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Users Manual Model 545™

Printer Assembly

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Installing the Applications Software

The software to drive the Paxar family of printers is covered in separate
documentation. The "PcMate Plus / Formatter " software to create formats on site
for the Paxar 545 printer is a Windows application. The original "Selfform" will not
support the 545. The new "PcMate Plus / Formatter " package is capable of creating
formats for all Paxar control printers. Version 3.16.3 or higher is needed.

The original DOS version of "PcMate" has been updated to drive the 545 printer.
PCMate DOS version 3.05 or higher is needed.

The printer is also capable of operating directly from a mainframe when using the
RS-232 interface and Paxar's PCL command language.

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Summary of Contents for 545

Page 1: ...Users Manual Model 545 PAXAR Systems Group Manual Edition 5 1 15 February 2002 Manual Part Number 341398 ...

Page 2: ...This page intentionally blank ...

Page 3: ...ion 10 Printer Description 10 Printer Specification 11 Personal Computer Specifications 12 Printer Assembly 13 Fuse Configuration 13 Installing the Power Cord 14 P C Board Identification 15 TCB Dip Switch Settings 15 Inserting a PCMCIA Card 16 Print Module Insertion and Removal 17 Print Module Handling 18 Installing the Stacker 18 Cable Installation 20 Installing the Applications Software 21 Print...

Page 4: ... 41 Front Panel Mode Descriptions 44 Maintenance 55 Print Module Handling 55 Print Module Replacement Height Adjustment 56 Print Head Swing Arm Stop Adjustment 57 Automated Print Head Cleaning 58 Manual Manifold Seal Cleaning 59 General Machine Cleaning 61 Knife Adjustment 61 Feed Open Interlock Switch Adjustment 61 Lubrication Procedure 62 Changing Stacker Belts 63 Electrical Trouble Shooting 67 ...

Page 5: ...r Unwind Parts List 97 Unwind Support Assembly Drawing 98 Unwind Support Parts List 99 Unwind Nip Roller Assembly Drawing 100 Unwind Nip Roller Parts List 101 Unwind Snubber Assembly Drawing 102 Unwind Snubber Parts List 103 Print Module Assembly Drawing 104 Print Module Parts List 105 Cartridge Support Deck Assembly Drawing 106 Cartridge Support Deck Parts List 107 Feed Assembly Drawing 108 Feed ...

Page 6: ...you will come to appreciate the efforts and quality which have gone into producing your PAXAR 545 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 Cautions NEVER INSERT YOUR HAND IN THE INK CARTRIDGE SLOTS AS THE PRINT ...

Page 7: ...fined above shall be provided at no charge for a period of six months following the shipment date When ordering machines and supplies in the U S A reference all correspondence to the address below PAXAR Corporation One Wilcox Street Sayre Pa 18840 Call 1 800 96PAXAR or 570 888 6641 Fax 570 888 5230 For spare parts requests for service or technical support Paxar Service Group 170 Monarch Lane Miami...

Page 8: ...ins optimum flow of your product while providing for the operator s comfort PAXAR has taken significant steps to ensure that the operator controls and operations are easily accessible This goal can only be met however if the printer is also located with human factors in mind These include the height of the printer the space around the printer and the accessibility to the printer The PAXAR 545 prin...

Page 9: ...nt connected to a PAXAR printer should follow standard electrical code practices including proper grounding and neutral requirements The PAXAR printer was designed to operate in an industrial setting for extended periods of time however the printer is controlled by a microprocessor which is very sensitive to brownouts or power spikes For this reason as well as the minimum recommended current suppl...

Page 10: ... the printer in the carton while it is being moved within your facility will help to protect the printer during any movements to this location Once the printer has reached its intended location you should begin the unpacking process Open the cardboard box from the top Do not cut deep into the carton as there are items located just under the top Remove the items located on the top insert Remove the...

Page 11: ...or the 545 printer also used to store Logos or additional fonts that were special ordered located in the back of the manual Any optional software ordered Tool kit NOTE Some of the above parts may be inside the envelope containing the tool kit PAXAR 545 TOOL KIT 341390 101324 7 64 Ball Driver 181301 2 5mm Ball Driver 241149 Anti Static Gloves 2 241132 Anti Static Wrist Strap 351156 Chip Removal Too...

Page 12: ...r or a main frame system thus allowing electronic data input or even custom design of labels with PAXAR S Formatter PcMate Plus program This printer can generate a complete label printed on one or two sides United States Patent Number 6 142 622 Design your own labels on a PC Computer interface IBM Compatible Mainframe direct interface RS 232 9 Pin D shell female Serial interface connector Paxar Mo...

Page 13: ...0 90 180 270 Logos No restriction on number or size per tag up to maximum image area All rotations 0 90 180 270 Care Symbols Full Ginetex Care Symbol set and full NAFTA Care Symbol Set Fully Scaleable All rotations 0 90 180 270 Justification Left Right and Center field selectable Stock Support for blank and pre printed fabrics Roll size up to 12 305mm diameter Interface PAXAR PCL via RS 232 serial...

Page 14: ...f Web Only Future Top Contrast Sensor Future PCMate DOS Spare Parts Kit International Hardware Kit Personal Computer Specifications This specification describes the hardware and application software requirements for the Personal Computer that is used to download to the PAXAR 545 Printer The PAXAR 545 Printer uses a DOS Version of PCMate or a Windows version of PcMate Plus Formatter These applicati...

