of unwind web guides Corrective Action 1 Be sure stock roll is as flat as possible and does not extend over core 2 Adjust rear web guide to 31 32 Machine fails to stop at end of roll 1 Incorrect adjustment of stock out switch trigger arm Stock do
28. d The printer is also capable of operating directly from a mainframe when using the RS232 interface and Paxar s PCL command language Printer Setup e 9 Product Description Printer Description The PAXAR MODEL 656 636 THERMAL PRINTER Figure 2 is an electronic printer that can print on Fabric Tapes Card Stock Heat Seal Stock and Pressure Sensitive roll stocks This printer interfaces to a computer or a main frame system that allows the customer to print computer input or even design a label with PAXAR S PCMate Plus s FORMATTER program This printer can generate a complete label printed on one side e Design your own labels on a PC e Computer interface IBM Compatible e Mainframe direct interface e RS232 9 Pin D shell female Serial interface connector Figure 2 PAXAR MODEL 656 636 LABEL PRINTER 10 e Product Description Users Manual Model 656 636 Personal Computer Specifications This specification describes the hardware and application software requirements for the Personal Computer that is connected to the PAXAR 656 636 Printer The PAXAR 656 636 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 W
29. d Sensor Not Blocked TP18 TP18 Adjustment Pot 7 Light Status On of Desired Voltage gt 3 50 VDC lt 0 75 VDC The Headlift Sensor allows the printer to register the platen roller on 656 printers Begin by rotating the platen roller until the flag is blocking the sensor The platen roller has been slotted to accept a regular screwdriver on the front of the machine to assist in this operation Adjust the pot until the high value is achieved Then rotate the platen roller until the flag is no longer blocking the sensor Adjust the pot until the low level is met The low level is the more crucial of the two adjustments NOTE The same pot is used for both adjustments and a compromise value must be achieved Full Stacker Sensor Jam Sensor A a a Sensor Blocked Sensor Not Blocked TP11 TP11 Adjustment Pot 6 Light Status On Of Desired Voltage gt 3 50 VDC lt 0 75 VDC The Full Stacker Sensor allows the printer to detect a full load of labels in the stacker The stack full condition will be detected by a switch and will stop the machine when the stacker is full The Jam Sensor feature will detect each cut label as it leaves the cutter If a cut fails to occur the machine will stop To adjust the jam sensor block the sensor and adjust the pot until the high value is achieved Remove the block from the sensor and adjust the pot until the low level is met The low level is the more crucial of the two adjustments NOTE
30. e power cord from the AC entry Remove the back cover and inspect the cable and connectors to and from the front panel Refer to the Electrical System Schematic Electrical Trouble Shooting e 45 Problem Front panel does not complete diagnostics test 2 Machine does not receive batches 46 e Electrical Trouble Shooting Probable Cause 1 One or more PC board s unplugged from the Mother Board 2 Relay unplugged or faulty 3 PCMCIA cartridge not inserted correctly in optional PCMCIA slot 1 Serial communications cable loose or unconnected 2 Machine not powered on or has not completed diagnostics tests 3 Data sent to wrong printer 4 Configuration incorrect in PCMate 5 Faulty Thermal Control Board 6 Jumpers not configured correctly Corrective Action 1 Power off and remove the power cord from the AC entry Remove the back cover and reseat the offending board 2 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 relay Refer to the Electrical System Schematic and Relay Assembly 3 Insert a PCMCIA cartridge with the arrow up and towards the front of the machine so that the ejector button pops out 1 Check and secure both ends of the serial cable with the thumbscrews 2 Power machine on and wait until machine displays Ready for batches Re download data 3 In PCMate change to the printer
31. e the user to the next screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen PRESS ENTER TO PRINT CHECKOUT FORMAT This screen follows the TRANSFER TYPE screen This screen allows the printing of a checkout format Pressing ENTER will print the checkout format Pressing the MODE Down Arrow key will take the user to the next screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen Life Counters Mode Use the Mode Y key to move to the following screen PRESS ENTER FOR LIFE COUNTS Users Manual Model 656 636 Use the Enter key to enter this mode Use the Mode J key to move to the following screens LABEL COUNTER 0000000000 ENTER TO RESET Used to count labels for a work period example a shift Enter will reset the count to 0 TOTAL LABELS PRODUCED 0000000000 Non resettable counter TOTAL STOCK INCHES 0000000000 Non resettable counter Use the EXIT to move to the HOME screens Protected Mode Use the Mode 4 key to move to the following screen PRESS ENTER FOR PROTECTED FEATURES Use the Enter key to enter this mode ENTER PASSWRD 4 DIGITS PASSWORD 0 The Protected Feature screen will appear as shown Use the lt YES key to decrease the number and the gt NO key to increase the number Use the Enter key to save the value and move to the next number The password is 4 numbers If an incorrect password is entered
32. en in board and outboard the inboard edge of the stock should be 31 32 24 6mm from the main vertical support plate of the printer To move the stock inboard away from the operator loosen the inboard set screw slightly This can be done while running the unit To move the stock outboard toward the operator loosen the outboard set screw slightly Users Manual Model 656 636 Mechanical Adjustment Of Feed Roller Pressure Blue Roller General The blue rubber pressure roller is supported by an eccentric shaft mounted in bearings located in vertical slots in the front and rear mounting plates of the drive module These bearings are supported by compression springs and controlled by set screws located in the top of the bearing mounts Adjustment Procedure 1 Release eccentric control lever and remove stock 2 Using a piece of the same stock being run as a feeler gauge adjust set screws until feeler gauge just slides between rollers evenly across width of rollers with pressure eccentric lever closed 3 Release pressure and rethread Further equally adjust set screws 2 clockwise 1 2 3 4 of a turn Close pressure lever 4 Operate machine Minor adjustments can now be made to the set screws to cause stock to run 31 32 24 6mm from upright frame Mechanical Adjustment of Stock Sense Mark Light Receiver Users Manual Model 656 636 General The receiver for light from the LED emissions bar for stock registration
33. es not pull smoothly through printhead module 1 Web guide in sensor plate incorrectly adjusted 24 6mm from case surface to guide surface touching roll 3 Adjust outer web guide to touch stock roll but not pinch the roll 1 Adjust stock out switch arm to approximately 3 4 19mm from back side of stock when threaded through machine 1 Adjust moveable web guide to touch outer edge of stock with rear edge touching rear web guide Do not pinch 2 Stock is slipping in drive or drive pressure is uneven Users Manual Model 656 636 2 Remove stock from drive rollers Using a piece of stock the same thickness as the stock being run as a feeler gauge adjust set screws in drive endplates clockwise until feeler gauge barely slides between rollers with pressure lever closed Rotate set screws clockwise an additional 1 2 3 4 turn Rethread and operate Minor adjustment can now be made to cause stock to run 31 32 24 6mm from upright frame Mechanical Trouble Shooting e 53 Problem Cracks or craze marks appear on face of finished labels Stock jams in bridge blade rollers or knife area Will not stack Knife will not cut or partial cut 54 e Mechanical Trouble Shooting Probable Cause 1 Incorrect adjustment of decurler 1 Knife mounted bridge blade too close to stationary bridge blade 2 Knife not cutting full width of stock 3 Stacker not operating or nip rollers not turning
