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Paxar 545 - page 1
Users Manual Model 545 PAXAR Systems Group Manual Edition 5.1 15 February 2002 Manual Part Number 341398 ...
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Users Manual Model 545™ • i Contents Scope 4 Introduction ............................................................................................................................... 4 Safety Issues / Warnings 4 Cautions ....................................................................................................................... .. ...
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ii • Users Manual Model 545™ Threading Diagram .............................................................................................................. .... 25 Web Guide Adjustment ........................................................................................................... 27 Stacker Position Adjustment .................... ...
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Users Manual Model 545™ • iii Appendix A 79 Error Messages ................................................................................................................. ....... 79 Appendix B 80 Chip Upgrade Positions / Jumper Settings .............................................................................. 80 Front Panel Diagnostic De ...
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4 • Scope Users Manual Model 545™ Scope Introduction This user’s manual was arranged for t he pe rson who is going to operate the printer. The information is arranged in th e order that is needed to install and th en operate the printer. It starts with general info rmation, then to unpacking the carton , setup, installing the i nk and fabric, ...
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Paxar 545 - page 7
Users Manual Model 545™ Warranty Information • 5 Warranty Information Limited Warranty PAXAR Systems Group, Di vision of PAXAR Corporation, extends t he following warranties to the original purchaser of a PAXAR 545 whic h has been installed and operated using recomm ended proce dures and operati ng conditions. Parts Parts found defective in mat ...
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Paxar 545 - page 8
6 • Location / Pow er Requirements Users Manual Model 545™ Location / Power Requirements Location of Printer The printer weighs approxim ately 80 Lbs. (~ 37Kg) and requires a table of sufficient quality and strength to handle this load while the printer is operating. PAXAR recomm ends an industrial t ype worktable having t he approximate dimens ...
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Paxar 545 - page 9
Users Manual Model 545™ Location / Pow er Requirements • 7 AC Power Line PAXAR requires that the electric servi ce be 10 Amps @ 115VAC or 10 Amps @ 230VAC. This will allow the computer and any additional support or service equipment to be pl ugged into the same servi ce. Any electrical service whi ch is supplying a PAXAR pri nter or peripheral ...
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Paxar 545 - page 10
8 • Unpacking / Inventory Users Manual Model 545™ Unpacking / Inventory Unpacking The PAXAR printer is shipped in 2 l arge cardboard boxes, of which one ma y be difficult to m ove by hand. DO NOT REMOVE THE PRINTER FROM THE BOX OR UNPACK IN THE SHIPPING / RECEIVING DEPARTMENT. NOTE: Unpacking in the shipping / receivi ng department is not recom ...
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Paxar 545 - page 11
Users Manual Model 545™ Unp acking / Inve ntory • 9 Inventory of Components The following list shows the additional pa rts (pieces) which should be included in your PAXAR 545 shipping containers. If any thing is m issing, notify PAXAR imm ediately - i n the U.S.A. at 570-888-9116. In other countries please cont act your local PAXAR supplier. - ...
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Paxar 545 - page 12
10 • Product Description Users Manual Model 545™ Product Description Printer Description The PAXAR model 545 ink jet pri nter is an electronic pri nter that can print on fabric rolled tape. The printer interfaces to a computer or a m ain frame system thus allowing electronic dat a input or even custom design of labels with PAXAR’S “Formatte ...
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Paxar 545 - page 13
Users Manual Model 545™ Product Description • 11 Printer Specification Print method: Narrow web ink jet one or two sided print – Single color only – 2/ 0 Future Speed – 4” (101.6mm ), 6” (152.4mm ) or 8” (203.2mm ) per second Label Size Max: up to 1.5” (38.1m m) web x up to 3.5” (88.9m m) feed - cut and stacked Up to 6" (15 ...
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Paxar 545 - page 14
12 • Product Description Users Manual Model 545™ Other Features - Downloading of in formation while printer is operating - Sequenced Fields (Printer instal led fonts) - Time / Dat e Stamping (US or European form at) - Operator adjustable: print positions, cut posit ion, baud rate - Error Detection of: fabric out , splice, ink out, full st acker ...
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Paxar 545 - page 15
Users Manual Model 545™ Printer Assembly • 13 Printer Assembly Fuse Configuration The main fuse(s) on the Paxar 545 are located i nside the AC entry. The entry has a fuse drawer that holds the fuse(s) and selects the appropria te line voltage. If t he voltage in the window DOES NOT m atch the AC line amplitude intended to be supplied to the p r ...
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Paxar 545 - page 16
14 • Printer Assembly Users Manual Model 545™ Configuration Number Two: Line voltage within the range of (See 230VAC Fuse Placement) 180 - 265VAC @ 50 - 60Hz 1) Install two 990757 6.0A 250V Fast Act ing 5 x 20MM NOTE : The fuse jumper m ust be removed to i nstall both 5 x 20m m fuses. 115VAC Fuse Placement 230VAC Fuse Placement The fuses must b ...