Page 15: ... NOT plug the power cord in Reconfigure as follows 1 Using a flat blade screwdriver open the AC entry by lifting the tab just above the voltage indicator window AC Entry 2 Remove the red fuse drawer 3 Remove all fuses and the fuse jumper if it is present 4 Insert into the fuse drawer the correct number and style of fuse s and fuse jumper for your application Configuration Number One Line voltage w...

Page 16: ...r into the AC entry with the desired voltage up 6 Close the AC entry and verify the correct voltage is now visible Installing the Power Cord A power cord is shipped with each printer The cord for 115 volt printers will use the standard three prong plug used in the U S A A 230 volt printer and some other 115 volt configurations will have the plug end of the cable removed It is the customer s respon...

Page 17: ...ot 4 D Thermal Control Bd 371105IJ AT Slot 2 E Front Panel Bd 511108 User interface system located on front of Machine Not Shown TCB Dip Switch Settings 1 PRINTHEAD RESOLUTION OFF 192 DPI ON 2 UNDEFINED OFF Default ON 3 PRINTER TYPE OFF Default ON 4 PRINTER TYPE OFF ON Default 5 STACKER JAM SENSOR OFF DISABLED ON ENABLED 6 UNDEFINED OFF Default ON 7 UNDEFINED OFF Default ON 8 LOKPRINT DOWN STACKER...

Page 18: ...with the holes goes in first Slide the card in until it reaches the back of the slot and the eject button pops out To eject the card push in the eject button and then pull the card out Some machines will ship with a double slotted card option If using a single IC card the card must be inserted into the slot closest to the rear of the printer NOTE The printer loads the data from the PCMCIA card at ...

Page 19: ...installed or removed The print module s must be in the parked position Remove the print module s from the separate packaging Remove the packaging from around the print module and save with the rest of the printer packing supplies Swing open the top cover to the printer In order to install or remove the print modules the ink cartridges MUST be out of the machine To install the print module push the...

Page 20: ...r Make sure that the stacker bed is in the most upright position by loosening the locking knob and rotating the bed up and then re tightening the locking knob Locate the clearance hole as shown below in the center of the knife s mounting bracket Place the stacker into position by inserting the screw in the stacker s mounting plate into the clearance hole and making sure that the stacker is resting...

Page 21: ...ded screw through the mating hole in the up right rail assembly Thread the spring loaded screw into the mounting block Repeat the above procedure for the other rail Remove the spring loaded screw and washer from the top of the inner stacker rail Place the threaded stud into the slot of the outer rail and reattach the washer spring and nut ...

Page 22: ...e which is provided with the printer If the cable was not found it can be ordered 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 at the TCB refer to the P C Board Identification section in this manual The female end of the cable is made to fit a 9 pin male RS 232 connector on the back of...

Page 23: ...s a Windows application The original Selfform will not support the 545 The new PcMate Plus Formatter package is capable of creating formats for all Paxar control printers Version 3 16 3 or higher is needed The original DOS version of PcMate has been updated to drive the 545 printer PCMate DOS version 3 05 or higher is needed The printer is also capable of operating directly from a mainframe when u...

Page 24: ...te the head Using ink not tested and approved by PAXAR may also damage the print heads Use the procedure and diagram below for loading the ink 1 Determine the color of the print module that needs an ink cartridge The print module in the left position prints the bottom of the label if the 545 is printing one over one 2 Remove an ink cartridge of the same color from its shipping package and insert i...

Page 25: ...Users Manual Model 545 Printer Operation Adjustments 23 3 Remove the ink cartridges by pulling them straight out from their current position ...

Page 26: ...humbscrew Loading Fabric for the First Time Once the unwind position has been adjusted for the job width load a roll of fabric on the unwind core support so that the fabric pulls off the top clockwise While holding the unwind from spinning tighten the core by turning the center knob clockwise Confirm that the core is against the back stop Pull the tab on leader to release the end of fabric and cut...

Page 27: ...pen the hinged cover to the printer and thread the fabric through the splice fabric out sensor B drawing two the active unwind the barrel rollers the head guards A drawing two the feed module the knife and then the stacker as shown FEED ROLL NIP ROLL 2 0 AND 1 0 THREADING PATH ...

Page 28: ...e has been threaded and is pulling fabric from the supply roll the active unwind will automatically sense the tension of the fabric and adjust the pull off speed accordingly This will result in a loop in the fabric under the active unwind sensor of about 250 as shown below 250 ...

Page 29: ... printer are located on the active unwind block These web guides are adjustable without the use of tools The only other web width adjustment is the stacker up right rails refer to the Stacker Label Width Adjustment To increase the web guide width turn the adjustment knob counter clockwise Turn the adjustment knob clockwise so the web guides are holding the fabric without deforming the sides ...

Page 30: ... is beyond the last roller continue straight into the feed rollers through the knife module and then through to the stacker belts You will need to lift the pre feed rollers between the feed and knife in order to push the fabric through the knife After the fabric is pulled through the knife continue feeding through to the stacker belts ...

Page 31: ...running confirm that equal numbers of belts exist on either side of the fabric and that the spacing to the nearest belt is the same on each side This is achieved by loosening the stacker mount screw and moving the stacker forward or back accordingly Stacker Label Width Adjustment Slide the left and right spring loaded upright rails to the desired position ...