34. ge to the printer the printer can now be lifted to its intended location Users Manual Model 656 636 In some cases a double box has been used to ship your printer i Figure 1b Shipping Carton Save the shipping materials to relocate the unit or return to factory for service Inventory of Components Users Manual Model 656 636 The following list shows the additional parts pieces which should be included in your PAXAR 656 636 shipping container If anything is missing notify PAXAR immediately in the U S A at 570 888 9116 In other countries please contact your local PAXAR supplier PAXAR 656 636 User s Manual A quick disconnect power cord Optional IC card for custom Logos or additional fonts that were special ordered in the back of the manual Stacker assembly Optional software ordered to drive the printer A serial communications cable NOTE Some of the above parts may be inside of the envelope which contains the tool kit PAXAR 656 636 TOOL KIT 351390 241149 Anti Static Gloves 2 921309 Hex Key Set 921316 3 16 Long Ball Driver 181301 2 5mm Ball Driver 301156 Chip Removal Tool 351398 656 636 Users Manual Customer Responsibility e 5 Printer Setup Installing the Stacker 6 e Printer Setup Remove the stacker from the separate packaging Remove the packaging from around the stacker and save with the rest of the printer packing supplies Swing open the top cover to the
35. he stock roll core over the outboard guide and slide the roll to the back guide Move the outboard stock guide in until it contacts the stock roll 2 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 Ifthe material was glued to the core cut off all material that has glue on any surface 3 Open the print head by pressing the release lever 4 Open the web guide just before the print head platen roller to a width wider than the stock to be used 5 With the cover in the up position slide the leading edge of the stock through the lower guide that also contains the sensor system Keep the stock to the back of the printer as the unit is a back justified printer 6 As the stock exits the sensor area continue to slide the stock through the print station At this point you may need to direct the edge of the stock below the ink drive roller 7 With the feed roller open slide the stock through the two feed rollers aux feed and through the knife into the stacker approximately 1 2 to 3 4 of an inch 8 Check that the stock is still to the back of the printer 9 Adjust the front web guide just in back of the platen roller until it just misses the front guide This is to allow for the slight tolerance variation in the stock 10 Close the feed roller and the print head station 11 Rewind any loose stock onto the supply
36. he troubleshooting section The following guidelines indicate the proper procedure used to calibrate the sensors A voltmeter is highly recommended for this procedure however the Bank of Lights will provide an estimation of sensor performance until peak performance can be achieved with a voltmeter Suggestion clean all optical sensors prior to adjustment as dust and debris will adversely effect their performance Users Manual Model 656 636 DIP Switch E J9 o NOTICE 288834 Bank of Lights Top Ink Sensor Bottom Ink Sensor Registration Sensor Opt Reflective Sensor RESERVED Full Stack Sensor Headlift Sensor RESERVED 24V enable 5VDC ok R48 R50 R51 R52 R49 R47 R54 11 12 13 18 16 8 10 SOSI AAR Wy T T ua Ap a O_o HT gor 001 10 gp 5VDC SSR I LI 9 Thermal Controller Board as viewed from back of printer All test point voltage measurements including sensor adjustments should be made on the DC scale with the black lead of the meter connected to the ground test point 22 Care should be taken to ensure that meter leads do not short against unintentional test points throughout the measurement procedures Hole Slot Index Registration Sensor PO Sensor Blocked Sensor Not Blocked TP13 TP13 Adjustment Pot PRS RSI 3 Light Status or Desired Voltage gt 3 50 VDC lt 0 75 VDC The Hole Slot Registration Sensor in conjunction with the light bar allows the printer to register to pre
37. her adjustments sense mark stock out arm stacker etc per trouble shooting section of manual Lubrication Procedure General The 636 656 series printers are factory equipped with either composition bearings not requiring lubrication or pre lubricated bronze bearings The one exception is the rub cams on either end of the rotary knife Periodic cleaning of the printer and removal of dust will greatly enhance the length of the time the printer will function Cam Lubrication Procedure 1 Clean dust and residue from cams using alcohol or other suitable solvent daily or approximately every 100K cuts Use any good quality general purpose grease not oil Apply with cotton swab or other non metallic device 2 If lubrication is omitted knife will squeak and draw attention to required lubrication Composition Iglide Bearings 1 If field replacement of an assembly fitted with an Iglide bearing is performed a single drop of spindle oil should be applied to assist in bearing break in 2 If after long use an Iglide bearing starts to squeak disassemble the component containing the bearing and lightly abrade the shaft surface Clean the bearing dust or old oil with alcohol re lubricate with 1 drop of light oil and reassemble No other printer lubrication should be required in normal use Users Manual Model 656 636 Mechanical Trouble Shooting e 59 Appendix A Error Messages On the Machine s detection of errors error
38. in 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 Unit Specification Print Narrow web thermal transfer or thermal direct one sided printer method Speed up to 7 IPS 177 8mm second Label Size Max up to 5 125 130 2mm web x up to 7 177 8 mm feed cut and stacked up to 14 0 355 6mm feed w rewind Min 1 25 4mm web x 1 25 4mm feed Print Area Max up to 5 127mm web x up to 13 875 352 4 mm feed Min None Resolution 240 DPI x 240 DPI standard domestic Si 300 DPI x 300 DPI standard internationally Fonts Two scalable fonts resident condensed standard and bold typefaces upper and lower case Apt up to 96pt 300 DPI 6pt up to 96pt 240 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 Full International Set Symbols 200 5 1mm x 200 5 1mm 240 DPI 4 care symbols per 1 25 4mm 156 3 9mm x 187 4 8mm 300 DPI 5 care symbols per 1 25 4mm 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 sens
39. ing tests and screens will be displayed ENGLISH ONLY VXX XX DIAGNOSTIC TEST 1 This screen is displayed during the Control Panel test This screen will be displayed while the Front Panel is initializing and waiting for the TCB response The top line will display the FRONT PANEL code version and the machine language ENGLISH GERMAN SPANISH ETC For example if German were the second language installed the screen would look as follows GERMAN ENGLISH VXX XX DIAGNOSTIC TEST 1 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 code will check the LCD display 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 BUTTON NAME KEY STUCK DIAGNOSTIC TEST 1 The BUTTON NAME will be one of the push button names on the front panel START FEED TEST STOP EXIT MODE lt YES NO gt OR ENTER When the code has finished the above tests the code will attempt to communicate with the Control Board TCB If all tests are complete and no errors detected then the sy