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Paxar 545 - page 17
Users Manual Model 545™ Printer Assembly • 15 P.C. Board Identification A B D C A – Mother Bd. (371170) - Horizontal on bottom of printer B – Head Driver Bd. (341106) - AT Slot 1(From R ear Of Printer) C – Mem ory Card Bd. (350016) - AT Slot 4 D – Thermal C ontrol Bd. (371105IJ) - AT Slot 2 E – Front Panel Bd. (511108) - User interfac ...
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Paxar 545 - page 18
16 • Printer Assembly Users Manual Model 545™ Inserting a PCMCIA Card A PCMCIA card can be used to store fonts, l ogos, and operating system upgrades. To insert the card, make sure t hat the manufacturer’s nam e is facing the front of t he machine. Insert the card so that the end w ith the holes goes in first. Slide the card in until it reach ...
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Paxar 545 - page 19
Users Manual Model 545™ Printer Assembly • 17 Print Module Insertion and Removal CAUTION: Turn off the power to the printer before removing or inserting the print module. Hot swap of the print module has been built into the design. However, a dirty connector from ink etc could prevent it from protecting the head. Therefore, we recommend that al ...
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Paxar 545 - page 20
18 • Printer Assembly Users Manual Model 545™ Print Module Handling CAUTION: Do not lay the print m odule flat on t he sides, back, or front if removed from the printer. The uni t must st and on end as shown below. Installing the Stacker Remove the stacker from the separate p ackaging. Remove the packaging from around the stacker and save with ...
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Paxar 545 - page 21
Users Manual Model 545™ Printer Assembly • 19 Install the stacker up-right rails. Rem ove one of the spring-loaded screws. Insert the spring-loaded screw through the ma ting hole in the up-right rai l assembly . Thread the spring-loaded screw into the m ounting block. Repeat t he above procedure for the other rail. Rem ove the spring-loaded scr ...
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Paxar 545 - page 22
20 • Printer Assembly Users Manual Model 545™ Cable Installation Stacker Cable There is a cable with a connector leading from the back of the st acker that plugs into a socket on the TCB (refer to th e P.C. Board Identification section in this manual). The socket and plug are polarized. Rotate the plug until the p olarized keyway and socket ali ...
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Paxar 545 - page 23
Users Manual Model 545™ Printer Assembly • 21 Installing the Applications Software The software to drive the Pax ar fam ily of printers is covered in separate documentation. The "PcMate Plus / Forma tter " software to create formats on site for the Paxar 545 printer is a Windows appli cation. The original "Selfform" will not ...
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Paxar 545 - page 24
22 • Printer Operation / Adjustments Users Manual Model 545™ Printer Operation / Adjustments Installing and Removing Ink Cartridges CAUTION: NEVER INSERT YOUR HAND IN THE INK CARTRIDGE SLOTS AS THE PRINT MODULE NEEDLES ARE UNPROTECTED WHILE THE PRINT MODULES ARE IN THE PRINTER. The individual ink cartridges are color sp ecific and are identifie ...
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Paxar 545 - page 25
Users Manual Model 545™ Printer Operatio n / A djustments • 23 3) Remove the i nk cartridges by pulli ng them strai ght out from t heir current position. ...
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Paxar 545 - page 26
24 • Printer Operation / Adjustments Users Manual Model 545™ Adjusting the Unwind Before loading fabric fo r the first time and anytime the fabric width changes - the unwind position m ust be adjusted - as the 545 is a center just ified machi ne. • Loosen the unwind back plate locking t humbscrew A. • Rotate the back plate B clockwi se to i ...
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Paxar 545 - page 27
Users Manual Model 545™ Printer Operatio n / A djustments • 25 Threading Diagram • Open the hinged cover to the printer and thread t he fabric through the splice / fabric out sensor (B drawing two), the act ive unwind, the barrel rollers, t he head guards (A drawing two), the feed modul e, the knife, and then the stacker as shown. FEED ROLL N ...
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Paxar 545 - page 28
26 • Printer Operation / Adjustments Users Manual Model 545™ A B Once the machine has been threaded and is pul ling fabric from the supply roll the active unwind will au tomatically sense the tension of the fabr ic and adjust the pull off speed accordingly. This will result in a loop in the fabric under the active unwind sensor of about .250” ...
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Paxar 545 - page 29
Users Manual Model 545™ Printer Operatio n / A djustments • 27 Web Guide Adjustment The Paxar 545 printer has been designed with crowned roll ers to maint ain center tracking. The only web guides in the pri nter are located on the active unwind bl ock. These web guides are adjustable without the use of tools. The only other web wi dth adjustmen ...
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Paxar 545 - page 30
28 • Printer Operation / Adjustments Users Manual Model 545™ • Open the feed roller by turning t he feed lever counterclockwise. • Once the fabric is beyond the la st roller - continue strai ght 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 ...
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Paxar 545 - page 31
Users Manual Model 545™ Printer Operatio n / A djustments • 29 Stacker Position Adjustment • Once the web has been centered in the printer or it has stabilized from running, confirm that equal numbers of belts exi s t on either side of the fabric, and t hat the spacing to the nearest belt is the same on each side. This is achieved by loosenin ...
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Paxar 545 - page 32
30 • Printer Operation / Adjustments Users Manual Model 545™ Stacker Label Length Adjustment • Loosen the “T” head thumbscrews on eit her side of the upright base. • Slide the entire base to the d esired position so that the cu t label hangs over the last belt roller approximately ¼” (6mm) Stacker Angle Adjustment • Turn the lock k ...
