Brady PAM3000 Service Manual

PAM 3000

Printer-Applicator-System

Service Manual

Edition 6/02

Identification Solutions Division 6555 W. Good Hope Road PO Box 2131 Milwaukee, WI 53201 U.S.A. Phone: 1-800-537-8791 Fax: 1-800-292-2289

In accordance with our policy of continual product improvement, we reserve the right to alter specifications without notice Données technique modifiables sans prévais Technische Änderungen vorbehalten

PAM 3000

Printer-Applicator-System

Spare Parts List

No part of this manual nor any translation may be reproduced or transmitted in any form or by any means, for any purpose other than the purchaser's personal use, without the express written permission of W.H. Brady Co.

Edition 6/02

3Printer-Applicator-System PAM 3000

4 Printer-Applicator-System PAM 3000

Table of Contents

1. Introduction ............................................................................................................................................6

1.1 Scope of Information ........................................................................................................ ........................ 6

1.2 General Safety Instructions ..................................................................................................................... 6

1.3 Safe Handling of Electricity ......................................................................................................................7

1.4 Printer Component Location .................................................................................................................... 8

2. Self Test ............................................................................................................................................... 12

2.1 Self Test Preparation............................................................................................................................ 12

2.2 Self Test Explanation ............................................................................................................................ 12

3. Internal Setup ...................................................................................................................................... 13

3.1 General Information .............................................................................................................................. 13

3.2 Starting the Internal Setup .................................................................................................................... 13

4. Maintenance ........................................................................................................................................ 19

4.1 General Cleaning .................................................................................................................................. 19

4.2 Cleaning the Printhead ......................................................................................................................... 19

4.3 Cleaning the Print Roller and the Transport System ............................................................................ 20

4.4 Cleaning the Brake ............................................................................................................................... 21

4.5 Cleaning the Pad .................................................................................................................................. 22

5. Replacing of Assembly Units.................................................................................................. ........... 23

5.1 Recommended Tools ............................................................................................................................ 23

5.2 Replacing the Printhead ....................................................................................................................... 24

5.3 Replacing the Print Roller and the Feed Roller .................................................................................... 25

5.4 Replacing the Transport Locking Roller................................................................................................ 26

5.5 Replacing the Pinch Roller ................................................................................................................... 27

5.6 Replacing the Label Edge Sensor ........................................................................................................ 28

5.7 Replacing the Slip Clutches .................................................................................................................. 29

5.8 Replacing the Main Drive Motor.............................................................................................. .............. 33

5.9 Replacing the PCBs CPU and Driver Electronic .................................................................................. 34

5.10 Firmware-Update of the Printer Module................................................................................................ 35

5.11 Replacing the PCB Applicator Control and Firmware-Update of the Applicator Module ...................... 36

5.12 Sensor Replacement ............................................................................................................................ 37

6. Alignings and Adjustments................................................................................................................ 41

6.1 Aligning the Peel-off Table .................................................................................................................... 41

6.2 Aligning the Printhead........................................................................................................................... 42

6.3 Aligning the Guide Plate ....................................................................................................................... 43

6.4 Adjusting the Sensors of the Peel-off Table.......................................................................................... 44

6.5 Adjusting the Sensors of the Printhead ................................................................................................ 45

6.6 Adjusting the Torque at the Hubs.......................................................................................................... 46

6.7 Adjusting the Brake at the Media Supply Hub ...................................................................................... 49

6.8 Adjusting the Label Edge Sensor ......................................................................................................... 50

6.9 Setting the Speed of the Compressed Air Driven Assemblies.............................................................. 50

6.10 Pneumatic Setting of the Printhead Pressure....................................................................................... 53

6.11 Pneumatic Setting of the Brake ............................................................................................................ 54

6.12 Pneumatic Setting of the Supporting Air ............................................................................................... 54

6.13 Mechanical Adjustments of the Sensors on the Applicator ................................................................... 55

6.14 Setting of Delay Times during Operation .............................................................................................. 58

6.15 Level Adjustment of the Applicator Module .......................................................................................... 59

6.16 Mechanical Alignment of the Pad ......................................................................................................... 60

7. Problem Solution ................................................................................................................................ 61

7.1 Errors during Printing and Applicating .................................................................................................. 61