40. is mounted on a square shaft directly above the web guide plate assembly just prior to the print module Although this bar is factory adjusted prior to shipment it may be necessary to readjust the bar to assure proper light reception Adjustment Procedure 1 Remove machine rear cover 2 Slide receiver block to the rear of the square bar 3 Thread pre punched stock through web guide and adjust outer guide to lightly touch outer edge of stock 4 Move stock until pre punched hole is visible in slot above LED bar 5 Slide receiver block out until it is located approximately over the hole accurate adjustment forward and back can be accomplished when printer is electrically activated Maintenance Adjustments e 39 Electrical Connections y Orange ECON Orange EE Machine Wiring Orange Gray Orange THERMAL CONTROL BOARD Gray HEAD DRIVER BOARD REAR VIEW OF 656 Users Manual Model 656 636 Electrical Connections e 41 Relay Assembly SIDE VIEW GREEN GRAY GRAY BOTTOM o YELLOW WHITE RED TOP VIEW Part 351136 TERM NATION CHART RELAY TERMINALS MACHINE TERMINALS TCB J 9 PIN 18 TCB J 9 PIN 24 POWER SUPPLY 24VDC POWER SUPPLY 5VDC TCB J 5 PINS 1 amp 2 AT POWER CONN PL1 PIN 1 42 e Electrical Connections BACK OF MACHINE RELAY
41. itive Interface PAXAR PCL via RS232 serial port 9 pin D shell Verifier serial port 8 pin MicroDin Users Manual Model 656 636 Product Description e 11 Panel 16 0 406 4 mm high x 27 685 8 mm wide including stacker x 18 5 469 9mm deep 41 F 5 C to 104 F 40 C Other Downloading of information while machine is operating Features Sequenced Fields Time Date Stamping Life Counts Operator adjustable strobe cut position print position baud rate and buffer size Error Detection of stock out ink out print head open guard open full stacker and print head over temperature Display labels left to print in a batch batch ID total life inches total life cuts Self Diagnostics Missed sense mark detection and correction Slot Notches Hole or Reflective registration detection Ink Ribbon PAXAR standard thermal colors and widths Options VL70 Barcode Verifier System Rewind Unit 110V or 220V Reflective Sensor Back of Web Only PCMate SELFFORM Spare Parts Kit International Hardware Kit 12 e Product Description Users Manual Model 656 636 Printer Operation Installing Ink Ribbon Users Manual Model 656 636 NOTE WHEN THIS MACHINE IS TURNED ON FOR THE FIRST TIME A PAXAR FIELD ENGINEER MUST BE PRESENT INK UNWIND INK REWIND SENSOR PRINTHEAD TURN BAR PLATEN ROLLER Figure 2 Threading path The ink ribbon comes pre packaged in a plastic bag For best
42. k guide is located on the back of the stock support bar This guide is moved by loosening the button head screw located to left of the support bar Loosen the screw and slide the forward or back as needed The ideal location is to measure from the front of the plate 31 32 24 6mm back to the housing Printer Operation e 15 The only other adjustment for the back of the web is the back stacker up right rail To move the location of the up right loosen the knob under the stacker and slide the unit in or out as needed The up right rail should be located approx 1 16 1 5mm to the back of the label or tag as it enters the stacker Print Head Open Close The print head module is to be opened and closed for threading the stock and ink The unit must also be opened to clean the head and for print head replacement Later in the manual under separate heading cleaning and replacement will be covered The print head has an interlock switch that prevents the printer from running with the head in the open position If the head is open the display will read GUARD OPEN Both the top cover and head use the same command WARNING DO NOT TOUCH THE PRINT HEAD WITHOUT WEARING THE ANTI STATIC GLOVES AND THE STATIC WRIST STRAP To open the print head for threading supplies press the lower portion of the latch see figure The head mount plate will hinge from the back to swing open Figure Print Head Open Closed To close the head mount plate move
43. l Trouble Shooting Probable Cause 1 No batches to be printed 2 An interlock condition exists 3 Ink motor unplugged or faulty 4 Thermal Control Board unplugged or faulty 5 Ink roller bound 6 Ink bound Corrective Action 1 Download batch if batch downloaded uses the same format as a previously downloaded batch the machine with start automatically 2 Determine the number and type of interlock s by reading the front panel display As each is corrected the number of errors will decrease Example Error 910 Stock Out reload stock 3 Check ink motor cable and or replace ink motor 4 Check Thermal Control Board AT board connection and or replace Thermal Control Board 5 With power off check that all rollers and arbors turn freely 6 With the print head open check that the ink will pull through the printer with little to no resistance Users Manual Model 656 636 Print Problem Machine advances stock but does not print Machine stops after ever third label Print registration is off in the feed direction Users Manual Model 656 636 Probable Cause 1 Stock registration sensor miss aligned 2 Miss adjusted print head position 3 Miss adjusted print head pressure 4 Print head cable unconnected or faulty 5 Print head faulty 6 Head Driver Board unplugged or faulty 1 Stock registration sensor miss aligned 2 Stock registration sensor uncalibrated
44. ller 2 Users Manual Model 656 636 Item Part Description Qty 17 990020 6 32 Button Hd Screw 8 18 19 20 21 4 20 Cap Screw e S gg A Optional Stackers e 101 Optional 4 25 Stacker Assembly 102 e Optional Stackers Users Manual Model 656 636 Optional 4 25 Stacker Parts List Item Part Description Qty 6 378130 RailSlideBracket 2 8 378210 BaseStackerRail 1 9 38215 Stacker Upright Front 1 Stacker Motor Harnessed Users Manual Model 656 636 Item Part Description 10 32 Cap Screw 4 Snap Ring 28 351160 Full Stacker Harn NS 1 J Ti 358018 Timing Belt NS 990006 4 40 Cap Screw a A Optional Stackers e 103 Optional Down Stacker Assembly Drawing Part 1 VA 104 e Optional Stackers Users Manual Model 656 636 Optional Down Stacker Parts List Part 1 Item Part Description Qty 6 168024 Pick Up Roller st 8 168087 Pressure Roller Assembly 4 9 168029 PlateMotorMount 1 Item Part Description __________ Qtyl 20 990020 6 32 Button Hd Screw 8 168022 Sensor Mount Upper 13 168001 Plate Sensor Cover 2 168007 Motor Shaft Extension Users Manual Model 656 636 27 928012 Sprin 3 Optional Stackers e 105 Optional Down Stacker Assembly Drawing Part 2 106 e Optional Stackers Users Manual Model 656 636 Optional Down Stacker Parts
45. lusive use of the PAXAR printer and it s peripherals The PAXAR printer is shipped in a large cardboard box 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 cardboard carton 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 carton while it is being moved within your facility will help to protect the printer during any movements to this new location Once the printer has reached its intended location you should begin the unpacking process Open the printer from the top of the box See Figure 1b Do not cut deep into the carton as there are items located just under the top Remove the items located on the top insert Remove the top insert Lift the printer onto the table with the two banding straps Remove the two straps and the plastic from the printer 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 other countries please contact your local PAXAR supplier Once you are satisfied that there was no obvious shipping dama