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Paxar 545 - page 33
Users Manual Model 545™ Printer Operatio n / A djustments • 31 Stacker Full Level Adjustment • To change the heig ht at which the machine will stop, first loosen the p lastic thumbscrew located on t he stacker upright and slide it up or down. • Once the desired stop level is r eached retighten the thumbscrew. • Do not bring the thum bscre ...
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Paxar 545 - page 34
32 • Printer Operation / Adjustments Users Manual Model 545™ Replenishing Fabric at End of Roll • The PAXAR 545 has been designed so that the fabric can be replenished quickly. • Cut the fabric from and remove the spent fabr ic roll core. • Place a new roll on the unwind and adhere the end of the last roll still threaded in the prin ter t ...
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Paxar 545 - page 35
Users Manual Model 545™ Printer Operatio n / A djustments • 33 Print Head Operation Each print module consists of two print heads m ounted one on each side of a swing arm. Through an electronic del ay the two heads form a si ngle print line. The arm has two positions, the parked posit ion and the print positi on. Upon the start comm and the hea ...
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Paxar 545 - page 36
34 • Printer Operation / Adjustments Users Manual Model 545™ Printer Setup From tim e to tim e it may be necessary or desirable to reset the printe r to a known state of print / cut. Th e following pro cedure can be used to make the necessary changes. Only adjust the adjustments th at are needed in th e order that follows; 1) Clean the mach ine ...
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Paxar 545 - page 37
Users Manual Model 545™ Printer Operatio n / A djustments • 35 -20 +20 8) On the front panel adjust the PRINT OFFSET STATION 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 . ...
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Paxar 545 - page 38
36 • Printer Operation / Adjustments Users Manual Model 545™ -10 +10 11) On the front panel adjust STATION 2 DOT SHIFT to cause stati on 2’s web print line to be d irectly over station 1’s web prin t line. -16 +16 Sensor Calibration The optical sensors used to detect error condit ions in production can be calibrate d without the use of a mu ...
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Paxar 545 - page 39
Users Manual Model 545™ Control Pan el Operation • 37 Control Panel Operation Control Buttons Start - Starts the printer. - ON LINE light must be GREEN. (Batches downloaded to be printed) - If “Stopped For Splice” error conditi on exists: Fabric will be advanced until the splice is beyond the print sta tions. Labels between the heads and kn ...
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Paxar 545 - page 40
38 • Control Panel Operation Users Manu al Model 545™ - Fabric moves through wi th test patte rn printing. Stop - The stop button will stop the printer at the end o f the current label being printed. Indicator Lights The Paxar 545 has three Indicator lights. These li ghts are used along with the LC display to tell the operato r the current stat ...
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Paxar 545 - page 41
Users Manual Model 545™ Control Pan el Operation • 39 mark hole. - Flashing light whi le the printer is runni ng, - the sensor is in-line wi th the registration HOLES. ORANGE = REFLECTIVE SENSOR - Flashing light whi le the printer is runni ng, - the sensor is in-line wi th the registration PRINTED MARKS. Error ORANGE - System inter-lock trigger ...
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Paxar 545 - page 42
40 • Control Panel Operation Users Manu al Model 545™ Front Panel Menu Map Ready For Batches Î Print / Cut Positions Î Print Head Cleaning Proc Î Calibrating Sensors Î Life Counts / Versions Î Feature Setup Î Verifier Setup ÐÐÐÐÐÐ → Print Checkout Format → Clean Station 1 → Hole / Slot In Sensor → Label Counter (Re settable) ...
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Paxar 545 - page 43
Users Manual Model 545™ Control Pan el Operation • 41 Front Panel Power Up / Home Screens POWER UP (DIAGNOSTICS TESTS) D I AGNO S T I C T E S T 1 This screen is displayed while the Fro nt Panel is initializing and waiting for the Thermal Cont rol Board (TCB) response. While this screen is displayed t he code will check the function ality of the ...
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Paxar 545 - page 44
42 • Control Panel Operation Users Manu al Model 545™ HOME SCREEN R EAD Y F O R BA T CH E S 545 OR BA T CH I D Q UAN T I T Y P C L001 10 When the pr inter is powered up and all initialization s are complete, if there aren’t any Batches to print, the "HOME" sc reen will be "READY FOR BATCHES" and the printer m odel number. ...
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Paxar 545 - page 45
Users Manual Model 545™ Control Pan el Operation • 43 Pressing the MODE / Down Arrow key will tak e the user to the various mode screens listed below (Refer to the Fro nt Panel Mode Descriptions section in this manual). Pressing the EXIT / Up Arrow key at any time will take the user b ack to the "HOME" screen. PRINTER ADJUSTMENTS PRE ...
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Paxar 545 - page 46
44 • Control Panel Operation Users Manu al Model 545™ Front Panel Mode Descriptions There are six (6) main m ode levels, whic h are selected and modi fied using the following function key s: Use the MODE ↓ key to move t hrough the main m ode screens shown below: PRESS ENTER FOR PRINT / CUT POSITIONS PRESS ENTER FOR PRINT HEAD CLEANING PROC PR ...