7.2 Failure of Device Functions .................................................................................................................. 64

7.3 Permanently displayed Hardware Errors .............................................................................................. 65

Appendices

Block Diagrams .............................................................................................................................................. A1

Circuit Diagrams .................................................................................................................................... B1-B12

Layout Diagrams ...................................................................................................................................... C1-C4

PCB Applicator Control .................................................................................................................................. D1

Pin Assignments .................................................................................................................................... E1-E10

5Printer-Applicator-System PAM 3000

1 Introduction

1.1 Scope of Information

This manual is intended for use by qualified service and maintenance personnel by BRADY Co. The technical information included relates to hardware and mechanical parts of the Printer-Applicator-System PAM 3000. Information related to operation will be found in the Operating Manual provided with the system.

Important information contained in this manual is marked as follows:

WARNING ! Impending danger! May cause death or physical injuries.

CAUTION ! Dangerous situation ! May cause equipment/material damage or data loss.

NOTICE ! Helpful additional information and tips for use.

If a problem occurs, which cannot be solved with the help of this manual, please contact the cab Technical Service Department.

cab Produkttechnik Sömmerda GmbH Am Unterwege 20 D - 99610 Sömmerda Telephone: 03634/6860-111 Telefax : 03634/6860-119

1.2 General Safety Instructions

CAUTION ! Follow the general safety rules below:

Keep the area around the device clean at all times! Avoid performing maintenance which might expose persons to danger or make the device a source of danger! Save housing or other parts of the device removed during maintenance! Keep tools out of the way to avoid injury to yourself or others not involved in the maintenance! Do not wear loose clothing that could be caught in moving parts of the device. Button up your shirt or jacket sleeves or roll them up.Tie back or put up long hair. Tuck the ends of scarves, ties and shawls into your clothing and attach them with a non-conducting clip. Do not wear jewelry, glasses with metal frame or clothing with metal fasteners!

WARNING ! If such metal parts contact the device, they cause an increased current flow due to good conductivity!

Wear protective goggles at work as follows:

- while working with compressed air by cleaning the machine

- while using spring hooks or springs

- while soldering

- while using solvents, cleaners or other chemical substances

- in any case where injury to the eyes is possible. Refit all protective devices such as covers, safety instructions, and grounding cable upon completion of the maintenance work! Replace all faulty or defective parts!

6 Printer-Applicator-System PAM 3000

1.3 Safe Handling of Electricity

Follow the additional instructions below when handling electricity:

Find out the positions of the emergency and the power switch in order to operate themquickly in an emergency situation! Do not work alone under dangerous working conditions or while working on devices with non-protected voltages (over 50 V AC or 120 V DC)! Turn off power to the printer before:

- removing or installing power units

- working near open power supply parts

- mechanical checkup of power supply parts

- changing circuit boards or electrical parts

If you cannot avoid working on devices with non-protected voltages, follow these safety precautions:

- Have a person nearby who is aware of the position and operation of the power switches, who will switch off the power in case of danger.

- Use only tools and test devices, which are suitable for the work being done.

- Work only with one hand on devices that are switched on. Keep the other hand behind your back or in your pocket until you have finished.

NOTICE ! A shock occurs only with a closed circuit. By using only one hand, as described above, you would avoid a current flow through your own body.

Do not use worn or defective tools! Never assume that a circuit is not powered. You must always verify that there is no voltage present! Always examine the work area for possible sources of danger, such as wet floors, defective extension cords, faulty protective grounding connectors etc. If you observe an accident with electricity:

- Be careful and avoid danger to yourself.

- Switch off power.

- Request medical assistance.

- Give first aid, if necessary.