Page 32: ...ide the entire base to the desired position so that the cut label hangs over the last belt roller approximately 6mm Stacker Angle Adjustment Turn the lock knob counter clockwise to allow the stack end of the stacker to rotate Once the stack is so that the stacker rails are approximately 5 to 30 off horizontal tighten the lock knob by turning it clock wise ...

Page 33: ...stacker upright and slide it up or down Once the desired stop level is reached retighten the thumbscrew Do not bring the thumbscrew in contact with the top of the slot The thumbscrew must be able to move up approximately 3 16 for the switch to be activated and stop the printer Note Not all material and or label sizes will reach the top of the stacker Set the stacker full level accordingly ...

Page 34: ...NDITION MANUALLY ADVANCE IT BEYOND THE PRINT STATIONS NOTE Whenever fabric of a different width is threaded through the printer a sample run should be performed If the print quality registration is acceptable you can immediately begin your production run If the print quality registration needs to be optimized refer to the Printer Setup procedure and make the necessary adjustments Splices The PAXAR...

Page 35: ... and the print position Upon the start command the heads are rotated 90 degrees to the print position and at the stop command the heads are retracted back to the parked position where head maintenance can take place if needed A sensor located on the PCB in the print module monitors the swing arm position Care should be taken not to obstruct the path of the print head swing arms as it may disrupt t...

Page 36: ... the image on the back of the label should appear square with no gap or overlap in the center 4 Adjust station 2 s head swing arm stop screw the same as station 1 to produce print on the front of the label that has neither a gap or overlap in the center of the print image 5 Using the print line label format adjust the mount angle of the knife as needed to produce a square cut Loosen the two mount ...

Page 37: ...N 1 to produce one straight continuous feed print line on the back of the label 20 20 9 On the front panel adjust the PRINT OFFSET STATION 2 to produce one straight continuous feed print line on the front of the label 20 20 10 On the front panel the CUT POSITION should be set to 0 as this is a non sense mark label ...

Page 38: ...ly over station 1 s web print line 16 16 Sensor Calibration The optical sensors used to detect error conditions in production can be calibrated without the use of a multi meter via the front panel One may need to be calibrated if it has just been replaced or put into service Refer to the Front Panel Mode Descriptions under the Control Panel Operation section ...

Page 39: ...ads and knife will be reproduced and stacked as finished labels Feed FEED and START must both be used Feed will stop when the buttons are released Labels between the heads and knife will be cut and stacked as finished labels Fabric moves through in one continuous strip Fabric moves through without printing Test TEST and START must both be used Test will stop when the buttons are released Labels be...

Page 40: ...or lights These lights are used along with the LC 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 s...

Page 41: ...NSOR Flashing light while the printer is running the sensor is in line with the registration PRINTED MARKS Error ORANGE System inter lock triggered see display for error LCD Display The LCD display is a 2 line 24 character with back lighting feature for easy readability The first line of the display in most cases will be a prompt or question The second line is the response ...

Page 42: ...ensor Total Labels Produced Emulation Mode Print Verifier Setup Ð Ð Ð Ð Ð Ð Print Position Station 2 Change Default Cleaning Level Station 1 Top Refl Over Mark Total Inches Of Stock Language Clear Scan Memory Ð Ð Ð Ð Ð Ð Print Offset Station 1 Change Default Cleaning Level Station 2 Top Refl Not Over Mark Controller Version Protocol Verifier Enabled Disabled Ð Ð Ð Ð Ð Print Offset Station 2 Statio...

Page 43: ...DIAGNOSTIC TEST 1 Each key is tested to see if it is stuck in the on state If a fault condition is detected the test is halted and the screen will display the first error key found with the following display B U T T O N N A M E K E Y S T U C K The BUTTON NAME will be one of the push button names on the front panel START FEED TEST STOP EXIT MODE YES NO OR ENTER When the code has finished the above ...

Page 44: ... be printed the HOME screen will be the BATCH ID QUANTITY screen The Batch ID Batch Qty screen displays the currently cutting batch ID and labels remaining to be cut When the Batch Id Qty screen is the home screen and the user presses the EXIT button the Model Number is displayed briefly before the Batch Id Qty screen is displayed again If the printer is performing a FEED or a TEST pattern the scr...

Page 45: ...he HOME screen PRINTER ADJUSTMENTS P R E S S E N T E R F O R P R I N T C U T P O S I T I O N S PRINTHEAD CLEANING P R E S S E N T E R F O R P R I N T H E A D C L E A N I N G P R O C CALIBRATE SENSORS P R E S S E N T E R F O R C A L I B R A T I N G S E N S O R S LIFE COUNTS VERSIONS P R E S S E N T E R F O R L I F E C O U N T S V E R S I O N S SETUP SCREEN P R E S S E N T E R F O R F E A T U R E S ...

Page 46: ...the following function keys Use the MODE key to move through the main mode screens shown below PRESS ENTER FOR PRINT CUT POSITIONS PRESS ENTER FOR PRINT HEAD CLEANING PROC PRESS ENTER FOR CALIBRATING SENSORS PRESS ENTER FOR LIFE COUNTS VERSIONS PRESS ENTER FOR FEATURES SETUP PRESS ENTER FOR VERIFIER SETUP Use the EXIT to move back to the HOME screens ...

Page 47: ... pressed the printer stops printing the checkout format and goes back to what it was doing before the checkout was requested Pressing the MODE Down Arrow key will take the user to the PRINT POSITION STATION 1 screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen P R I N T P O S I T I O N S T A T I O N 1 V A L U E X X N E W V A L U E Y Y This screen follows the PRINT CHEC...