46. ments require a tool Guide adjustments have already been covered in the stock loading procedure The first guide is on the roll support bar The front guide must be slid to the back of the printer to hold the supply roll against the back guide plate Place your thumb against the round stub close to the support bar Push the guide until it firmly contacts the front of the supply roll This will hold the supply against the back guide This completes the adjustment for this guide The second guide is located just to the left of the print head and platen roller This guide must be set close to the front edge of the card stock but must not pinch the edges If the guide is too tight the card stock will have rolled up edges To move this guide place your finger to the inside or the guide opposite the guide pressure screw and pull to widen the opening To close down the opening place your thumb against the side of the pressure screw to slid the guide in NOTE THE BACK EDGE OF THE WEB GUIDES HAVE BEEN FACTORY SET CHECK THAT THE FORMAT HAS BEEN MADE CORRECTLY BEFORE MAKING FURTHER ADJUSTMENTS There are two independent adjustments and one fixed back guide The one fixed back guide is opposite the platen roller guide This has been located to control the edge of the stock to the first dot on the print head This location is critical to Paxar s Formatter software Do not adjust this guide with out consulting a Paxar service engineer The adjustable bac
47. n Item Part Description 990251 8 x 1 2 Dowel Pin 990133 1 990133 Qty 990102 10 SAE Washer rant 990091 10 32 x 1 2 Button Head Screw Assembly Drawings e 81 1 Ink Rewind Arbor Assembly Field Retrofit Kit 82 e Assembly Drawings Users Manual Model 656 636 Ink Rewind Arbor Parts List Part Description Qt 1 NoLongerUsed 356191 Fixed Rewind Shaft Assembly 356192 Front Bearing Housing Assembly 991038 Serrated Bellville Washer 11 991037 047 Steel Shim 1 356108 42T Timing Belt Pulley 990134 20 x Button Head 14 990434 External Tooth Washer Users Manual Model 656 636 Assembly Drawings e 83 Feed amp Ink Drive Assembly 84 e Assembly Drawings Users Manual Model 656 636 Feed amp Ink Drive Parts List Item Part Description Qty 15 990111 10 32x Flat Head Screw 6 1 9 16 Stand Off 3 18 351141 InkMotor sd CC 19 245026 FeedMotor Cd Cd 20 990081 10 32x Cap Screw 12 194023 1 3 8 Stand Off 3 284025 14 Tooth Pulley Ex N A 356109 Ink Timing Belt 85 Tooth sl ist dai Tooth Tooth Users Manual Model 656 636 Assembly Drawings e 85 Timing Belt Threading Diagram Users Manual Model 656 636 86 e Assembly Drawings Timing Belt Parts List bail Pb O Number First 100 units onl 20T Idler Pulley w Bronze Bushing 23C 356195 1 First 100 units onl 24A 1
48. nt 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 Paxar has developed the following procedures Handling Static discharge is very detrimental to thermal print heads To avoid contacting print heads with a static charge follow these simple procedures All print heads should be kept in original anti static bags until they are placed in the machine The 656 636 printer is supplied with an anti static wrist strap Locate the strap it must be worn at all times when handling the print heads Do not touch any terminals extending from the print head or the print line Anti static gloves are provided with your machine upon installation and extras may be ordered from Paxar These gloves must be worn at all times when handling the print head If an anti static glove is not available make absolutely certain to thoroughly wash and dry your hands before handling the print head Oils from your hands can contaminate the print line and quickly destroy the printing elements Users Manual Model 656 636 Maintenance Adjustments e 29 Print Head Cleaning 30 e Maintenance Adjustments CAUTION TURN OFF THE POWER TO THE PRINTER BEFOR
49. oll disc not shown 32 990026 6 6 32x 3 4 fh screw__ not shown Mad A E RA Assembly Drawings e 95 Stock Out Sensor Assembly Drawing 96 e Assembly Drawings Users Manual Model 656 636 Stock Out Sensor Parts List Item Part Qty Description Number 6 989973 2 440x 50CapScrew 8 990255 1 3 16x3 4DowelPin 9 990261 1 3 16SnapRing Users Manual Model 656 636 Assembly Drawings e 97 Optional Stackers 98 e Optional Stackers Users Manual Model 656 636 4 25 Stacker Specifications e 4 25 Web x 1 Feed e Will work on 636 656 amp 676 e Old machines may require the knife strut to be replaced with one that has a mount hole Part number 355018 e Fabric and heat seal only not for pressure sensitive or tags e Stack height dependent on material size and weight may not reach full stacker height e Jam sensor will require relocating the LED to the center position for the 676 and back set of holes for the 636 amp 656 e If changing from standard stacker to 4 25 stacker the knife guard must be changed to match the stacker being used Users Manual Model 656 636 Optional Stackers e 99 Optional 4 25 Pick up Assembly 100 e Optional Stackers Users Manual Model 656 636 Optional 4 25 Pick up Parts List Item Part _ Description Qty 6 378204 SensorMountUpper___ 1 8 378119 Side Frame Near Stacker 1 9 378129 Support Pick Up Ro
50. pring in detent 2 Loosen shear adjustment screws and move outer end of knife until full cut is obtained Users Manual Model 656 636 Ink Problem Ink wrinkles or will not pull smoothly Ink rolls loosely on take up roller Users Manual Model 656 636 Probable Cause 1 Incorrect adjustment of unwind roller brake resistance 2 Unwind roller and ink take up roller misaligned 3 Ink buildup on turn bar s 4 Incorrect ink width 1 Take up roller not turning 2 Take up core binding on locator plate 3 Take up core not contacting ink drive roller 4 Take up roller too full Corrective Action 1 Adjust knurled knob clockwise as far as possible without breaking ink or stalling ink motor Do not bottom adjustment knob Replacement of fiber brake disc may be required if printer has high hours 2 Align rear edge of ink with rear of print area allow approximately 1 8 3mm overlap Loosen thumb cap screw on ink out sensor mount plate and adjust until it touches rear of ink roll on unwind arbor Lock slide rewind core toward rear of printer until 1t just contacts plate 3 Clean with alcohol 4 Use an ink width no wider than stock being printed This is especially critical when using a narrow web with cut down rollers 1 Check that roller swing arm rear of printer is not binding and Roundthane belt is not broken or slips excessively 2 Move core 015 030 38mm 76mm
51. printed media The low level is the more crucial of the two adjustments Note that the same pot is used for both adjustments and a compromise value must be achieved Begin by removing the stock from the sensor path Measure the low voltage throughout the mechanical travel of the sensor by sliding it inboard and outboard The voltage at all points should not vary more than 0 75VDC If it does the sensor slide bar and or the light bar must be mechanically aligned see Hole Slot Index Registration Sensor Mechanical Adjustment below Once this is achieved find the web location where the low voltage is the highest and adjust the pot until the reading is 0 75VDC or less Now block the sensor path with the media you intend to run The high level should be greater than 3 5VDC at all points of the sensor s travel Hole Slot Index Registration Sensor Mechanical Adjustment There are two areas that can be adjusted to correct the voltage readings The upper sensor square bar may be loosened from the back of the printer and rotated The second adjustment is to loosen the light bar mount screws and move the bar in the web direction When the light bar screws are retightened be careful not to over tighten and brake the light bar PC board Users Manual Model 656 636 Maintenance Adjustments e 35 Reflective Index Registration Sensor Not on Mark Mark 4 LightStatus On CE Desired Voltage The Optional Reflective Registration Sensor if installed