7Printer-Applicator-System PAM 3000

1.4 Component Location

Printer

1112131415

Fig. 1a Front view

1 - Display 2 - Function keys with indicator LEDs 3 - Ribbon take up hub 4 - Ribbon supply hub 5 - Print mechanism 6 - Guide roller 7 - Media rewind hub 8 - Knurled knob 9 - Flange

10 - Adapter

11 - Media supply hub 12 - Swing arm with guide roller 13 - Pre-dispense key (for applicator) 14 - Electronic connector for the applicator 15 - Air connectors for the applicator

67 8

8 Printer-Applicator-System PAM 3000

67 981011

Fig. 1b Detailed view of the print mechanism

1 - Adjusting plate 2 - Printhead 3 - Print roller 4 - Feed roller 5 - Pinch roller 6 - Transport locking lever 7 - Peel-off table 8 - Label edge sensor 9 - Brake

10 - Media guide axle

11 - Media guide

9Printer-Applicator-System PAM 3000

Fig. 1c Side view

1 - Connector for the compressed air 2 - Power connector with power switch 3 - Parallel interface port 4 - Serial interface port 5 - Scanner connector 6 - Connector warning sensor transfer ribbon end 7 - Connector warning sensor label end 8 - PLC interface port 9 - DIP switches

10 - Connector warning light

11 - Silencer 12 - Memory card module slot

10 Printer-Applicator-System PAM 3000

Applicator

Fig. 1d Front view

1 - Connector for the electronics 2 - Pad holder 3 - Pad 4 - Turn cylinder 5 - Slide valve 6 - Lift cylinder

11Printer-Applicator-System PAM 3000

2 Self Test

2.1 Self Test Preparation

The PAM 3000 Label Printer has a built-in self test, which makes troubleshooting easier and gives information about the configuration of the device. In order to make a self test printout please load material (labels, continuous paper) which covers the entire printing width. If you wish to make a test printout in thermal transfer mode, use transfer ribbon of maximum width.

NOTICE ! The test printout is made regardless of label gaps, and is about 230 mm long. Continuous media would be best suited for test prints, otherwise, a normal sheet of paper which is cut to a width of 115 mm can be used in thermal transfer mode, too.

Before starting the self test the DIP-switch 3 located in the opening at the right side of the printer has to set on

OFF (see Operators Manual). The self test is initiated by either pressing the key when switching on the printer and keep them pressed until the system test is completed. The display will show Testprint. You may start

the self test by pressing the pre-dispense key at the front side of the printer. Test printout can be aborted by

pressing the key.

2.2 Self Test Explanation

Firmware version

Bar code with test information

Setup and status information

Available character sets

Test pattern

Fig. 2a Self test printout

12 Printer-Applicator-System PAM 3000

3 Internal Setup

3.1 General Information

In addition to the setup facilities that can be accessed by the user (see Operating Manual), the printer has an internal setup which is to be used by service personnel only.

In order to use the internal setup you need a terminal application. Therefore you can use Windows-Terminal on a Windows-PC, ZTERM on a Macintosh, connect on an ATARI or KERMIT under UNIX.

This example describes the use of the Windows Terminal application. It is recommended to remove the machine out of the production line while using the Internal Setup.

3.2 Starting the Internal Setup

For preparation, set the parameter "Interface" in the user setup of the printer to specify RS-232, baud rate 9600. Now start the Windows terminal program on the PC. Select "Transfer" from the menu "Preferences" and adjust the terminal program to the printer setup (baud rate etc.).

Now start the user setup of the printer again by using one of the following options :

1. Hold the keys

ONL

and

when switching on

CAN

2. Hold the keys

ONL

and

longer than 5 seconds.

CAN

The message Setup is shown on the display of the printer, followed by Country. In this printer condition, enter the characters secret into the terminal program on the PC. RS232Setup is displayed and the terminal program shows the following menu on screen :

SETUP PAM 3000 2.67 (Nov 29 2001) - SETUP

1) Complete system test (9600 baud, last results: 0000)

2) Print head test pattern

3) Reset counters - Hours Transfer Thermal Total 0 0 m 0 m Since Service 0 0 mm 0 mm

4) Save as default values

5) Adjust label gap sensor

9) Main motor current: 16/16

A) Delay for peel off: On B) Backfeed on power-on: Off C) Paper-end lever build-in: Yes D) Peel-off edge at 13 mm E) Ignore protocol error: Off F) Additional offset gap sensor : 0

Z) Quit

(15.03.02 13:15:57) ? _

13Printer-Applicator-System PAM 3000

1) Complete system test

By selecting 1, a detailed internal selftest will be activated (This includes more detail than the self test which runs after powering on the printer). The printer will clear the memory completely after finishing the detailed selftest, by issuing a RESET at the end. The display shows:

Self test (no return!) ? (Y/..)