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Paxar 545 - page 47
Users Manual Model 545™ Control Pan el Operation • 45 PRINT / CUT POSITIONS PRE SS EN T ER FO R PR I N T / CUT PO S I T I O N This screen follows the "BATCH ID / BATCH QTY" screen if there are batch es to be printed, otherwise it follows th e "READY FOR BATCHES / MODEL" home screen. Pressing ENTER will take the user to the & ...
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Paxar 545 - page 48
46 • Control Panel Operation Users Manu al Model 545™ PR I N T PO S I T I O N S T A T I O N 2 VA LU E : ± X X NE W VA LU E : ± Y Y This screen follows the "PRINT POSI TION STATION 1" screen. This screen allows the print po sition of station 2 to be ad justed in the feed direction. The <YES / NO> buttons are used to change the ...
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Paxar 545 - page 49
Users Manual Model 545™ Control Pan el Operation • 47 CHANGE CU T P OS I T I O N VA LU E : ± X X NE W VA LUE : ± Y Y This screen follows the "PRINT OFFSET ST ATION 2" screen. This screen allows the cut position to be adjusted on sense m ark form ats. The <YES / NO> buttons are used to change th e new cut value. The value is di ...
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Paxar 545 - page 50
48 • Control Panel Operation Users Manu al Model 545™ PRE SS EN T ER FO R CLEA N I N G STAT I O N 2 This screen follows the "CLEANING STATION 1" screen. This screen allows the user to initiate a cleaning cycle fo r station 2. Pressing ENTER will initiate a cleaning procedure on station 2 based on it ’s default cleaning level setting ...
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Paxar 545 - page 51
Users Manual Model 545™ Control Pan el Operation • 49 CALIBRATE SENSORS PRE SS EN T ER TO CA L I BRA T E S E N SO RS This screen follows the "PRI NT HEAD CLEANING PROC" screen. Pressing ENTER will take the user to the "CALIBRATE SENSORS" screen s. Pressing the MODE / Down Arrow key will take th e user to the "LIFE COUNT ...
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Paxar 545 - page 52
50 • Control Panel Operation Users Manu al Model 545™ BOT R E F L OV E R M ARK V A L U E : 000 N E W V A L U E : 000 This screen follows the "TOP REFL NOT OVER MARK" screen. Place the fabric over the bottom reflective sensor so that the reflective mark is over the sensor and when NEW VALUE is at the highest value press ‘Enter’. Pr ...
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Paxar 545 - page 53
Users Manual Model 545™ Control Pan el Operation • 51 ST O C K O UT N O T BL O C K E D V A L U E : 000 N E W V A L U E : 000 This screen follows the "STOCK OUT BLOCKED" screen. Repos ition the fabric so that a splice is within the senso r site path and when NEW VALUE is at the lowest value press ‘Enter’. Pressing the MODE / Down A ...
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Paxar 545 - page 54
52 • Control Panel Operation Users Manu al Model 545™ CON T RO L L E R V E R S I ON XXXXX This screen follows the "TOTAL INCHES OF STOCK" screen. This screen shows the operating system version for the controller (TC B). Pressing the MODE / Down Arrow key will take the user to the "IMAGER VERSION" screen. Pressin g the EXIT / ...
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Paxar 545 - page 55
Users Manual Model 545™ Control Pan el Operation • 53 LA N G U A G E : XXXXXX N E W LA N G U A G E : YYYYYY This screen follows the "EMULATION MODE" screen. This screen allo ws the front panel display l anguage to be change d. Use the <YES and NO> keys t o move between the supported languages on the pri nter. Any number of front ...
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Paxar 545 - page 56
54 • Control Panel Operation Users Manu al Model 545™ VERIFIER SETUP PRE SS EN T ER FO R VE R I F I ER SE TU P This screen follows the "FEATURE SETUP" screen. Pressing ENTER will take the user to th e "VERIFIER SETUP" screen s. Pressing the MODE / Down Arrow key will take the user b ack to the "PRINT / CUT POSITIONS&quo ...
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Paxar 545 - page 57
Users Manual Model 545™ Maintenance • 55 Maintenance Print Module Handling Warning Print heads contained in the print m odules can be dama ged easily, and are subject to premature failure i f not properly handled. Careful handling must be exerci sed so as not to damage the nozzle plate. Please follow the procedures carefully to help ensure prin ...
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Paxar 545 - page 58
56 • Maintenance Users Manual Model 545™ Print Module Replacement / Height Adjustment CAUTION: Turn off the power to the printer before removing or inserting the print module(s). DUE TO THE TOLERANCES IN THE PRINT MODULES AND OF THE PRINT HEADS THEMSELVES, TH E ENTIRE PRINT MODULE MUST BE REPLACED - ONCE A PRINT HEAD HAS REACHED ITS END OF LIFE ...
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Paxar 545 - page 59
Users Manual Model 545™ Maintenance • 57 Print Head Swing Arm Stop Adjustment If a gap or overlap appears in the image on t he front or back of the label it m ay be necessary to adjust the p rint head swing arm stop screw A for that print station. A Using a 5/64” hex key - adjust screw A for the stat ion needing the adjustm ent. Rotating the ...