52. printer Locate the large knob and two round pins on the right hand side of the printer Loosen the knob enough to allow the stacker to slide between the printer housing and the knob The stacker will rest on the two pins Slide the stacker to the back until it contacts the up right frame Tighten the knob Adjusting the stacker is covered later Install the stacker up right rails Remove one of the thumb screws Insert the thumb screw through the mating hole in the up right rail assembly Thread the thumb screw into the mounting block Repeat the above procedure for the other thumb screw There is a harness and connector leading from the back of the stacker that plugs into the center connector on the last PC board The connector and plug are polarized Rotate the plug until the polarized plug and connector align and push them together Users Manual Model 656 636 Fuse Configuration The main fuse s on the Paxar 656 636 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 screw driver open the AC entry by lifting the tab just above the voltage indicator window 2 Remove the red fuse drawer 3 Remove all fuses and the fuse jumper if it is present 4 Insert into the fuse drawe
53. quare I C s HEAD DRIVER BOARD Upgradeable software I C s include U1 U2 U8 and U18 62 e Appendix B Users Manual Model 656 636 Align angled corners of chip with socket and arrow denotes pin 1 or dimple on chip Front Panel Board P N 351108 Use chip removal tool p n 351156 for square I C s FRONT PANEL BOARD Upgradeable software for FPNL x x Align angled corners of chip with socket and arrow denotes pin 1 or dimple on chip Users Manual Model 656 636 Appendix B e 63 Appendix C Ink and Stock Transfer Types Value 051 052 054 058 Fabric 2800 amp HR 1111 Ink 060 066 069 64 e Appendix C Users Manual Model 656 636 s Fabric 2795 amp HR3IT Ink 3 Fabric 2795 amp HRAN Ink 076 or 078 07s om 078 om oso ost MEM 083 084 New Pressure Sensitive no xfer amp TT 3111 Ink 086 087 oss 089 MOM oat 092 093 094 095 096 3_ New Pressure Sensitive no xfer amp GP I111 Ink 5 2795 Fabric amp GP 1111 Ink ew Pressure Sensitive no xfer amp HR 1111 Ink 6 7 8 8 8 8 9 0 1 6 7 8 9 1 x 3 x S gt 7 2 4 2 4 07 07 07 07 07 07 07 07 07 08 08 08 08 08 08 08 08 08 08 09 09 09 09 09 09 Users Manual Model 656 636 Appendix C e 65 Transfer Type 591SST 601SST Fabrics amp CT 1114 Ink 601SST Fabric amp CT 1111 Ink 591SST 601SST Fabric
54. r 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 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 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 P C Board Installation Install P C Boards as follows Users Manual Model 656 636 Printer Setup e 7 Memory Card Option Board 350016 Slot 5 from back Diskless Rom Bd 281164 Slot 4 Thermal Control Bd 351105 Slot 2 Head Control Bd 351106 Slot 1 TCB Dip Switch S2 Settings TCB DIP SWITCH S2 SETTINGS 1 DPI OFF 240 ON 300 2 DPI Undefined OFF Default ON 3 MACHINE TYPE OFF 656 ON 636 4 MACHINE TYPE Undefined OFF Default ON 5 JAM SENSOR OFF not installed ON installed 6 UNDEFINED OFF Default ON 7 UNDEFINED OFF Default ON 8 UNDEFINED OFF Default ON Installing the Power Cord A power cord is shipped with each printer The cord for 110 volt printers will use the st
55. re and maintenance of the unit We at PAXAR hope that you will come to appreciate the efforts and quality which have gone into producing your PAXAR 656 636 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 Users Manual Model 656 636 Scope e 1 Warranty Information Limited Warranty PAXAR Systems Group Division of PAXAR Corporation extends the following warranties to the original purchaser of a PAXAR 656 636 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 656 636 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 addres
56. 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 1 Unwrap the ink ribbon and put it on the ink ribbon supply arbor Figure 2 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 below and is threaded as illustrated see Figure 2 NOTE A new ink ribbon has a leader which makes it easier to use when threading the ribbon through the print area 3 Put an empty ink ribbon take up core on the ink ribbon take up arbor The ink take up core must be at least as wide as the ink supply The tape on the supply roll of ink will be used to fasten the leader to the core 4 Advance the ink until the leader starts to wrap around the take up core 5 Lower the take up arbor into place You will have to rotate the ink arbor as the swing arm is returned to the drive roller to keep excess slack ink from between the print head and the take up roller NOTE Make sure that the ink ribbon take up core and the ink ribbon supply roll are against the edge guide plate so that the ink ribbon tracks straight through the print station Printer Operation e 13 Loading Stock J Ink Take up lt Stock ouf Decurler FIGURE 3 STOCK THREADING LOADING STOCK FOR THE FIRST TIME 1 Slide the outboard stock guide to a position wider than the roll of stock to be loaded Set t
57. reworked assemblies e 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 put on the plunger and inserted into the solenoid C Clip 991013 Sm Nylon Washer Lo ON O Ya 351123 6x6 Solenoid Harness w Plunger 197313 Spring 990729 Lg Nylon Washer 68 e Appendix D Users Manual Model 656 636 e There should be a 010 020 gap for roller clutch only between the two clutch pieces I 010 020 GAP e Test on the solenoid test box The knife must cut both fabric and card stock The solenoid should operate on both the high and low settings e Excessive motor drag must be minimal at start stop and while running Replace or repair problem component On old knife assemblies there are bronze bushings in outer support They may be causing a bind Ream bushing and retest Do not ream if it is a roller bearing e 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
58. rily appear whenever the EXIT Up arrow is pressed and there are batches to be printed After this momentary display the HOME screen is again displayed Pressing the MODE Down Arrow key will take the user to the next screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen Users Manual Model 656 636 Display Modes Users Manual Model 656 636 There are four 4 main mode levels which are selected and modified using the following function keys Use the MODE J key to move through the main mode screens shown below PRESS ENTER FOR PRINT REPORTS PRESS ENTER FOR SETUP PRESS ENTER FOR LIFE COUNTS PRESS ENTER FOR PROTECTED FEATURES Use the EXIT to move to the HOME screens Print Report Mode Use the Mode Y key to move to the following screen PRESS ENTER FOR PRINT REPORTS Use the Enter key to enter this mode PRESS ENTER TO PRINT LAST VERIFIER SCAN This is the first screen under Reporting features This screen will appear if a verifier is connected to the printer This screen allows the user to print the last scan report Prints the failure cause for the last bad barcode scan Control Panel Operation e 23 24 e Control Panel Operation PRESS ENTER TO PRINT VERIFIER HISTORY This screen follows the PRINT LAST VERIFIER SCAN screen if a verifier is connected to the printer This screen allows the user to print history report of the scanner reads Prints a report of the his
59. robable Cause Corrective Action Knife stops during cut in stock 1 Check life of blades 1 If warn and dull may stall in stock If life is greater than 2 million replace blades 2 Clean cams and lubricate 2 Make sure oiler is on knife Instruct Operator to oil weekly Make sure oil is available 3 Clutch worn out and can t stay 3 Replace Clutch engaged Slight Long and Short Tags 1 Sticking Solenoid 1 Check gap on the trip arm to clutch body must be about 040 inches If too large solenoid has less force Check assembly of spring and washers Use latest engineering assembly procedure Clean Solenoid 2 Sticking Trip Arm to Clutch Roll 2 Check for burr on trip arm catching on Pin clutch stop roll pin File off burr on clutch roll pin and or replace trip arm 3 Clutch has trouble picking up 3 Clean 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 2 Clean clutch and replace if not solved stock runs into blades Knife does not cycle 1 Solenoid not engaging 1 Trip knife solenoid by hand to see if knife cycles If cycles and cuts check cable to solenoid check solenoid adjustments and assembly check gap and replace solenoid if necessary 2 Knife Motor Broken 2 Replace Knife Motor good for 10 million labels by spec