By pressing Y, the selftest will be initiated. In the Terminal program, the following (or similar) text will be displayed:

Fill memory with $00 Test memory for $00 Fill memory with $FF Test memory for $FF Fill memory with mux test values Test memory for mux test values Test RTC Test ROM for mirroring Test ROM checksum Clear memory using movem Test lower memory Test upper memory Test refresh Test lower memory Test upper memory Clear memory Writing single byte access (16K) Reading single byte access (16K) Test remainder for $00 Test internal sRAM Test QSPI and ADC Test watchdog

Every line represents a selftest stage. If an error occurs, the next line shows the message >>>ERROR. If this occurs, you should replace the CPU PCB.

2) Printhead test pattern

This part of the Internal Setup supports the printhead alignment. There will be a grid test pattern printed by selecting this option. After keying a 2 in Terminal, the following message will appear:

Adjust printhead ? (Y/..)

After pressing Y on the keyboard of your PC you have to press the pre-dispense key on the printer to get the test pattern. You can now adjust the position of the printhead until the quality of the printed image is optimum. During adjustment you have to repeat the whole procedure to get some more test pattern.

In order to cancel the operation, press the

14 Printer-Applicator-System PAM 3000

CAN

-key.

3) Reset counters

There are two sets of counters, each containing three counters which track:

working time transfer printing total length thermal printing total length

The first counter set reflects the totals over the lifetime of the printer. The second counter set is intended to show totals for the interval since last technical service. Having completed the maintenance work, you can reset this second set of counters as follows: After keying a 3, the following prompt will display on your monitor:

Mode ?

Enter the password CARRY to reset the service counter and the result of the system test (test printout, status display) to 0000.

The test result can be reset also without resetting the service counter. To achieve this, use the password RESLT.

4) Save as default values

By selecting option 4 you can specify as defaults the parameters you have set up using operator setup. This will store your current values for the following as defaults:

- country

- transfer print

- label edge sensor

- interface

- cut position

- peel position

- heat level

- character set

- brightness

Save defaults ? (Y/..)

Generally, you will only need to save new setup parameters as defaults when components have been replaced (e.g. printhead), the tolerances of which differ from those of the old components.

5) Adjust label gap sensor

Use option 5 to adjust the label gap sensor. This will be necessary when the label gap sensor itself or the CPU PCB have been replaced. Once initiated, follow the prompts, removing and reinserting label stock, as indicated below.

NOTICE ! Check the adjustment of the sensor without influence of outside light!

15Printer-Applicator-System PAM 3000

Adjust label gap sensor? (Y/..)

Please remove label stock (any key)

Using 5/64 : 0 Using 6/64 : 0 Using 7/64 : 0 Using 8/64 : 0 Using 9/64 : 0 Using 11/64 : 0 Using 12/64 : 1 Using 13/64 : 3 Using 14/64 : 7 Using 15/64 : 15 Using 16/64 : 23 Using 17/64 : 34 Using 18/64 : 46 Using 19/64 : 58 Using 20/64 : 71 Using 21/64 : 84 Using 22/64 : 98 Using 23/64 : 111 Using 24/64 : 125 Using 25/64 : 139 Using 26/64 : 153 Using 27/64 : 166 Using 28/64 : 180 Using 29/64 : 193 Using 30/64 : 205 Using 31/64 : 208

Please insert label liner (any key)

Using 31/64 : 170 Using 32/64 : 181 Using 33/64 : 192 Using 34/64 : 202

Finished adjustment, Values 31 - 34 (any key)

7) Print adjustment

This option is not valid for PAM 3000-printer. It is only valid for devices which are offered as left-handed and right-handed types. The left-handed-position should be selected.

16 Printer-Applicator-System PAM 3000

9) Main motor current

Several types of motors are available as main drive motors. Following menu item #9, you can adjust the motor current of the main drive motor to one of the several types of motors (e.g.after motor replacement). The standard motor is the type Nanotec 4T5718L5208. The adjusted value for this type is 16/16. It is recommended from the producer to use this standard motor.

The actual motor current value will be displayed under menu item #9:

9) Main motor current : 16/16

Upon entering "9" the display will change to:

Value : 10+/-/ENTER ?+

Using the keys "+" and "-" you can alter the motor current value. Having setup the required value you can return to the internal setup main menu by pressing the "ENTER" key.