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Paxar 545 - page 60
58 • Maintenance Users Manual Model 545™ Automated Print Head Cleaning Before performing the Automated Print H ead Cleaning procedure check the print head guard slots for any foreign objects that maybe deflect ing or blocking the ink while in flight. Automate d Print Head Cleaning is performed on operator com mand from the front panel. From tim ...
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Paxar 545 - page 61
Users Manual Model 545™ Maintenance • 59 Manual Manifold Seal Cleaning CAUTION: The print head nozzle plates are very delicate, use extreme care not to contact the print head nozzle plates w hile the print heads are in the print position. Use nothing other than foam tips w ith minimal pressure while cleaning the manifold seals. From tim e to ti ...
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Paxar 545 - page 62
60 • Maintenance Users Manual Model 545™ Cleaning • Take a new foam tip swab (not a cotton swab) and clean any excess ink and debris from both of the ma nifold seals for each print module present as shown. • Use a wiping action across the seals t o avoid pushing any debris down into the manifold seal hol es. • When done cleaning, press th ...
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Paxar 545 - page 63
Users Manual Model 545™ Maintenance • 61 General Machine Cleaning The machine should be cleaned every eight hours of use or as needed. With the exception of the print heads and the optical sensors, the machine can be cleaned using an alcohol base solution. Sim ply apply a l iberal amount of al cohol to a clean rag and wipe down the machine com ...
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Paxar 545 - page 64
62 • Maintenance Users Manual Model 545™ Lubrication Procedure General The 545™ series printers are factory equipped wi th pre-lubricated bronze bearings that do not require lubricat ion. The one exception is the rub cam s on either end of the rotary knife. Periodic cleanin g of the printer and removal of du st will greatly enhance the leng t ...
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Paxar 545 - page 65
Users Manual Model 545™ Maintenance • 63 Changing Stacker Belts 8-32 CAP SCREWS FULL STAC KER CONNECTOR FIGURE 1 1. Remove stacker rai l assembly by removing full stacker connector and (2) 8-32 cap screws from stacker mounti ng plate. (See figure 1) ...
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Paxar 545 - page 66
64 • Maintenance Users Manual Model 545™ JAM SENSOR HARNESS RIVETS SNAP RING FIGURE 2 2. Remove upper conveyor rol ler assemb l y by removi ng 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 bel t cover. 4. Loosen 6-32 set screws in ends of ...
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Paxar 545 - page 67
Users Manual Model 545™ Maintenance • 65 5. Insert an 8-32 screw into the threaded hole in the front side of the roller pin and remove the pin. (See figure 3) 6. Remove the thum bscrew on the front side of the st acker rail base and let the square nut on the underside fall out. Loosen the t humbscrew on the far side to allow slack for the belts ...
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Paxar 545 - page 68
66 • Maintenance Users Manual Model 545™ SMALL DUAL DRIVE BELTS (SEE ITEM 8) FIGURE 5 8. Remove sm all dual drive belt s from one si de of front roller to allow assembly of new belts. 9. To re-assemble, reverse procedure above. ...
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Paxar 545 - page 69
Users Manual Model 545™ Electrical Trouble Shooting • 67 Electrical Trouble Shooting Power Up / Sign On / Communications Problem Probable Cause Corrective Action Printer fails to power up. 1) Incorrect power amplitude. 1) Confirm that the AC entry is configu red for the line voltage inten ded to be applied to th e printer. Failure to do so can ...
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Paxar 545 - page 70
68 • Electrical Trouble Shooting Users Manual Model 545™ Problem Probable Cause Corrective Action Front panel does not com plete diagnostics test 2. 1) One or more PC board(s) unplugged from the M other Board. 1) Power off and remove the power cord from the AC entry. Remove the back cover and reseat the offending board. 2) PCMCIA cartridge not ...
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Paxar 545 - page 71
Users Manual Model 545™ Electrical Trouble Shooting • 69 Fabric Advance Problem Probable Cause Corrective Action Fabric does not advance when the start button is depressed. 1) No batches to be printed. 1) Downlo ad batch (if batch downl oaded uses the same form at as a previously downloaded bat ch the printer with start auto matically). 2) An i ...
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Paxar 545 - page 72
70 • Electrical Trouble Shooting Users Manual Model 545™ Print Problem Probable Cause Corrective Action Printer advances fabric but does not print. 1) If sense mark form at fabric registration sensor m iss aligned. 1) Adjust sensor position so that t he sensor light on the front panel flashes as a sense ma rk / hole passes under the sensor. 2) ...
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Paxar 545 - page 73
Users Manual Model 545™ Electrical Trouble Shooting • 71 Problem Probable Cause Corrective Action Voids in print image in th e feed direction. 1) Nozzles clogged or void of ink. 1) Enter the Print Head Cleaning Mode and clean the print modul e. 2) Print head swing arm st op misadjusted. 1) Adjust the swing arm st op position as needed to preven ...