60. roll 14 e Printer Operation Users Manual Model 656 636 Butt Splice NOTE DO NOT RUN BUTT SPLICES THROUGH THE PRINT STATION The PAXAR 656 636 has been designed with the operators need to change supplies quickly in mind Re threading the stock is quicker than butt splicing If you have determined a butt splice is necessary tape the free end of the new stock roll amp the free end still in the printer together Make sure you have determined how the new roll will go on the printer to prevent any twist in the stock Following the procedure previously outlined load new supply roll onto the printer Remove all slack by rotating the supply roll counterclockwise Advance splice beyond the print station This can best be accomplished by using the stock feed function switch combination see push button description in Control Panel section NOTE Whenever stock of a different type or width is put on the printer a sample run should be performed If the print quality is acceptable you can immediately begin your production run If the print quality needs to be optimized refer to the Setup Procedures and perform the procedure needed to make the necessary improvement Web Guide Adjustment Users Manual Model 656 636 The Paxar 656 636 printer has been designed with the operators needs in mind Therefore there are only two web guides in the printer that may need to be changed as the width of the rolls change for formats Neither of these adjust
61. s amp CT 1115 Ink 591SST 601SST Fabrics amp CT 1117 Ink 591SST Fabric amp CT 1112 Ink 122 601SST Fabric amp CT 1112 Ink 66 e Appendix C Users Manual Model 656 636 Appendix D Knife MFG Guideline Solenoid Trigger Setting AF 5 FEELER GUAGE 1 After the clutch and actuator is mounted to the knife attach the solenoid assembly to the inside support using two 6 32 x 3 8 cap screws flat washers and lock washers Make sure the plunger moves freely and does not bind Motor and faceplate must be mounted also 2 Check the gap between the actuator and the top of the pin on the clutch as shown in drawing The plunger should be pushed in to make the measurement Other hints if there is still a problem e Ifthe gap is greater then 047 an old solenoid bracket is being used Replace P N 357003 or slot the bracket e If plunger binds the solenoid is not parallel with the base of the bracket that mounts to the knife support and or the actuator slot is bottoming out on the roll pins that are on the plunger Make adjustment or replace the bracket Users Manual Model 656 636 Appendix D e 67 e Torsion Spring should be at an angle of 60 2 Lay the spring over the drawing below to see if the spring is made properly e Plunger pins should be centered on shaft If either pin is loose DO NOT use the plunger The pins should be checked before installing e Rev 3 Replace both roll pins on all
62. s for no apparent reason while it is in the middle of printing a batch of tickets you may be missing sense marks three consecutive tickets in which a sense mark was not found Check for the following The front panel will display a screen indicating that there has been a missed sensor error Maintenance Adjustments e 33 34 e Maintenance Adjustments Check that the front web guides have been positioned properly both on the supply roll and in front of the print roller Check that the feed roller pressure has been set equally across the roller Check to see that the print head pressure has been set properly Repeat the sensor alignment procedure Cleaning Print Sensor When print registration in reference to sense mark becomes inconsistent or erratic the Sensor and Light Bar may need to be cleaned Supplies Always use clean supplies when cleaning the sensor and light bar Never use anything abrasive to the sensor and light bar NEVER use an alcohol based solution when cleaning the sensor or light bar Dry air or a cotton swab are the PAXAR recommended items to use when cleaning the sensor and light bar Sensor Trim Pots Your 656 636 printer is equipped with several sensors used to detect the status of the printer and its supplies While these sensors are calibrated at the time your printer is manufactured there may be times when re calibration is required Re calibration times are indicated in t
63. s 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 656 636 printer is a high resolution thermal printer While PAXAR has designed the printer to be reasonably quiet it is recommended to location 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 656 636 Customer Responsibility e 3 AC Power Line Unpacking 4 e Customer Responsibility PAXAR requires that the electric service be 10 Amps 110VAC or 10 Amps 220VAC 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 period 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 exc
64. s 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 OH 45342 Call 800 543 6650 Fax 937 865 2092 for Warranty Parts Fax 937 865 2707 or 937 865 6605 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 1t considers necessary and does not assume any obligation to make said changes in equipment previously sold 2 e Warranty Information Users Manual Model 656 636 Customer Responsibility Location of Printer The printer weighs approximately 57 Lbs 26Kg 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 la Figure la Recommended workstation layout The location of the PAXAR 656 636 printer should be based on human factors The printer should be located in an area which 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 operation
65. screws e Rev 2 All new knife assemblies have a blue clutch The clutch outer race bushing has an I D of 500 and the 2 extension springs are 012 dia wire e Rev 2 The 2 extension springs on all rebuilt clutches must have the 009 dia wire springs replaced with 012 wire springs e Rev 5 Replace Knife Actuator 357020 if it is worn or if there is a bulge at the 90 degree bend e Rev 6 Changed feeler gauge tolerance from 047 MIN Users Manual Model 656 636 Appendix D e 69 Assembly Drawings Users Manual Model 656 636 Assembly Drawings e 71 Unwind Assembly Drawing 72 e Assembly Drawings Users Manual Model 656 636 Unwind Parts List Users Manual Model 656 636 Item Part Description Qty 1 353001 Guide Unwind Rear 1 353005 Optional Unwind backer plate not 1 shown 353002 Bracket Unwind 353003 Guide Unwind Front 990170 5 16 18 x 3 4 Cap Screw 1 990277 5 16 Bellville Washer 990439 340 x 740 Nylon Washer 990089 10 32 x 1 4 Button Head sa 6 Assembly Drawings e 73 Web Guide Light Bar Assembly Drawing 74 e Assembly Drawings Users Manual Model 656 636 Web Guide Light Bar Parts List Part Description Qty 354006 Bracket Web Guide Sensor___ 1 354003 Web Guide Outer st 1 354001 Plate Web Guide Mount 1 990066 8 32 x 1 4 Button Head 2 Users Manual Model 656 636 Assembly Drawings e 75 Drive Assembly Drawing