Value: 10 +/-/ENTER?+ Value: 11 +/-/ENTER?+ Value: 12 +/-/ENTER?+ Value: 13 +/-/ENTER?+ Value: 14 +/-/ENTER?+ Value: 15 +/-/ENTER?+ Value: 16 +/-/ENTER? <ENTER>

Upon completion of the setup procedure the new motor current value will be displayed under menu item #9.

A) Delay for peel-off

This option is not valid for PAM 3000-printer.

The ON position should be selected.

B) Backfeed on power-on

This option is not valid for PAM 3000-printer.

The OFF position should be selected as standard.

C) Paper-end lever build in

The printer is equipped with a sensor which recognizes the end of material. This parameter is set on "Yes" when the sensor should be active. That means the printer will be stopped when the paper is out and the display is shown a message. Otherwise the sensor would be disregarded.

Button C allows the user to switch yes or no and the display indicates.

C) Paper-end lever build in : No

C) Paper-end lever build in : Yes

The YES position must be selected as standard.

17Printer-Applicator-System PAM 3000

D) Peel-off edge at 13 mm

This option is not valid for PAM 3000-printer.

The setting 13 mm must be selected as standard.

E) Ignore protocol error

The printer is equipped with a comprehensive self diagnostic system which will indicate errors in the display of the printer. Also, the operator will be informed by the LEDs whether a protocol error occurs and will be able to correct it and to continue the current print job after corrections, or to cancel the current print job. When this parameter is On the printer ignores the protocol error and no message is shown at the display.

Button E allows the user to switch this paramter on or off and the display indicates.

E) Ignore protocol error : On

E) Ignore protocol error : Off

The OFF position should be selected as standard.

CAUTION ! This parameter should only be set "ON" if the configuration of the computer requires this setting. It is possible that data are lost when the setting "ON" is active and therefore faults will be ignorized.

F) Additional offset gap sensor

This option is not valid for PAM 3000-printer.

The setting 0 mm must be selected as standard.

Z) Quit

By keying Z, you can leave the internal setup. A prompt inquiring whether changes should be saved will be displayed as follows:

Save changes ? (../N)

Having completed the internal setup, the printer will now perform a reset and will be placed in the ONLINE mode. You can now exit the Windows Terminal Program, if desired.

18 Printer-Applicator-System PAM 3000

4 Maintenance

4.1 General Cleaning

Dust particles can accumulate during operations. Remove dust and label fragments with a soft brush or vacuum cleaner.

The exterior surfaces may be cleaned with a general purpose cleaner.

NOTICE ! Do not use abrasive cleaners or solvents.

4.2 Cleaning the Printhead

After extensive printer operation or if poor quality paper or ribbon has been used, foreign particles may collect on the printhead. They cause characters or bar codes to appear light or faded, and can cause continuous light streaks to always appear in the same physical position. When this happens, you must clean the printhead. We recommend cleaning the printhead every time changing the ribbon.

To clean the printhead, proceed as follows:

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 4a Cleaning the printhead

1. Remove label stock and transfer ribbon from the printer.

2. Remove the dirt and adhesive from the print surface of the printhead (1) using a cleaning pen.

CAUTION ! Do not use any sharp objects to clean the print surface of the printhead.

3. Allow the printhead to dry for 2 - 3 minutes.

19Printer-Applicator-System PAM 3000

4.3 Cleaning the Print Roller and the Transport System

If the print roller and the rollers of the tranport system become contaminated with dirt, label adhesive, ink or rest of labels, the movement of the media and print quality may also be adversely affected.

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 4b Opening the transport system

1. Unlock the transport locking roller by pressing the knurled knob (1) downwards.

Fig. 4c Cleaning the transport rollers and the print roller

2. Remove label stock and transfer ribbon from the printer.

3. Using a clean cloth and isopropyl alcohol, wipe off any acumulated dirt from the rollers (2-4) of the transport system and from the print roller (5).

20 Printer-Applicator-System PAM 3000

4.4 Cleaning the Brake

It is also recommended to clean the brake (1) regularly. Otherwise it is possible that the transport of the paper is adversely affected.

WARNING ! Disconnect power supply ! Switch off compressed air !