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Paxar 545 - page 74
72 • Mechanical Trouble Shooting Users Manual Model 545™ Mechanical Trouble Shooting Fabric Problem Probable Cause Corrective Action Fabric will not roll or jumps 1) Incorrect adjustment of unwin d web guides 1) Be sure fabric roll is as fl at as possible and does not extend over core. 2) Adjust the web guides to touch the fabric roll without p ...
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Paxar 545 - page 75
Users Manual Model 545™ Mechanical Trouble Shooting • 73 Ink Problem Probable Cause Corrective Action Print Problem Probable Cause Corrective Action ...
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Paxar 545 - page 76
74 • Mechanical Trouble Shooting Users Manual Model 545™ Sensor Locations A – Fabric Out / Splice Sensor – Detect s wh en the fabric is depleted or a splice is present. B – Active Unwind Loop Sensor – Detects the fabri c to mainta in a predetermined amount of slack in t he active unwind. C – Jam Sensor – Detects a jam in the stacker ...
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Paxar 545 - page 77
Users Manual Model 545™ Mechanical Trouble Shooting • 75 Non-volatile Memory Reset It may be necessary from tim e to time to reset the non-volatile SRAM in the m achine. This can be 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 num ber 2 ...
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Paxar 545 - page 78
76 • Electrical Draw ings Users Manual Model 545™ Electrical Drawings Printer Wiring ...
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Paxar 545 - page 79
Users Manual Model 545™ Electrical Draw ings • 77 Electrical System Schematic 181134 LINE CORD AT J1 BOARD 2 MODULE J5 J3 341105 INK CARTRIDGE OUTBOARD PROCESSOR BOARD 1 MODULE J7 J6 J3 J2 J1 341106IJ BOARD DRIVER HEAD J4/J5 N.C. CONN 4 PRINT MODULE INBOARD PRINTHEAD 345090 X 2 J2 J3 J1 PRINTHEAD CABLE 341123 J2 J5 341105 INBOARD OUTBOARD STATI ...
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Paxar 545 - page 80
78 • Electrical Draw ings Users Manual Model 545™ Motherboard Power Connectors The power supply connector on any PC / XT or PC / AT compati ble motherboard is made up of dual six-pi n male connect ors. Two female connect ors from the power supply plug directly onto these male conn ectors. The following diagram s illustrate the proper method of ...
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Paxar 545 - page 81
Users Manual Model 545™ A ppendix A • 79 Appendix A Error Messages On the Machine's detection o f error(s), the display will show the first error encountered and allow the display ing of any other errors with the <YES / NO> keys, which will "Scroll" through additional errors if any. XX is the total number of errors at the t ...
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Paxar 545 - page 82
80 • A ppendix B Users Manual Model 545™ Appendix B Chip Upgrade Positions / Jumper Settings PN . 341106 RE V0 PAXAR SN. U17 D8 D10 D39 D27 D20 D2 D26 D14 D1 R5 A58 D7 D19 D4 D38 D16 D13 D41 D29 D37 D3 D25 D15 U2 C9 C7 R56 R55 R54 R42 R41 C6 U11 R53 R52 R51 R50 R49 U13 C5 C2 C8 C4 J6 1 J1 16 D47 D23 D11 D35 D22 A45 A1 C1 D9 D46 D34 D21 D44 D32 ...
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Paxar 545 - page 83
Users Manual Model 545™ Appendix B • 81 3 U31 C57 J3 C33 U29 C23 SN. REV 3.9 PAXAR 371105 U1 C18 U2 C19 U3 U4 U 3 U 4 C16 U24 C86 C22 C20 U39 + Y1 C46 WT 2 WT3 U 2 2 U 2 1 C49 U23 C26 U 2 3 C48 U21 C2 C21 C47 C83 U6 C3 U38 R60 R43 C24 U22 C53 C52 C72 R29 U 18 U36 Y2 C7 C51 + C27 18 C28 C4 C73 U18 U 3 6 SIP1 C7 5 C50 R61 R33 C25 C45 R16 C32 U28 ...
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Paxar 545 - page 84
82 • A ppendix B Users Manual Model 545™ Front Panel Board P/N 511108 (Use chip removal tool P/N. 351156 for square I.C removal ) FRONT PANEL BOARD, Upgradeable software I.C.'s include U1. PLCC CHIPS align angled corner of chi p with angled corn er of socket that i s counter clockwise to the arrow. Front Panel Diagnostic Descriptions Diagn ...
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Paxar 545 - page 85
Users Manual Model 545™ A ppendix C • 83 Appendix C Ink Management / Shelf Life The liquid ink contained i n the ink cartridges has a shelf life of one year. It is therefore recomm ended that any inventory supply be rotated on a regul ar basic to prevent exceeding its expiration date. Caution : Expired ink m ay damage pri nt heads. Check the ex ...
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Paxar 545 - page 86
84 • A ppendix D Users Manual Model 545™ Appendix D Knife MFG Guidelines Solenoid Trigger Setting +.000 -.020 1. After the clutch and actuator i s mounted to t he knife, attach the solenoid assembly to t he inside support using two 6-32 x 3/8 cap screws, flat washers, and lock washers. Make sure the plunger m oves freely and does not bind. Moto ...