66. stem will go to DIAGNOSTIC TEST 2 and display the TCB code version CONTROLLER VXX XX DIAGNOSTIC TEST 2 This screen should be displayed once the TCB has requested signon from the Front Panel and the system is waiting for the AT to complete its initialization Control Panel Operation e 21 22 e Control Panel Operation HOME SCREEN READY FOR BATCHES IMAGER VXX XX OR BATCH ID QTY PCL001 000000010 When the printer is powered up and all initializations are complete and if there are no Batches to print the HOME screen will be READY FOR BATCHES and the A T code version number IMAGER VXX XX will be displayed When at the READY FOR BATCHES screen and the HOST is mapping the screen will display BUILDING IMAGE IMAGER VXX XX When at the READY FOR BATCHES screen and there are no batches and the ENTER key is held down the screen will display the last batch printed if any LAST BATCH WAS XXXXXXX IMAGER VXX XX When there are Batches to be printed the HOME screen will be BATCH ID QTY screen the Batch ID Batch Qty screen will display the currently cutting batch ID and labels left to cut If the printer is performing a FEED or a TEST pattern this screen will show FEEDING or PRINTING TEST PATTERN respectively on line two PAXAR 656 240 IMAGER VXX XX This is the MACHINE ID screen This screen shows the machine model 656 or 636 and the print head type 240DPI or 300 DPI This screen will momenta
67. t Panel Menu Functions ieei enero is Eisis Eiee oaee e Era e 20 Users Manual Model 656 636 e iii LCD Display cise sile Ra lella 21 Display Modest ele 23 Maintenance Adjustments 29 Print Head Handling acces ag ia EIA oA as wee SRA 29 PrittttHeadCleanin G3 E A a Re Be eA aaa 30 Print Head Replacement ini nana 31 Print Head Adjustment 32 Registration Sensor Adjustment 33 Stock out AUS MOE rocio tinas eaei ani 37 Knife Square AUS iia 37 Stacker Adpustments sica 38 Stock Feed Adjustment ian RA aaa 38 Mechanical Adjustment Of Feed Roller Pressure Blue Roller 39 Mechanical Adjustment of Stock Sense Mark Light Receiver i 39 Electrical Connections 41 Machine Wiring nascere aa Ea Lora nai 41 Relay Assembly ti Un A A A ua o 42 Electrical System Schematic ara tew a hatin arene 43 Motherboard Power Connectors sscaicisstes ccs Aa E niece een 44 Electrical Trouble Shooting 45 Power Up Sign On CommunicationS e 45 Stock Inik Advance a3 conside esa 47 Print tica nadia e ets tee re ONG ius nen ect et a i are Ci 49 Cut Stack e aa gh Ae oe ET a Bie dees 51 Electrical Trouble Shooting Machine Set Up Sequence 52 Mechanical Trouble Shooting 53 SOC aot tie a O 53 IMC AE etude tt A RARO bd E iaa 55 Dd A A AAA A AA Aaa 56 ner hase E A AIE NO RA A TA 57 Mechanical
68. t head 1 Review the Printhead Handling Procedure Sheet packaged with each print head to determine if any procedures have changed before beginning this procedure 2 Remove the ink from the machine for easy print head removal 3 Unplug the ribbon cable that runs to the print head Unplug the cable by firmly but gently pulling it out 4 Back the print head pressure screws off counterclockwise as far as possible 5 Place your hand with static gloves on underneath the print line of the print head and push up to release the locator pins on the heat sink while pulling the print head to the right of the machine This will remove the print head assembly from the mount plate You may need to help the print head out by pushing on the heat sink with your left hand 6 Remove the two print head mount screws located on the top of the print head with a 2 5mm ball driver 7 Remove the old printhead carefully from the heat sink 8 Place the new print head into the heat sink Check to see that the new printhead sits square in the heat sink and that there is no end play If there is end play or the head does not seat properly the heat sink guide will need adjustment 9 Replace the two print head lock screws Be sure that the head is resting flat on the heat sink before tightening these screws 10 Replace the print head assembly in the printer making sure that the pin at the back of the heat sink goes into the hole in the mount plate M
69. th 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 sensor on the inboard stack up right is used to stop the printer when the stack is full A thumb screw adjustment is provided to set the stack height Warning some stock materials can not be stacked to the full height of the stacker because of excessive weight Stock Feed Adjustment 38 e Maintenance Adjustments When changing stock type the stock feed should be readjusted This is important to reduce any slip for too light an adjustment and reduce excessive roller wear for too tight an adjustment To adjust loosen the two top set screws using the 5 64 Allen key in the kit With the new stock in the drive roller fully close the stock feed lever rotate fully counter clockwise Tighten both set screws until there is slight pressure on the stock Run the one inch pull format and adjust the set screws an equal amount based on the results If the one inch label measures less than one inch tighten clockwise each screw slightly and repeat the measurement It the one inch label exceeds one inch loosen counter clockwise the tension on both set screws equally As a final check for stock feed balance betwe
70. the print head and platen Refer to Print Head Cleaning 3 After cleaning head and running the test pattern to confirm that a void still exists replace the print head 4 Set print head position Refer to Print Head Tangent Point 5 Set print head pressure Refer to Print Head Pressure Setting 6 Replace platen roller 1 Determine which sensor and re calibrate as needed Refer to Sensor Trim Pots 2 Determine which sensor and relocate accordingly 3 Either change the ink or the ink type in the format Users Manual Model 656 636 Cut Stack Problem Machine fails to cut labels the rotary knife does not rotate The stacker fails to run Users Manual Model 656 636 Probable Cause 1 The cut is disabled in the setup menu 2 Knife cable unconnected 3 Knife jammed causing auto resetting fuse to trip on the Thermal Control Board 4 Faulty knife motor 5 Faulty knife motor drive circuit on the Thermal Control Board 1 The stacker cable is unconnected 2 Faulty stacker motor 3 Stacker jammed causing auto resetting fuse to trip on the Thermal Control Board 3 Faulty stacker motor drive circuit on the Thermal Control Board Corrective Action 1 Enable the knife in the setup menu via the front panel 2 Power off and remove the power cord from the AC entry Remove the back cover and inspect the cable and connector to the knife module Refer to the Electrical
71. the displays will show the first error encountered and allow the displaying of any other errors with the lt and gt keys which Scroll through additional errors if any ERROR SCREENS The screen advances to next error with each depression of the gt key The screen retreats to prior error with each depression of the lt key ERROR MESSAGE ERROR NUMBER 1 10 ERRORS 901 STOCKOUT 1 10 ERRORS 904 INK OUT 1 10 ERRORS 910 HEAD OR FEED OPEN 1 10 ERRORS 701 MISSED SENSE MARK 1 10 ERRORS 903 DOOR OPEN 1 10 ERRORS 902 STACK FULL 1 10 ERRORS 404 HEAD OVTEMP 1 10 ERRORS 912 VERIFIER HALT 1 10 ERRORS 911 SYS ERRORS 1 10 ERRORS 913 DOWN LOAD ERR 60 e Appendix A Users Manual Model 656 636 Appendix B Software Upgrade Chip Placement Positions Thermal Control Board P N 351105 Use chip removal tool p n 351156 for square I C s THERMAL CONTROL BOARD Upgradeable software I C s include U16 and U53 Align angled corners of chip with socket and arrow denotes pin 1 or dimple on chip Users Manual Model 656 636 Appendix B e 61 Diskless Rom Board P N 281164 DISKLESS ROM BOARD Upgradeable software I C s include U12 U16 and U20 Position new I C s in same orientation as pictured above SWITCH POSITIONS SWI l and 6 OFF 2 thru 5 ON SW2 1 thru4 ON A A Head Driver Board P N 351106 Use chip removal tool p n 351156 for s
