Frequently Asked Questions

This error indicates that one of the devices attached to the I2C bus (the M4A motor driver board) is not responding. The error needs to be acknowledged by pressing the ONLINE key, after which the following things should be checked:

1. Determine if any additional error messages follow, and acknowledge them where required. [See Secondary and Tertiary Indicators below.]
2. Turn the printer off, and allow it to sit idle for at least 30 seconds.
3. If the error recurs on power up, re-acknowledge any cascading errors as in step 1, then check peripheral device settings under System Parameters. Reset to the proper configuration, and allow the printer to re-initialize.
4. After re-setting the peripherals or any other menu elements, turn the printer off again. Let the printer sit idle for at least 30 seconds, and then turn it back on. The printer should initialize normally.

NOTE: A persistent bus device error is indicative of either attempting to run the printer with incorrect settings, trying to override sensors, or failure of one of the M4A peripheral device boards.

Acknowledgement of the bus device error will generally produce a secondary error—either 5005, 5006, or 5008. These errors indicate that the associated device is not connected to its peripheral board, or may indicate a problem on the board itself. The secondary error must be acknowledged by pressing the ONLINE key. [For further details on these errors, see the specific notes below on errors 5005, 5006, and 5008.]

If one of the secondary errors occurs, acknowledgement of it may result in a third error, which will always be in the group 5020-5025. These errors provide more specific information about the source of the original bus device error by indicating the device ID for the particular fault. For a summary of the device ID’s, see details on errors 5020 through 5025.

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The 5001 error indicates that the printer is unable to detect the gap or notch in the media. The error should be acknowledged by pressing the ONLINE key.

Several different sorts of problems may cause this error to occur. Following is a short list of things to consider:

• 1. Incorrect material type inserted in the machine.
• 2. Incorrect sensor type selected. Check settings on both the printer itself and in the software and/or driver that is being used.
• 3. Incorrect positioning of the paper sensor on the material. Examine the paper path to make sure that the material is actually passing through the sensor and that the gap or notch is visible to it.
• 4. Material jammed up at the platen roller.
• 5. Dirt on the photoelectric sensor.
• 6. Failure of the photoelectric sensor

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The material end error indicates that the printer is unable to detect the presence of any material at all in the paper sensor field of vision.

Possible Causes

• Material may have run out. At the end of a roll of labels or tags, the Material End indicator will be displayed.
• Improper tracking of the label or tag stock may result in the material moving out of the paper sensor altogether, thus triggering the error message.

Resolution:

1. Acknowledge the error by pressing the ONLINE key. The LCD display will read ‘OFFLINE .......... x JOBS’.
2. Re-insert media and make sure that it is passing through the paper sensor. Also check the media guides behind the print block to ensure that label tracking is maintained from the media holder forward to the print head.
3. Press the ONLINE button. Any outstanding print job(s) will resume.

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The 5005 error indicates a problem with the cutter or the peripheral device board that controls it. Acknowledge the error by pressing the ONLINE key. Normal printing should resume.

In cases where the error cannot be cleared, check the peripheral device settings under System Parameters and make sure that the correct cutter module has been selected. Printer will automatically re-initialize after selection is made.

Also see notes under error 5000.

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The Head Fault error denotes a problem with the head sensor function, which basically indicates whether the print head is raised or lowered.

[A] AP4.4 and AP5.4 Printers

Opening and closing of the print head on these machines is a manual operation. Make sure that the print head is fully lowered and locked into position.

[B] AP7.t and 64-xx Printers

On these printers, movements of the print head are controlled by a head stepper motor. Possible sources of trouble might be one or more of the following:

• 1. Print head is not fully secured on the thermal print bar. Check the position of the print head on the bar, and make sure the thumbscrews are snug.
• 2. Problem with connection between peripheral device board and the print head (either a bad or loose cable, or malfunction on the board).
• 3. Failure of the head stepper motor.
• 4. Broken or cracked sensor disk on the head stepper motor (requires replacement of the whole motor).
• 5. Faulty head sensor.

For the AP7.t and 64-xx printers, also see notes under error 5000.

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The 5008 error indicates that the printer has been unable to detect the presence of a ribbon. Resolution of the problem is partly dependent on the mode of operation of the printer as described below.

[A] Direct Thermal Mode

Since the normal operating condition for direct thermal mode does not involve the use of a ribbon at all, it is very rare that this error would occur. However, it can happen if the printer is being run in direct themal mode with the ribbon save device activated.

Resolution:

• Press the ONLINE button to acknowledge the error.
• Locate the Ribbon Autoecon function under System Parameters, and make sure that it is deactivated.
• When the printer is returned to Online mode, the print job should continue.

[B] Thermal Transfer Mode

Typically this error is associated with insufficient tension on the ribbon, or it may simply signal that the printer is out of ribbon.