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Paxar 545 - page 87
Users Manual Model 545™ A ppendix E • 85 Appendix E Material Safety Data Sheet ======================== SECTION I - GENE RAL INFORMATION ======================== PRODUCT NAME: IJ1111 DATE PREPARED: September 28, 1998 MANUFACTURER'S NAME: PAXAR CORPORATION, Systems Group MANUFACTURER'S ADDRESS: PAXAR CORPORATION 1595 Cedar Line Drive R ...
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Paxar 545 - page 88
86 • A ppendix E Users Man ual Model 545™ =========================== SECTION V - REACTI VITY DATA =========================== STABILITY: Stable INCOMPATIBILITY: Strong oxidizing agents HAZARDOUS DECOMPOSITION PR ODUCTS: None known to exist. HAZARDOUS POLYMERIZA TION: Will not occur. ======================== SECTION VI - HEALTH HAZARD DATA ==== ...
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Paxar 545 - page 89
Users Manual Model 545™ A ppendix E • 87 ======================== SECTION VIII - CONTRO L MEAS URES ======================== RESPIRATORY PROTECTION: None is specific ally recommended for handling this product. VENTILATION: None required. Respiratory exposure to material in aerosol form should be avoided. EYE PROTECTION: None required. Avoid con ...
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Paxar 545 - page 90
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Paxar 545 - page 91
Users Manual Model 545™ Assembly Draw ings • 89 Assembly Drawings ...
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Paxar 545 - page 92
90 • Assembly Draw ings Users Man ual 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 ...
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Paxar 545 - page 93
Users Manual Model 545™ Assembly Draw ings • 91 Frame Cover Parts List Item Part # Description Qty 1 341203 560 Base Pan 1 2 341206 Frame, Upright 1 3 341202 Back Cover 1 4 341204 Hinged Cover 1 5 341201 Front Cover 1 6 341216 Mounting Block, Triangle 1 7 990053 8-32 x ¾ Cap Screw 4 8 341210 Feet, 1 ½” Dia. Rubber 4 9 991079 8-32 ½ Thread ...
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Paxar 545 - page 94
92 • Assembly Draw ings Users Man ual Model 545™ Frame Assembly Drawing ...
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Paxar 545 - page 95
Users Manual Model 545™ Assembly Draw ings • 93 Frame Parts List Item Part # Description Qty 1 341206 Frame, Upright 1 2 341128 Assembly, Print Module Cable 1 3 345046 Chase Way, Trailing 2 4 345108 Actuator, Shroud Lock 2 5 341203 #10 Lock Washer 10 6 990082 10-32 x 5/8 Cap Screw 10 7 345037 Knob, Chase 2 8 345043 Mount, Chase Bar 2 9 345038 B ...
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Paxar 545 - page 96
94 • Assembly Draw ings Users Man ual Model 545™ Sub - Frame Assembly Drawing ...
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Paxar 545 - page 97
Users Manual Model 545™ Assembly Draw ings • 95 Sub - Frame Parts List Item Part # Description Qty Item Part # Description Qty 1 341206 Frame, Upright 1 16 343038 Spindle .65 1 2* 343045 Shaft, ABC Spindle 2 17 343110 Bracket, “F” Post 1 3 343044 Spacer, Outer Race 1 18* 343058 Roller, Convex 2 4 343041 Standoff, Partition Short 4 19 343055 ...
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Paxar 545 - page 98
96 • Assembly Draw ings Users Man ual Model 545™ Power Unwind Assembly Drawing ...
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Paxar 545 - page 99
Users Manual Model 545™ Assembly Draw ings • 97 Power Unwind Parts List Item Part # Description Qty Item Part # Description Qty 1 341206 Frame, Upright 1 20 989966 Washer, 4 Star 1 2 343135 Ass’y, Bracket Unwind 1 21 990001 4-40 x 5/8 Cap Screw 1 3 990486 E-ring 3/8 1 22 990122 ¼-20 x ¾ Cap Screw 3 4 343120 Shaft, Capstan 1 23 990145 ¼ Loc ...
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Paxar 545 - page 100
98 • Assembly Draw ings Users Man ual Model 545™ Unwind Support Assembly Drawing ...
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Paxar 545 - page 101
Users Manual Model 545™ Assembly Draw ings • 99 Unwind Support Parts List Item Part # Description Qty Item Part # Description Qty 1 A 990058 8-32 x ¼” Set Screw 1 14 343207 Bracket, Indicator 1 2 A 105023 Knob 1 15 343224 Label, Indicator 1 3 A 143016 3” Unwind Core 1 16 991138 6-32 x 5/8” Slotted F.H. Screw 2 4 A 990371 ¼” Collar 3 1 ...
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Paxar 545 - page 102
100 • Assembly Draw ings Users Manual Model 545™ Unwind Nip Roller Assembly Drawing 9 9 10 2 1 11 4 5 3 6 7 8 8 ...
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Paxar 545 - page 103
Users Manual Model 545™ Assembly Drawin gs • 101 Unwind Nip Roller Parts List Item Part # Description Qty . 1 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 9 ...
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Paxar 545 - page 104
102 • Assembly Draw ings Users Manual Model 545™ Unwind Snubber Assembly Drawing ...
