Paxar 545 User Manual

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Users Manual

Model 545

PAXAR Systems Group

Manual Edition 5.1

15 February 2002

Manual Part Number 341398

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Contents

 

Scope

4

Introduction ...............................................................................................................................

4

Safety Issues / Warnings

4

Cautions.....................................................................................................................................

4

Warranty Information

5

Limited Warranty.......................................................................................................................

5

Parts ...........................................................................................................................................

5

Service .......................................................................................................................................

5

Location / Power Requirements

6

Location of Printer.....................................................................................................................

6

AC Power Line ..........................................................................................................................

7

Unpacking / Inventory

8

Unpacking..................................................................................................................................

8

Inventory of Components ..........................................................................................................

9

Ink Cartridge Return Program ...................................................................................................

9

Product Description

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

Printer Operation / Adjustments

22

Installing and Removing Ink Cartridges..................................................................................

22

Adjusting the Unwind..............................................................................................................

24

Loading Fabric for the First Time ...........................................................................................

24

Users Manual Model 545™

i

Threading Diagram..................................................................................................................

25

Web Guide Adjustment ...........................................................................................................

27

Stacker Position Adjustment....................................................................................................

29

Stacker Label Width Adjustment.............................................................................................

29

Stacker Label Length Adjustment ...........................................................................................

30

Stacker Angle Adjustment .......................................................................................................

30

Stacker Full Level Adjustment ................................................................................................

31

Replenishing Fabric at End of Roll..........................................................................................

32

Splices......................................................................................................................................

32

Print Head Operation ...............................................................................................................

33

Printer Setup ............................................................................................................................

34

Sensor Calibration ...................................................................................................................

36

Control Panel Operation

37

Control Buttons........................................................................................................................

37

Indicator Lights........................................................................................................................

38

LCD Display............................................................................................................................

39

Front Panel Menu Map ............................................................................................................

40

Front Panel Power Up / Home Screens....................................................................................

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

Power Up / Sign On / Communications...................................................................................

67

Fabric Advance........................................................................................................................

69

Print .........................................................................................................................................

70

Cut / Stack................................................................................................................................

71

Mechanical Trouble Shooting

72

Fabric .......................................................................................................................................

72

Ink............................................................................................................................................

73

Print .........................................................................................................................................

73

Sensor Locations......................................................................................................................

74

Non-volatileMemory Reset.....................................................................................................

75

Electrical Drawings

76

Printer Wiring ..........................................................................................................................

76

Electrical System Schematic....................................................................................................

77

Motherboard Power Connectors ..............................................................................................

78

ii

Users Manual Model 545™

Appendix A

79

Error Messages ........................................................................................................................

79

Appendix B

80

Chip Upgrade Positions / Jumper Settings ..............................................................................

80

Front Panel Diagnostic Descriptions .......................................................................................

82

Appendix C

83

Ink Management / Shelf Life...................................................................................................

83

Appendix D

84

Knife MFG Guidelines ............................................................................................................

84

Appendix E

85

Material Safety Data Sheet ......................................................................................................

85

Assembly Drawings

89

Frame Assembly Cover Drawing ............................................................................................

90

Frame Cover Parts List ............................................................................................................

91

Frame Assembly Drawing .......................................................................................................

92

Frame Parts List.......................................................................................................................

93

Sub - Frame Assembly Drawing..............................................................................................

94

Sub - Frame Parts List .............................................................................................................

95

Power Unwind Assembly Drawing .........................................................................................

96

Power 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 Parts List .......................................................................................................................

109

Feed Roller Assembly............................................................................................................

110

Feed Roller Parts List ............................................................................................................

111

Knife Assembly Drawing ......................................................................................................

112

Knife Parts List......................................................................................................................

113

Stacker Assembly Drawing – Part 1......................................................................................

114

Stacker Parts List – Part 1......................................................................................................

115

Stacker Assembly Drawing – Part 2......................................................................................

116

Stacker Parts List – Part 2......................................................................................................

117

Rewind Assembly Drawing...................................................................................................

118

Rewind Parts List...................................................................................................................

119

Users Manual Model 545™

iii

Scope

Introduction

This user’s manual was arranged for the person who is going to operate the printer. The information is arranged in the order that is needed to install and then operate the printer. It starts with general information, then to unpacking the carton, setup, installing the ink and fabric, printer operation, control panel operation, and finally care and maintenance of the printer.