• Insufficient Ribbon Tension. Press the FEED button to acknowledge the error. The LCD display will read ‘OFFLINE ......... x JOBS’. Adjust the ribbon and make sure that it is taut. Press the ONLINE key to resume printing.
• Out of Ribbon. Press the CUT key and then the FEED key to acknowledge the error. The display will read ‘OFFLINE ........ x JOBS’. Install a new ribbon. Press ONLINE to resume printing.

Also see notes under error 5000.

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One or another of the errors in this group may occur following a bus device error. (For details, see notes on error code 5000.) The specific code isolates both the type of problem that the printer encountered and the particular system device that was the source of the trouble. Each system device is assigned a number, which also appears as part of the informational message. (See the Device Table below for details.)

The errors in this group will appear on the LCD display somewhat as follows:

502x
Error Name I2C ........ xx

The variable ‘xx’ represents the device that is the source for the immediate error. The device number assignments for the 64-xx, AP4.4, AP5.4, and AP7.t are listed here.

NOTE: x denotes the printer models on which the designated device is or may be installed.

IMPORTANT: All errors in the group 5020-5025 disable printer functionality. Printer must be turned off, and re-initialized.

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There are a number of factors that control overall print quality. Here are a few ideas to consider:

• For all Avery 64-xx printers and for the AP7.t, you should be using near-edge ribbon.
• The AP4.4 and AP5.4 printers use a ribbon designed for flat print heads.
• The ribbon should be compatible with the labels or tags that are being printed. The effective bonding temperature of ribbons varies according to their chemical composition, and so their ability to bond or adhere to different types of surfaces also varies.
• Check the darkness or temperature setting in your software. If you are using a Windows driver, you may also need to check the temperature settings there as well. The default darkness for Avery-Dennison printers is 50, which in this case defines average darkness under typical print conditions.

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Incorrect label tracking is generally the result of poor alignment of the labels themselves. This problem can occur for a number of reasons:

• [A] Sliding of the label roll on the supply holder
  Since Avery-Dennison printers are left justified, the label roll must be placed flush against the media holder plate mounted on the main printer wall. In addition the media adapter rings should be used along with the outside supply holder to keep the roll in position.
  As labels pass under the print block, the label edge closest to the wall of the printer should just touch the red media guide mounted on the lower back side of the print block closest to the wall side of the printer.
• [B] Failure to secure the outside paper feed guide against the outside label edge
  The paper feed guide is located on the metal bar just at the rear of the print block. The guide should be moved along the metal bar until it just touches the outside edge of the label stock.

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Printing voids can arise from a number of causes. Here are some things to consider:

• [A] No printing at all:
   

  Is the ribbon loaded correctly? Is the ribbon properly matched for the type of material on which you are printing? Is the darkness set correctly? Are the print head power and communication cables plugged in?

• [B] Sharply defined vertical white lines or rectangles:
   

  This type of pattern generally indicates a damaged print head.

• [C] Uneven contrast from left to right across the print head:
   

  This type of problem may be the result of misalignment of the print head or the print head cam. A worn platen roller can also produce a similar effect. In most instances, this problem is a repair issue.

• [D] Irregular white lines in print:
   

  (1) If the lines are basically vertical, then the trouble is probably just dirt. Try cleaning the print head.
  (2) If the lines wander around the label, then the issue is ribbon wrinkle

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• Check to make sure that the ribbon is loaded correctly.

  Since the Avery-Dennison AP 4.4, AP5.4, AP7.t, and 64-xx series printers are left justified, the ribbon cores should always be positioned so that they are flush with the ribbon stoppers.

• Use a ribbon that is at least as wide as or just a tiny bit wider than the label being printed. Six-inch wide labels need a six-inch ribbon; four-inch labels a four-inch ribbon; and so on. Trying to print a four-inch wide label with a six-inch ribbon will inevitably cause wrinkling of the ribbon.

  CAUTION: Running label material that is wider than the ribbon, or allowing the left or right edges of the material to be exposed beyond the edge of the ribbon can cause damage to the dot rows on the print head. For more on this topic see Printing Voids.

• Check the darkness or temperature setting in your software. Higher temperatures may at times produce wrinkling.

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12. How can I restore my Avery-Dennison printer to its original factory settings?

The procedure for resetting the printer's factory defaults is this:

1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
3. Press the CUT key until you arrive at ‘SPECIAL FUNCTION'.
4. Press the ONLINE key to enter the submenu, at which point you will likely see the phrase, ‘Delete Job’.
5. Press the CUT key again until you come to ‘FACTORY SETTINGS’.
6. Hit the ONLINE key once. The printer will display a prompt indicating whether you want to go ahead with the factory reset. Press the ONLINE key to continue.
7. The printer will automatically re-initialize and return to ONLINE mode.