Page 48: ...nt offset value The value is displayed in a positive negative format The value ranges for XX and YY can be from a 20 to a 20 Pressing ENTER will change the VALUE to the NEW VALUE A more positive number will move the outboard half of the image printed by station 1 to the right while a more negative number will move it to the left Pressing the MODE Down Arrow key will take the user to the PRINT OFFS...

Page 49: ... The value ranges for XX and YY can be from a 16 to a 16 Pressing ENTER will change the VALUE to the NEW VALUE A more positive number will move the print of station 2 to the front of the machine while a more negative number will it to the back of the machine Pressing the MODE Down Arrow key will take the user back to the PRINT CHECKOUT FORMAT screen Pressing the EXIT Up Arrow key will take the use...

Page 50: ...N 2 screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen C H A N G E D E F A U L T C L E A N I N G L E V E L F O R S T A T I O N 2 Y Y This screen follows the CHANGE DEFAULT CLEANING LEVEL STATION 1 screen This screen allows the user to adjust the default cleaning level for station 2 The ENTER button is used to change the cleaning level value The value is displayed in a...

Page 51: ...een Place the fabric under the sensor so that it blocks the sensor and when NEW VALUE is at its highest value press Enter Pressing the MODE Down Arrow key will take the user to the TOP REFL OVER MARK screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen T O P R E F L O V E R M A R K V A L U E 0 0 0 N E W V A L U E 0 0 0 This screen follows the HOLE SLOT NOT IN SENSOR scr...

Page 52: ...0 0 0 This screen follows the BOT REFL NOT OVER MARK screen Place the fabric in the stacker jam sensor so that the fabric is within the sensor site path and when NEW VALUE is at the highest value press Enter Pressing the MODE Down Arrow key will take the user to the STACKER NOT BLOCKED screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen S T A C K E R N O T B L O C K E ...

Page 53: ...creen is the first screen under LIFE COUNTS VERSIONS This screen shows total labels produced since the last counter reset Pressing the ENTER key will reset the counter to zero Pressing the MODE Down Arrow key will take the user to the TOTAL LABLES PRODUCED screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen T O T A L L A B E L S P R O D U C E D 0 0 0 0 0 0 0 0 0 0 This...

Page 54: ...rrow key will take the user to the VERIFER SETUP screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen C U T T E R I S E N A B L E D P R E S S E N T E R T O D I S A B L E OR C U T T E R I S D I S A B L E D P R E S S E N T E R T O E N A B L E This screen is the first screen of the FEATURE SETUP This screen allows the cutter to be enabled or disabled Pressing ENTER will to...

Page 55: ...rted protocols RTS CTS is considered hardware handshaking and XON XOFF is considered to be software Pressing ENTER will update the communications protocol with the selection Pressing the MODE Down Arrow key will take the user to the BAUD RATE screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen B A U D R A T E X X X X X X N E W B A U D R A T E Y Y Y Y Y Y This screen fo...

Page 56: ...n follows the PRINT VERIFIER HISITORY screen Pressing ENTER will cause the printer to print a report containing the present verifier setup Pressing the MODE Down Arrow key will take the user to the CLEAR SCAN HISTORY screen Pressing the EXIT Up Arrow key will take the user back to the HOME screen P R E S S E N T E R T O C L E A R S C A N M E M O R Y This screen follows the PRINT VERIFIERP SETUP sc...

Page 57: ...maged through a number of ways Paxar has developed the following recommendations Handling ESD Electro Static Discharge is very detrimental to print heads and PCBs To avoid damaging the components of a print module follow these simple procedures Do not touch any terminals extending from the print modules Do not touch the print head nozzle plates Store the print modules near the printer to reduce th...

Page 58: ...be adjusted These stop blocks are located beneath the print module under the front nose cover of the machine With the power off remove the cover by removing four screws two on either end of the cover then while holding the active unwind pinch roller down slide the cover forward far enough to unplug the front panel PCB Once the PCB is unplugged remove the cover and set aside Adjust the print module...

Page 59: ... the print head swing arm stop screw A for that print station A Using a 5 64 hex key adjust screw A for the station needing the adjustment Rotating the screw counter clockwise will decrease the overlap or increase the gap Rotating it clockwise will decrease the gap or increase the overlap Once adjusted properly the image should appear square with no gap or overlap in the center ...

Page 60: ...NOTE Each cycle moves 0 3mL of ink from the supply bag into the waste bag A new supply bag has 110mL of ink The machine will shut down the module pump when 30mL of ink has been pumped into an ink cartridge waste bag The balance of new ink in that cartridge s supply bag can be consumed by printing See the Front Panel Menu map for the location of the default cleaning levels WHAT LEVEL TO USE Level 3...

Page 61: ... environment the manifold seals may need to be cleaned by wiping This will maintain the module s ability to form a seal between the print heads and the manifold Use the following procedure to position the print module swing arms to the print position for cleaning purposes and then back to the parked position when done Positioning Swing Arms for Seal Cleaning Go to the PRINT HEAD CLEANING PROC menu...

Page 62: ...an any excess ink and debris from both of the manifold seals for each print module present as shown Use a wiping action across the seals to avoid pushing any debris down into the manifold seal holes When done cleaning press the NO button to swing the active print station s to the home park position ...