1 2

Fig. 4d Cleaning the brake

1. Unlock the transport locking roller by pressing the knurled knob downwards.

2. Remove label stock and transfer ribbon from the printer.

3. Loosen the screw (2).

4. Remove the brakeplate (3).

5. Using a soft brush or a vacuum cleaner, wipe off any acumulated dirt from the area around the brake.

6. Remount the brakeplate (3) and tighten the screw (2).

21Printer-Applicator-System PAM 3000

4.5 Cleaning the Pad

During operation, dust particles accumulate on the pad. Remove these particles with a soft brush or a vacuum cleaner. Remove label fragments and traces of adhesive with alcohol if necessary.

If the slide foil is damaged, it must be replaced.

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 4e Opening the valve

1. Slightly pull the valve (1) until the "bleed" position is reached. So it is possible to move the pad manually.

2 3 4

Fig. 4f Cleaning the pad

2. Slide the pad (2) to a position where the underside of the pad is easily accesible.

3. Clean the underside of the pad.

4. The suction holes (4) must be free.

5. Perform a visual check of the pad (2) and the slide foil (3).

NOTICE ! Slide the valve (1) back to the operate position !

22 Printer-Applicator-System PAM 3000

5 Replacing of Assembly Units

5.1 Recommended Tools for Servicing

For servicing the PAM 3000 Printer-Applicator-System following tools are recommended :

1. Standard tools

- double open-end wrench 4x5

- double open-end wrench 5,5x7

- double open-end wrench 8x9

- double open-end wrench 10x13

- double open-end wrench 12x14

- double open-end wrench 14x17

- allen key 1,5; angular

- allen key 1,25; angular

- allen key 2; angular

- allen key 2,2; angular

- allen key 3; angular

- allen key 4; angular

- allen key 5; angular

- norm allen key 2,5; with hilt

- precision allen key size 0

- Philipps screw-driver size 1

- Philipps screw-driver size 2

- socket wrench 4,5

- socket wrench 7

- snap ring pliers

- flat pliers

2. Special tools

- allen key 0,9 with long hilt (cab part number : 5945114)

- spring hook (cab part number : 5906109)

- spring scale 5N (cab part number : 5909017)

- spring scale 25N (cab part number : 5909018)

- spring scale 10N (cab part number : 5906108)

- test collar (cab part number : 5534199)

- manometer (cab part number : 5538317)

- tube loosener (manufacturer : SMC; SMC part number : TG-1)

23Printer-Applicator-System PAM 3000

5.2 Replacing the Printhead

WARNING ! Disconnect power supply ! Switch off compressed air !

NOTICE ! Ground yourself to the chassis before you remove or install the printhead. This will prevent a static discharge from your body through the printhead to ground.

1 2 3 4

6 7 869 10

Fig. 5a Replacing the printhead

1. Remove label stock and transfer ribbon from the printer.

2. Open the cable holder (3) at the rear side of the printhead carrier.

3. Pull the plug connectors of the cables (1, 2) out of the printhead.

4. Release the printhead mounting screw (4) and remove the printhead.

5. Loosen the two screws (6) and remove the carrier (7).

6. Replace the printhead (9) and tighten the two screws (6) again.

7. Carefully slide the printhead with the mounted carrier under the adjustment plate (10) of the printhead carrier assembly.

NOTICE ! Make sure that the long hole (5) and the hole (8) on the carrier fit tightly in two pins on both sides of the printhead carrier assembly.

8. Tighten the printhead mounting screw.

9. Connect the cables to the plug connectors of the printhead.

10. Attach the cables with the cable holder.

24 Printer-Applicator-System PAM 3000

5.3 Replacing the Print Roller and the Feed Roller

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 5b Dismantling the head plate

1. Remove label stock and transfer ribbon from the printer.

2. Hang out the spring (1).

3. Loosen the four screws (2) on the bearing plate (3).

4. Loosen and remove the five screws (5) on the head plate (4).

5. Remove the head plate (4).

Fig. 5c Replacing the print roller or the feed roller

6. Replace the print roller (7) or the feed roller (6).

7. Mount the components in the revers order.

25Printer-Applicator-System PAM 3000

5.4 Replacing the Transport Locking Roller

WARNING ! Disconnect power supply ! Switch off compressed air !