NOTE: Resetting the factory defaults erases any special settings that may be required for particular applications. Any such special functions will need to be turned back on manually.

IMPORTANT: After doing a factory reset, make sure that the Print Head Resistance Value is reset and that any required peripheral device options are turned on.

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13. How do I set up my Avery-Dennison AP5.4 or 64-xx printer to use the MLI emulation?

The MLI emulation must be used in association with an appropriate printer driver, and must be activated on the printer front panel. The front panel setup procedure follows:

1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
3. Press the CUT key until you arrive at 'SYSTEM PARAMETERS'.
4. Press the ONLINE key to enter the submenu. The display will read, ‘Foil End Warning’.
5. Press the CUT key again until you come to ‘PRINT EMULATION’.
6. The default setting for this parameter is ‘EasyPlug’. Use the CUT or FEED keys to change the setting to either MLI or EasyPlug/MLI. [The latter setting allows the printer to accept either Easy Plug or MLI commands.]
7. Hit the ONLINE key once. The printer will automatically re-initialize and return to ONLINE mode.

NOTE: Once the MLI emulation is active, it is necessary to do a paper sensor calibration.

ADDITIONAL NOTE: On AP5.4 printers earlier than firmware version 3.32 and on 64-xx printers earlier than firmware version 5.32, this emulation is listed as ZPLII.

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14. How do I calibrate the paper sensor on my AP5.4 or 64-xx printer when it is in MLI mode?

Before beginning the calibration, make sure that labels and ribbon (if required) are already loaded in the printer, and that, in the case of the AP5.4, the print head is closed. [The 64-xx print head is automatically controlled by its own stepper motor.]

1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
3. Press the CUT key until you arrive at ‘MLI PARAMETERS’. [This menu is available only if the printer is already in MLI mode.]
4. Press the ONLINE key to enter the submenu. The LCD display will read 'Darkness'.
5. Press the CUT key until you come to ‘MANUAL CALIBRATION’.
6. Press the ONLINE key to begin the calibration. The printer will feed forward one or two labels, and display a label length calculation.
7. To exit from the menu, press the ESC key until the display reads ‘OFFLINE’. Then press the ONLINE key to return to normal operation.

NOTE: On AP5.4 printers earlier than firmware version 3.32 and on 64-xx printers earlier than firmware version 5.32, this emulation is listed as ZPLII.

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15. My Avery-Dennison printer is printing fine, but the label material stops right at the edge of the print head and so cannot be easily torn off.

In order for the printer to operate in ‘tear-off’ mode, it is necessary to change the peripheral device mode to ‘tear-off’. The procedure is as follows:

1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
3. Press the CUT key until you arrive at ‘SYSTEM PARAMETERS’.
4. Press the ONLINE key to enter the submenu. The LCD display will read ‘Foil End Warning’.
5. Press the CUT key until you come to ‘PERIPHERAL DEVICE’.
6. Press the ONLINE key. The default setting here is ‘None’. Press the CUT or FEED keys to change the setting to ‘Tear-Off’.
7. Hit the ONLINE key. The printer will automatically re-initialize and return to normal operation.

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16. How do I go about setting the print head resistance value?

After a factory reset or replacement of a print head, it is necessary to set the print head resistance value. The value required is printed on the identification label for the print head. The procedure for inputting the value is this:

1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
3. Press the CUT key until you arrive at ‘SYSTEM PARAMETERS’.
4. Press the CUT key again until you come to ‘Head Resistance’.
5. Press the ONLINE key to display the current value.
6. Use the CUT or FEED keys to decrease or increase the value to the proper level.
7. Press the ONLINE key.
8. To exit the menu, press the ESC key until the LCD reads ‘OFFLINE’. Then press the ON/OFFLINE key to return to normal operation.

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17. How do I activate peripheral devices like cutters for my Avery printer?

Cutters, applicators, and other peripheral devices that are attached to the printer must be turned on using the printer's peripheral device menu. The procedure follows:

1. With the printer in ONLINE mode, press the ON/OFFLINE key. The LCD display will read ‘OFFLINE’.
2. Press the ESC key. The printer will now be in System mode, which provides access to all of the printer’s parameter menus. The first menu that you will see reads, ‘PRINT INFO’.
3. Press the CUT key until you arrive at ‘SYSTEM PARAMETERS’.
4. Press the ONLINE key to enter the submenu. The LCD display will read ‘Foil End Warning’.
5. Press the CUT key until you come to ‘PERIPHERAL DEVICE’.
6. Press the ONLINE key. The default setting here is ‘None’. Press the CUT or FEED keys to change the setting to select the particular device that you wish to use.
7. Hit the ONLINE key. The printer will automatically re-initialize and return to normal operation.

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