Page 63: ...r erratic a sensor may need to be cleaned Always use clean supplies when cleaning sensors Never use anything abrasive on any of the sensors Never use an alcohol based solution on any of the sensors Dry air or a foam swab are the recommended supplies to use when cleaning a sensor Either blow the dust debris from the sensor using dry clean compressed air or wipe the sensor with a dry clean swab Knif...

Page 64: ...ll greatly enhance the length of the time the printer will function Cam Lubrication Procedure 1 Clean any dust and residue from cams using alcohol or other suitable solvent as needed or approximately every 100 000 cuts Use any good quality general purpose oil to keep the oilers from drying out Excess oil may migrate onto the blades and cause jamming 2 If lubrication is omitted the knife will squea...

Page 65: ... 545 Maintenance 63 Changing Stacker Belts 8 32 CAP SCREWS FULL STACKER CONNECTOR FIGURE 1 1 Remove stacker rail assembly by removing full stacker connector and 2 8 32 cap screws from stacker mounting plate See figure 1 ...

Page 66: ...E 2 2 Remove upper conveyor roller assembly by removing jam sensor harness connector snap rings and rivets 8 32 SCREW SEE ITEM 5 DRIVE BELT COVER 6 32 SET SCREWS REMOVE LOOSEN FIGURE 3 3 Remove the drive belt cover 4 Loosen 6 32 set screws in ends of main drive roller See figure 3 ...

Page 67: ...ide fall out Loosen the thumbscrew on the far side to allow slack for the belts to slide on See figure 3 FIGURE 4 7 Pull the drive away from the frame enough to allow the roller belts to be lifted out of the frame This will allow removal of the center roller bearing assembly from the frame and provide slack sufficient to remove front roller from bearing blocks It is not necessary to loosen or remo...

Page 68: ...ntenance Users Manual Model 545 SMALL DUAL DRIVE BELTS SEE ITEM 8 FIGURE 5 8 Remove small dual drive belts from one side of front roller to allow assembly of new belts 9 To re assemble reverse procedure above ...

Page 69: ... into has power 3 Missing or blown fuse s 1 Check that the fuse s located inside the AC entry are present and intact Replace as needed 4 Unconnected cable connector inside printer 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 supplies 5 Thermal Control Board unplugged from the Mother Board 1 Power off and r...

Page 70: ...tches 1 Serial communications cable loose or unconnected 1 Check and secure both ends of the serial cable with the thumbscrews 2 Printer not powered on or has not completed diagnostics tests 1 Power printer on and wait until front panel displays Ready for batches Re download data 3 Data sent to wrong printer 1 In PcMate change to the printer that the data is intended to be sent 4 Configuration inc...

Page 71: ...ed 3 Feed roller s not gripping the fabric 1 Clean the feed rollers in the active unwind and the feed module 4 Feed rollers bound 1 With power off check that all rollers turn freely 5 Fabric bound 1 With the feed open and the pressure roller held open in the active unwind check that the fabric will pull through the printer with little to no resistance 6 Feed motor s unplugged or faulty 1 Check the...

Page 72: ...ensor position so that the sensor light on the front panel flashes as a sense mark hole passes under the sensor 2 Fabric registration sensor uncalibrated 1 Calibrate the sensor Print registration is off in the feed direction 1 Printer incorrectly threaded 1 Check and rethread the fabric as needed 2 Printer print position s are incorrect 1 Enter the Print Cut Positions Mode on the front panel and r...

Page 73: ...abels the rotary knife does not rotate 1 The cut is disabled in the Feature Setup mode 1 Enter the Feature Setup Mode on the front panel and Enable the knife 2 Knife cable unconnected 1 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 3 Knife jammed causing auto resetting fuse to trip on the Thermal Control Board 1 ...

Page 74: ...ccomplished 3 Stacker not operating or nip rollers not turning 1 Be sure the nip roller is free to rotate and moves easily in the bearing slots Will not stack 1 Stacker not operating 1 See step 3 above 3 Incorrect rail position or stacker bed angle 1 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 clam...

Page 75: ...Users Manual Model 545 Mechanical Trouble Shooting 73 Ink Problem Probable Cause Corrective Action Print Problem Probable Cause Corrective Action ...

Page 76: ...p Sensor Detects the fabric to maintain a predetermined amount of slack in the active unwind C Jam Sensor Detects a jam in the stacker D Full Stacker Detects when the stacker is full E Ink Cartridge Status Detects if an ink cartridge is inserted into the machine and also gives information about the ink cartridge F Feed Open Sensor Detects if the feed lever is open E B A F C D ...

Page 77: ...done by using the DIP switch setting of the TCB at power up Use the following steps to perform this function 1 Power off the machine 2 Change switch number 2 from its present position 3 Power on the machine wait at least 30 seconds then turn power off 4 Change switch number 2 back to its original position 5 Power on the machine and reset the front panel adjustments as needed ...

Page 78: ...76 Electrical Drawings Users Manual Model 545 Electrical Drawings Printer Wiring ...

Page 79: ...AL 351124 STACKER HARNESS TCB TO VERIFIER HARNESS 371158 THERMAL CONTROL J7 J2 J5 371105IJ BOARD J6 J9 351125 CONN 3 HARNESSED 351123 CONN 3 CONN 2 OPTIONAL IN LINE VERIFIER 351144 351184 PCB VERIFIER VERIFIER HARNESS 351159 351144 SCANNER ACTIVE UNWIND MOTOR 351141 TOP REFLECTIVE REGISTRATION HEAD MOTOR BOTTOM REFLECTIVE REGISTRATION TOP CONTRAST REGISTRATION HEAD MOTOR HARNESS ASSEMBLY 341126 SY...