72. the screen will display INVALID PRESS ENTER PASSWORD XXXX Users Manual Model 656 636 Control Panel Operation e 27 28 e Control Panel Operation If password is correct the Mode Y key will go to the next screen CHANGE DATE TIME 01 04 95 08 55 AM Use the lt YES gt NO buttons to increment through numbers All 10 digits can be changed and also the A will toggle between A and P The date is always in the MONTH DAY YEAR format and the time is always in the 12 hr AM PM format Use enter to move to the next digit or to the AM PM field Use the Mode 4 key to save new time and date and move to the next screen CHANGE PASSWORD 4 DIGITS NEW WORD 0 Use the lt YES gt NO buttons to increment through numbers Use enter to move to the next digit Final enter saves new password PRESS ENTER FOR 2ND LANGUAGE Use Enter to toggle between ENGLISH and 2ND LANGUAGE Note Pressing the TEST button and the MODE button at the same time will toggle the second language from any screen OR If no second language available the screen will display as follows NO 2ND LANGUAGE AVAILABLE Use the Mode Y key to move to the following screen VERIFIER IS ENABLED PRESS ENTER TO DISABLE Use Enter to toggle between ENABLED and DISABLE for the verifier Use the EXIT 7 to move to the HOME screens Users Manual Model 656 636 Maintenance Adjustments Print Head Handling Warning Pri
73. ting Probable Cause 1 Machine incorrectly threaded 2 Web guides incorrectly adjusted 3 Unwind incorrectly adjusted 4 Incorrect DIP switch settings on the Thermal Control Board 1 Incorrect strobe setting selected in the format 2 Incorrect strobe setting in the machine setup 3 Miss adjusted print head position 4 Miss adjusted print head pressure 1 Ink miss aligned with format 2 Print head dirty 3 Faulty print head 4 Miss adjusted print head position 5 Miss adjusted print head pressure 6 Worn platen roller 1 Sensor uncalibrated 2 Sensor position miss adjusted 3 Ink sensor type light dark incorrect in the format for the ink type being used Corrective Action 1 Check and rethread the media as needed Refer to Loading Stock 2 Check and adjust as needed Refer to Web Guide Adjustment 3 Check and adjust as needed Refer to Web Guide Adjustment 4 Check and reset DIP switches as needed Refer to TCB Dip Switch S2 Settings 1 Using Formatter check and adjust the strobe setting according to the media and ink being used 2 Enter the setup menu and readjust the strobe as needed 3 Set print head position Refer to Print Head Tangent Point 4 Set print head pressure Refer to Print Head Pressure Setting 1 Adjust ink position on the arbors to achieve full ink coverage over all fields on the format 2 Power off the machine clean
74. tment required If the entire test pattern is broken up the printhead is probably not adjusted to the proper tangent point To adjust the tangent point loosen the two print head lock screws one half turn with a 2 5mm ball driver provided in your spare parts kit Do not remove the print head from the printer Once the screws have been loosened use the adjustment thumb screw to move the head forward and backwards Since the adjustment is very precise do not turn the thumb screw more than 1 4 of a turn before running another test pattern to determine if you are adjusting the print head in the proper direction Tighten the two mount screws Do not over tighten Run a test pattern again to determine further adjustment required Once you have restored a smooth even test pattern re tighten the two print head mount screws Do not over tighten and run one last test pattern Registration Sensor Adjustment Users Manual Model 656 636 Adjusting Print Sensor Position If you are running sense mark material with a hole or slot for registration Open the feed roller and print head Move the stock by hand in the feed direction until the registration desired is in the slot window for the pickup sensor Close both the feed and print head Slide the top sensor assembly using the sensor handle while looking at the registration index sensor When the light turns on and stays on the sensor is over the registration hole If your machine stop
75. tory of barcode scan quality PRESS ENTER TO PRINT VERIFIER SETUP This screen follows the PRINT VERIFIER HISTORY REPORT screen ifa verifier is connected to the printer This screen allows the user to print a verifier report containing verifier setup information Prints a report of all verifier current settings ENTER TO CLEAR VERIFIER SCAN MEMORY This screen follows the BARCODE VERIFIER ON screen if there is a verifier connected to the printer This screen allows the user to clear the scan history memory in the verifier Pressing ENTER clears the verifier scan history Pressing the MODE key will take the user to the Strobe adjust screen Pressing the EXIT T key will take the user back to the HOME screen Setup Mode Use the Mode Y key to move to the following screen PRESS ENTER FOR SETUP Use the Enter key to enter this mode CHANGE PRINT PRINT 0 NEW PRINT 2 For 300 and 240 dpi machines 016 increments Use the lt YES key to decrease the number and the gt NO key to increase the number Adjustment from 9 to 10 Zero is the middle of the range Use the Enter key to save the new value Users Manual Model 656 636 Use the Mode Y key to move to the following screen CHANGE THE CUT CUT 0 NEW CUT 2 Each increment for 300 dpi machine 026 Each increment for 240 dpi machine 025 Use the lt YES key to decrease the number and the gt NO key to increase the number Adjustment from 9 to
76. types such as barcodes logos care symbols will not be the exact size of the fields printed on the older printer Users Manual Model 656 636 Control Panel Operation e 25 26 e Control Panel Operation e The 650 printer is center justified meaning the web is centered under the printhead The 656 636 is a back justified printer meaning the web is to the back of the printer This will not cause a discrepancy unless the web of the stock does not match the web defined in the format e The verifier will be setup to a specific setting when a verifier is present The verifier can be disabled from the front panel The lt YES gt NO buttons are used to change the emulation Pressing ENTER will change the current emulator mode to the new emulator 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 TRANSFER TYPE 052 NEW TRANSFER TYPE 000 This screen follows the EMULATION MODE screen This screen allows the selection of a ink and stock TRANSFER TYPE See appendix C for details of ink and stock combinations The lt YES gt NO buttons are used to increment or decrement each digit Pressing ENTER will advance to the next digit After changing the last digit pressing ENTER will change the current transfer type to the new transfer type Enter all three digits including the leading zero Pressing the MODE Down Arrow key will tak
77. y by performing a test pattern as documented elsewhere in this manual A properly adjusted print head will produce an even grid of chevrons when the test pattern is performed Before making any judgments as to the quality of the printhead it is absolutely necessary to ensure that the platen roller and the printhead is clean of all debris Clean the platen roller located immediately beneath the print head with a clean cloth and a small amount of alcohol Be careful not to damage the platen roller while cleaning If the roller is worn replace the roller Print Head Pressure Setting The print head pressure setting is very important Keep the lightest setting possible This will improve print head life while maintaining quality print The printer has been factory set Further adjustment of pressure adjusting screw should be minimal If readjustment is required proceed as follows Power on the printer Remove the ink and card stock from the printer With the print head open turn the pressure screw counterclockwise until it does not contact the printhead mount plate it should slide freely back and forth Close the print head Slide the pressure screw until it sits directly over the center of the web Turn the pressure screw clockwise until it makes contact with the head mount plate plus 1 2 turn to add pressure As the web width changes adjust the pressure screw accordingly Download the proper format for the stock that is loaded Press start The

Paxar 656 / 636 User's Manual

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