We at PAXAR hope that you will come to appreciate the efforts and quality, which have gone into producing your PAXAR 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 MODULE NEEDLES ARE UNPROTECTED WHILE THE PRINT MODULES ARE IN THE PRINTER.

This printer has some pinch points. All of these areas have been well guarded and it is recommended that the safety features of this printer are never altered or defeated.

4 Scope

Users Manual Model 545™

Warranty Information

Limited Warranty

PAXAR Systems Group, Division of PAXAR Corporation, extends the following warranties to the original purchaser of a PAXAR 545 which has been installed and operated using recommended procedures and operating conditions.

Parts

Parts found defective in material or workmanship will be replaced at no charge for a period of six months following the printer's shipment date. Parts damaged by negligence, abuse, or normal wear are not covered. PAXAR 545 parts classed as normal wear items include print heads, feed and turn rollers, stacker belts, and knife blades.

Service

Service to replace defective parts as defined above, shall be provided at no charge for a period of six months following the shipment date.

When ordering machines and supplies in the U.S.A., reference all correspondence to the address below.

PAXAR Corporation

One Wilcox Street

Sayre, Pa. 18840

Call: 1-800-96PAXARor (570)888-6641Fax: (570)888-5230

For spare parts, requests for service or technical support Paxar Service Group

170 Monarch Lane Miamisburg, OH 45342

Call:

(800) 543-6650

Fax:

(937)

865-2092for Warranty Parts

Fax:

(937)

865-2707or (937)865-6605for Customer Parts Orders

For parts and service in other countries please contact your local PAXAR supplier.

PAXAR Apparel Identification Systems Group reserves the right to incorporate any modifications or improvements in the machine system and machine specifications which it considers necessary and does not assume any obligation to make said changes in equipment previously sold.

Users Manual Model 545™

Warranty Information 5

Location / Power Requirements

Location of Printer

The printer weighs approximately 80 Lbs. (~37Kg) and requires a table of sufficient quality and strength to handle this load while the printer is operating. PAXAR recommends an industrial type worktable having the approximate dimensions of 96" wide to 30" deep to 32" high.

Recommended Workstation Layout.

The location of the PAXAR 545 printer should be based on human factors. The printer should be located in an area that maintains optimum flow of your product while providing for the operator’s comfort. PAXAR has taken significant steps to ensure that the operator controls and operations are easily accessible. This goal can only be met, however, if the printer is also located with human factors in mind. These include the height of the printer, the space around the printer, and the accessibility to the printer.

The PAXAR 545 printer is a high-resolutionink jet printer. While PAXAR has designed the printer to be reasonably quiet, it is recommended to locate the printer in an area where printing and cutting repetitious noise is acceptable.

The unit should always be operated with the cover closed to minimize the amount of dust and dirt in the printer.

6 Location / Power Requirements

Users Manual Model 545™

AC Power Line

PAXAR requires that the electric service be 10 Amps @ 115VAC or 10 Amps @ 230VAC. This will allow the computer and any additional support or service equipment to be plugged into the same service.

Any electrical service which is supplying a PAXAR printer or peripheral equipment connected to a PAXAR printer should follow standard electrical code practices including proper grounding and neutral requirements.

The PAXAR printer was designed to operate in an industrial setting for extended 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 supply, PAXAR recommends that a separate “clean” service be installed or reserved for the exclusive use of the PAXAR printer and it’s peripherals.

Users Manual Model 545™

Location / Power Requirements 7

Unpacking / Inventory

Unpacking

The PAXAR printer is shipped in 2 large cardboard boxes, of which one may be difficult to move by hand.

DO NOT REMOVE THE PRINTER FROM THE BOX OR UNPACK IN THE SHIPPING / RECEIVING DEPARTMENT.

NOTE: Unpacking in the shipping / receiving department is not recommended for the following reasons.First: The cardboard carton in which your PAXAR printer was shipped allows the printer to be moved with a forklift, or handcart. Because of the weight of the printer, it is easier and safer to use one of these devices to move the printer to its intended installation location.Second: Leaving the printer in the carton while it is being moved within your facility will help to protect the printer during any movements to this 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 top insert. Remove the printer from the box. Inspect the printer for shipping damage. If damage is discovered, contact PAXAR for further instructions - in the U.S.A. at (570)-888-9116.In other countries please contact your local PAXAR supplier. Once you are satisfied that there was no obvious shipping damage to the printer, continue with the installation.

Shipping Cartons.

Save the shipping materials to relocate the printer or return to factory for service.

8 Unpacking / Inventory

Users Manual Model 545™