Page 80: ...proper method of attaching the connectors Ensure that 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 are 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 tur...

Page 81: ...S The screen advances to next error with each depression of the NO key The screen retreats to prior error with each depression of the YES key The screen reverts back to the first error when the EXIT key is pressed X X E R R O R S S T O P P E D F O R S P L I C E 9 X X E R R O R S I N K O U T S T A T I O N 1 9 0 4 X X E R R O R S I N K O U T S T A T I O N 2 9 0 5 X X E R R O R S F E E D O P E N 9 1 ...

Page 82: ...0 C 19 C18 R64 C17 R62 R61 D31 D18 D30 R63 D40 D28 D17 D5 D42 J4 U9 R3 R 22 U 4 R 13 R 12 C 1 6 U 1 R24 R 9 R 21 R 1 9 R 10 C 3 R 1 1 U 8 U 7 R23 Q 1 R 8 R 6 R 18 R 16 R 15 C 14 C10 U 6 C11 A1 R 7 R 17 R1 U 3 C13 C12 U 5 J7 4 3 2 1 U 1 5 J5 R 38 R39 R37 R36 R20 R32 R40 R31 R30 R29 R28 R27 R26 R25 K1 R33 R47 R46 R35 R34 C23 U 1 0 C 15 J2 R48 R45 R44 R43 U 12 U 1 7 U 1 U 1 4 JP 2 JP 1 P IN 1 Head Dr...

Page 83: ...J10 D 6 D 5 5 C 97 U 20 U 19 U 20 C 34 1 A 31 U9 C 29 U 19 C 30 U15 C 31 C 35 U43 C 93 U 11 C 98 C 94 D18 R 19 R 11 U5 R 24 R 2 5 C 1 R 1 D14 D17 D13 D15 D19 U14 D 25 D 26 D 30 R 13 JP 1 JP4 D 28 D 29 D 24 10 R 12 JP9 D 1 JP14 JP12 J6 C36 C 15 C 95 C 96 C 40 D31 R15 R 58 C 59 R 57 D32 R59 C 14 A1 J4 U16 C13 R 3 U17 R 4 U13 L1 C 10 C 11 D 38 C8 Q 9 Q 2 C37 C 39 D 37 C 38 C 58 JP7 6 JP 2 JP8 JP3 JP1...

Page 84: ...2 TCB Opsys initialization 5 Attempting Serial Host Initialization 6 Initializing Verifier 7 Executing Protected Mode Imaging Code 8 Checking PCMCIA Card 9 Attempting to read in scalable fonts 10 Initializing Font Scaler 11 Attempting to load code pages 12 Attempting to read in logos 13 Attempting to read in care symbols 14 Waiting for Machine Definition from TCB 15 Attempting to create test patte...

Page 85: ...fe of one year It is therefore recommended that any inventory supply be rotated on a regular basic to prevent exceeding its expiration date Caution Expired ink may damage print heads Check the expiration date on the cartridge label Do not use expired ink Contact your Paxar representative for instructions on returning expired cartridges ...

Page 86: ...ust be mounted also 2 Check the gap between the actuator and the top of the pin on the clutch as shown in drawing The plunger should be pushed in to make the measurement Other hints if there is still a problem If the gap is greater then 047 an old solenoid bracket is being used Replace P N 357003 or slot the bracket If plunger binds the solenoid is not parallel with the base of the bracket that mo...

Page 87: ...Hydrocarbon solvent 70 80 200 ppm 200 ppm Alcohol 10 30 143 28 2 N A N A Pigment 10 20 N A N A SECTION III PHYSICAL DATA BOILING POINT F 250 C SPECIFIC GRAVITY H2O 1 0 88 VAPOR PRESSURE 0 01 kPA 38 C FREEZING POINT 10 C EVAPORATION RATE BUTYL ACETATE 1 N A WEIGHT PER GALLON 7 3 SOLUBILITY IN WATER Dispersible but immiscible VOLATILES PER VOLUME 80 APPEARANCE AND COLOR Solvent based ink mild hydroc...

Page 88: ...tion Symptomatic treatment Skin Remove contaminated clothing and wash affected area with mild soap and large amounts of water If irritation or rash develops get medical attention Ingestion Symptomatic treatment SECTION VII HANDLING PROCEDURES SPILL OR LEAK Contain spill with inert material sand earth etc Transfer liquids and solid material to separate containers for recovery or disposal Keep spill...

Page 89: ... None is specifically recommended for handling this product OTHER PRECAUTIONS This product is intended for industrial use only SECTION IX SPECIFIC INFORMATION HMIS RATING HEALTH 1 FLAMMABILITY 1 REACTIVITY 0 The information contained herein is furnished without warranty of any kind It is compiled with the best information available to Paxar at the time of its preparation Users should consider thes...

Page 90: ......

Page 91: ...Users Manual Model 545 Assembly Drawings 89 Assembly Drawings ...

Page 92: ...90 Assembly Drawings Users Manual Model 545 Frame Assembly Cover Drawing 14 9 10 8 10 11 7 7 6 1 9 8 15 14 3 16 16 13 12 2 13 18 17 12 16 14 9 5 8 14 19 10 10 14 14 18 14 12 7 7 17 4 ...