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Paxar 545 - page 105
Users Manual Model 545™ Assembly Drawin gs • 103 Unwind Snubber Parts List Item Part # Description Qty 1 343128 Carrier, Snubber 1 2 343162 Bracket, Snubber 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 ...
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Paxar 545 - page 106
104 • Assembly Draw ings Users Manual Model 545™ Print Module Assembly Drawing ...
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Paxar 545 - page 107
Users Manual Model 545™ Assembly Drawin gs • 105 Print Module Parts List There are no parts in the print module that can be changed by the user. If a print module becom es defective, it will have to be sent back to the factor y for rebuilding. The same module is used in both the right and the left print stations. The part number for the complet ...
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Paxar 545 - page 108
106 • Assembly Draw ings Users Manual Model 545™ Cartridge Support Deck Assembly Drawing ...
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Paxar 545 - page 109
Users Manual Model 545™ Assembly Drawin gs • 107 Cartridge Support Deck Parts List Item Part # Description Qty Item Part # Description Qty 1 346202 Bracket, Left Enclosure 1 11 346206 Lever, Actuator 2 2 343042 6-32 SEM x 3/16” Screw 6 12 990225 3/16 x 1/8” Shoulder Screw 2 3 990038 6-32 Hex Nut 2 13 346205 Lever, Actuation Bar 2 4 197312 S ...
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Paxar 545 - page 110
108 • Assembly Draw ings Users Manual Model 545™ Feed Assembly Drawing ...
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Paxar 545 - page 111
Users Manual Model 545™ Assembly Drawin gs • 109 Feed Parts List Item Part # Description Qty 1 341206 Frame, Upright 1 2 351141 Ink Motor 1 3 344056K Drive Gear, 24T 1 4 990081 10-32 x ½ Cap Screw 6 5 990728 #10 Lock Washer 3 6 990017 6-32 x ½ Cap Screw 1 7 990037 #6 Washer SAE 1 8 991073 Standoff, 1 ¾, 10-32 THD 3 9 344051 Fixed Idler Shaft ...
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Paxar 545 - page 112
110 • Assembly Draw ings 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 ...
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Paxar 545 - page 113
Users Manual Model 545™ Assembly Drawin gs • 111 Feed Roller Parts List Item Part # Description Qty Item Part # Description Qty 1 341206 Frame, Upright 1 16 354008A Gear, Idler 1 2 514001 Shaft, Idler Roller 1 17 990023 6-32 x ½ F.H.S. 1 3 999037 Iglide, .50 x .50 FL Bearing 2 18 990416 ½-20 x ½ F.H.S. 1 4 344054 Upper Drive Roller 1 19 3540 ...
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Paxar 545 - page 114
112 • Assembly Draw ings Users Manual Model 545™ Knife Assembly Drawing ...
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Paxar 545 - page 115
Users Manual Model 545™ Assembly Drawin gs • 113 Knife Parts List Item Part # Description Qty Item Part # Description Qty 1 197003 #10 Washer 1 20 357016 Standoff, Solenoid Arm 1 2 197308 Adjuster, Knife 1 21 357019K Clutch, Square Drive 1 3 197311 Cam, Knife Homing 1 22 990019 6-32 x ¼ Button Head Screw 1 4 197312 Spring, Cam 1 23 357091 Brac ...
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Paxar 545 - page 116
114 • Assembly Draw ings Users Manual Model 545™ Stacker Assembly Drawing – Part 1 ...
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Paxar 545 - page 117
Users Manual Model 545™ Assembly Drawin gs • 115 Stacker Parts List – Part 1 Item Part # Description Qty Item Part # Description Qty 1 348001 Frame, Rear Stacker 1 19 990019 6-32 x ¼ Button Head Screw 8 2 348002 Frame, Near Stacker 1 20 378216 Sensor Mount, Lower 1 3 348017 Support, Pick-Up Roller 2 21 991029 Knob, 3 Prong, 10-32 Stud 1 4 99 ...
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Paxar 545 - page 118
116 • Assembly Draw ings Users Manual Model 545™ Stacker Assembly Drawing – Part 2 ...
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Paxar 545 - page 119
Users Manual Model 545™ Assembly Drawin gs • 117 Stacker Parts List – Part 2 Item Part # Description Qty Item Part # Description Qty 1 348106 Plate, Stacker Support 1 24 348021 Roller, Idler 1 2 348192 Assembly, Rear Stacker Side 1 25 348093 Assembly, Drive Roller 2 3 348191 Assembly, Front Stacker Side 1 26 348019 Roller, Drive 1 4 348005 Br ...
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Paxar 545 - page 120
118 • Assembly Draw ings Users Manual Model 545™ Rewind Assembly Drawing ...
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Paxar 545 - page 121
Users Manual Model 545™ Assembly Drawin gs • 119 Rewind Parts List Item Part # Description Qty Item Part # Description Qty 1 112033 Shaft, 6x6 rewind 1 19 112037 support, shaft bearing 1 2 112035 Key, 1/8 x 1/8 x 3/8 1 20 990090 10:32 x 3/8 btn hd screw 2 3 923009 10" roll disc 1 21 351161 Stacker motor harnessed 1 4 111032 Rubber feet 4 2 ...
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