Page 93: ...1 7 990053 8 32 x Cap Screw 4 8 341210 Feet 1 Dia Rubber 4 9 991079 8 32 Thread Forming Screw 4 10 341215 10 32 x Sem Screw 4 11 341111 AC Entry With Switch 1 12 511209 Bracket Angle 3 13 990051 8 32 x 3 8 Cap Screw 2 14 991054 8 32 x 3 8 Btn Hd Socket Screw 7 15 990456 8 32 x Flat Head Socket Screw 1 16 990055 8 32 x 3 8 Flt Hd Socket Screw 3 17 341209 Hinge 101 Invisible 2 18 990023 6 32 x Flat ...

Page 94: ...92 Assembly Drawings Users Manual Model 545 Frame Assembly Drawing ...

Page 95: ...10 6 990082 10 32 x 5 8 Cap Screw 10 7 345037 Knob Chase 2 8 345043 Mount Chase Bar 2 9 345038 Bar Chase 2 10 991115 20 x 1 Flt Hd Socket Screw 4 11 990102 10 Washer 2 12 990091 10 32 x Button Head Screw 2 13 990081 10 32 x Cap Screw 5 14 990243 Roll Pin 3 16 x 2 15 143027 Spring Brake Press 6 16 341132 Motor Stepper Harnessed 2 17 990448 Washer 125 x 313 x 031 Fl 4 18 991033 4 40 x 3 16 Cap Screw...

Page 96: ...94 Assembly Drawings Users Manual Model 545 Sub Frame Assembly Drawing ...

Page 97: ...ion 2 7 343103 Standoff Adjuster 2 22 343101 Bearing Retainer Spindle 3 8 990023 6 32 x Flat Head Screw 4 23 990053 8 32 x Cap Screw 1 9 991125 8 32 x 3 16 SK Set Screw Soft Tip 2 24 345116 Standoff Static Brush 1 10 991137 3 48 x Cap Screw 2 25 345115 Static Brush 1 11 990145 Lock Washer 6 26 990066 8 32 x Button Head Screw 2 12 990121 20 x 5 8 Cap Screw 6 27 346407 Bracket Nozzle Guard 2 13 9900...

Page 98: ...96 Assembly Drawings Users Manual Model 545 Power Unwind Assembly Drawing ...

Page 99: ...pindle Idler 1 27 343057 Belt Timing 1 5 1 9 990329 E ring 7 32 1 28 990102 10 Washer 3 10 343208 Bracket Sensor Mount 1 29 424022 Pulley 1 5 12T I D 37 3 11 371133 Sensor Harness 1 30 343056 Pulley 14 Tooth 1 12 343118 Shaft Web Guide 1 31 990053 8 32 x Cap Screw 2 13 343117 Guide Web Outside 1 32 990082 10 32 x 5 8 Cap Screw 2 14 154020 Web Guide Shaft 1 33 343146 Stripper Active Unwind 1 15 343...

Page 100: ...98 Assembly Drawings Users Manual Model 545 Unwind Support Assembly Drawing ...

Page 101: ...A 143020 Stud Unwind Core 1 18 990294 3 8 x 5 8 x 010 Shim 1 6 343204 Bracket Arbor Disk 1 19 990019 6 32 x Button Head Screw 4 7 343225 Assembly Collar Clamp 1 20 991055 8 32 Hex Nut 6 8 990894 10 32 x T Thumb Screw 1 21 343206 Bracket PC Board Mount 1 9 343202 Shaft Unwind Arbor 1 22 191104 Standoff 4 10 343222 Knob Adjustment 1 23 341107 Finishing Interface Board Ass y 1 11 990105 10 32 x Set S...

Page 102: ...100 Assembly Drawings Users Manual Model 545 Unwind Nip Roller Assembly Drawing 9 9 10 2 1 11 4 5 3 6 7 8 8 ...

Page 103: ... 343192 Post Snubber 1 2 343134 Arm Unwind Nip 1 3 343131 Cradle Unwind Nip 1 4 343130 Anchor Nip Spring 1 5 990051 8 32 x 3 8 Cap Screw 1 6 343195 Assembly Roller Nip 1 7 343133 Shaft Nip Roller 1 8 990325 E Ring 3 16 2 9 990052 8 32 x Cap Screw 2 10 990329 E Ring 7 32 1 11 343142 Spring Unwind Ext 1 ...

Page 104: ...102 Assembly Drawings Users Manual Model 545 Unwind Snubber Assembly Drawing ...

Page 105: ...bber Comb 1 3 343192 Post Snubber 1 4 343143 Stud Snubber Spring 1 5 343144 Spring Extension Snubber 1 6 343145 Anchor Snubber Spring 1 7 343139 Roll Pin 156 x 1 25 2 8 990329 E Ring 7 32 1 9 341137 Harness Loop Sensor 1 10 989985 Washer 2 SAE 1 11 990000 2 56 x Cap Screw 3 12 343227 Bracket Snubber Cover 1 13 990019 6 32 x Button Head Screw 1 ...

Page 106: ...104 Assembly Drawings Users Manual Model 545 Print Module Assembly Drawing ...

Page 107: ...e no parts in the print module that can be changed by the user If a print module becomes defective it will have to be sent back to the factory for rebuilding The same module is used in both the right and the left print stations The part number for the complete assembly is 345090 ...

Page 108: ...106 Assembly Drawings Users Manual Model 545 Cartridge Support Deck Assembly Drawing ...

Page 109: ...90038 6 32 Hex Nut 2 13 346205 Lever Actuation Bar 2 4 197312 Spring Cam 2 14 345105 3 32 x 312 Roll Pin 2 5 990019 6 23 x Button Head Screw 4 15 990015 6 32 x Cap Screw 2 6 989974 8 32 x 5 8 Cap Screw 4 16 346208 Ext Lever Return 2 7 346212 Bracket Ground Clip 2 17 991058 Ext Bar Return 2 8 346204 Bracket Ink Support 2 18 991114 x 3 8 Shoulder Screw 2 9 346201 Ink Support 1 19 989976 6 Star Washe...

Page 110: ...108 Assembly Drawings Users Manual Model 545 Feed Assembly Drawing ...

Page 111: ... 5 990728 10 Lock Washer 3 6 990017 6 32 x Cap Screw 1 7 990037 6 Washer SAE 1 8 991073 Standoff 1 10 32 THD 3 9 344051 Fixed Idler Shaft 1 10 374028 Pulley 14T PBL FLG 3 8 I D 1 11 990065 8 32 x 3 8 Button Head Screw 4 12 344053 Gear 156T 3 8 O D 1 13 344052K Idler Shaft 1 14 244012 Pulley 14T SFL I D 1 15 344055 Belt Timing 42T 1 16 354094 Roller Drive Assembly 1 17 989513 4mm E Ring 1 ...

Page 112: ...110 Assembly Drawings Users Manual Model 545 Feed Roller Assembly 21 29 29 12 11 10 27 20 23 22 23 12 30 5 3 23 9 15 4 19 3 20 27 13 8 28 16 24 14 2 7 15 25 6 17 18 26 1 ...

Page 113: ...ort Drive Rear 1 21 355018 Support Knife Drive Print 1 7 514010 Spring Lever Rear 1 22 354004 Bridge Blade Lower 1 8 514094 Lift Cam Assembly 1 23 990090 10 32 x 3 8 B H S S 4 9 514009 Spring Lever Front 1 24 354009A Gear Driven 1 10 514093P Assembly Support Drive Front 1 25 344097 Assembly Pre Feed 1 11 514012 Knob Feed Cam Lift 1 26 344061 Bracket Rear Drive Spacer 1 12 990120 20 x Cap Screw 5 2...

Page 114: ...112 Assembly Drawings Users Manual Model 545 Knife Assembly Drawing ...

Page 115: ... Solenoid Harness 1 27 990016 6 32 x 3 8 Cap Screw 2 9 517099 Knife Motor Assembly 1 28 990082 10 32 x 5 8 Cap Screw 4 10 991067 8 32 x 5 16 Knurled Pt Set Screw 2 29 990120 1 4 20 x 1 2 Cap Screw 5 11 999097 Flg Bushing Inc w 357021K 1 30 990123 1 4 20 x 1 Cap Screw 2 12 355018 Support Knife Drive Print 1 31 990102 10 SAE Washer 2 13 357003 Mount Solenoid 1 32 990261 3 16 Snap Ring 1 14 357021K A...

Page 116: ...114 Assembly Drawings Users Manual Model 545 Stacker Assembly Drawing Part 1 ...

Page 117: ... Socket F H Screw 2 25 991060 Knob 20 Thread Thru 1 8 378213 Roller Driven Pick Up 1 26 348094 Assembly Base Plate 1 9 378208 Roller Center Drive 1 27 990066 8 32 x Button Head Screw 2 10 378201 Roller Pressure 1 28 357011 Static Brush 1 11 378287 Pressure Roller Assembly 4 29 348110 Shaft Label Hold Down 1 12 378204 Sensor Mount Upper 1 30 348111 Bracket Hold Down Finger 1 13 378203 Sensor Lock 2...

Page 118: ...116 Assembly Drawings Users Manual Model 545 Stacker Assembly Drawing Part 2 ...

Page 119: ... x 5 8 Button Head Screw 2 33 348024 Drive Pulley 20 Tooth 1 11 999012 x Flg Ball Bearing 2 34 358018 1 5P 40T Timing Belt 1 12 378215 Rail Stacker Upright 1 35 990019 6 32 x Button Head Screw 2 13 378035 Rail Stacker Upright Rear 1 36 991067 8 32 x 5 16 Knurled Pt Set Screw 2 14 990006 4 40 x Cap Screw 2 37 348020 Shaft Roller 1 15 990466 Washer 1 8 Nylon 1 38 351125 Stacker Harness NS 1 16 99003...

Page 120: ...118 Assembly Drawings Users Manual Model 545 Rewind Assembly Drawing ...

Page 121: ...Decurler roller assy 1 8 112028 Driven disc 1 26 990264 3 8 snap ring 2 9 112032 Friction disc 1 27 112034 Decurler shaft 1 10 112030 Drive disc 1 28 111025 Hub 3 rewind insert 2 11 999118 1 2 x 5 8 x 1 1 4 bushing 1 29 989974 8 32 x 3 8 cap screw 3 12 112005 28t 1 5p timing belt pulley 1 30 351183 6x6 rewind motor harness NS 1 13 990091 10 32 x 1 2 btn hd screw 2 31 923010 10 roll disc NS 1 14 19...

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