1 2

Fig. 5d Preparation

1. Remove label stock and transfer ribbon from the printer.

2. Remove the two E-rings (2) from the axle.

3. Unlock the transport locking roller (1) by pressing the knurled knob (3) downwards.

1 3

Fig. 5e Replacing the transport locking roller

2 3

4. Pull out the axle with the knurled knob (3) sidewards.

5. Remove the transport locking roller (1) and replace it.

6. Mount the components in the revers order.

26 Printer-Applicator-System PAM 3000

5.5 Replacing the Pinch Roller

WARNING ! Disconnect power supply ! Switch off compressed air !

1 2

Fig. 5f Preparation

1. Remove label stock and transfer ribbon from the printer.

2. Remove the cover at the rear side.

3. Loosen the belt (2) by taking off it from the roller (1).

4. Loosen the four screws at the main drive motor and take off the motor (3).

5. Remove the belt (4) from the pulley (6).

6. Remove the snap ring (5) from the axle of the pinch roller and take off the pulley (6).

5 6

7 98

Fig. 5g Replacing the pinch roller

7. Hang out the spring (7).

8. Loosen and remove the four screws (8) on the bearing plate (9).

9. Remove the bearing plate (9).

10. Replace the pinch roller (10).

11. Mount the components in the revers order.

27Printer-Applicator-System PAM 3000

5.6 Replacing the Label Edge Sensor

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 5h Exchange of the label edge sensor

1. Remove label stock and transfer ribbon from the printer.

2. Remove the cover at the rear side.

3. Pull out the plug (1) of the label edge sensor.

4. Remove the label edge sensor (2) by pulling it out of the mounting plate.

Fig. 5i Mounting the new label edge sensor

5. Slide the new label edge sensor through the opening of the mounting plate into the shape (3) of the head plate.

6. Put the plug of the new label edge sensor into the socket of the PCB Driver Electronics belonging to it.

NOTICE ! Make sure that the cable not touch or hinder moving parts.

7. Mount the cover.

8. Adjust the label edge sensor (Internal Setup).

28 Printer-Applicator-System PAM 3000

5.7 Replacing the Slip Clutches

The rewinders for the transfer ribbon and the label liner are equipped with slip clutches (1, 3). The brake (2) for the transfer ribbon supply hub is equipped with another slip clutch. One of the three slip clutches has to be replaced when the clutch concerned can not longer be adjusted. The assembly instructions for the clutches also have to be observed when a winder has to be replaced. The winding torque of the clutch concerned always has to be readjusted after replacing a clutch or if it has been disassembled at any intermediate time (see section 6.6)

WARNING ! Disconnect power supply ! Switch off compressed air !

1. Remove label stock and transfer ribbon from the printer.

2. Remove the cover at the rear side.

Fig. 5j Slip clutches

5.7.1 Replacing the Slip Clutch on the Media Takeup Hub

Fig. 5k Slip clutch on the media takeup hub

1. Turn the knurled nut (1) of the slip clutch in the counterclockwise direction.

2. Remove the knurled nut.

29Printer-Applicator-System PAM 3000

2 3 3 4

Fig. 5l Replacing the slip clutch

NOTICE ! Be careful with the six small springs (2) inside the knurled nut, as they can easily fall out.

3. Loosen the two threaded pins (3) on the hub with a 2 mm allen key.

4. Remove the hub with the clutch disks.

5. Slide the hub of the new clutch onto the axle so that the lugs (4) of the innermost disk snap into the slots (5) of the tooth gear.

4 6

1/3A

213

Fig. 5m Slot depth

CAUTION ! Between the lug (4) and the tooth gear (6) there must remain a gap of a third of the slot depth A.

6. Tighten the threaded pins (3) on the hub with a 2 mm Allen key.

7. Mount the knurled nut (1) with the springs (2) and tighten it, so that the springs are pressed. Check again the distance between the lug and the tooth gear. Readjust the position of the hub if necessary.

8. Adjust the torque of the new slipping clutch as shown in section 6.6.

30 Printer-Applicator-System PAM 3000

5.7.2 Replacing the Slip Clutch on the Ribbon Supply Hub

1 2 2 3 4 5

Fig. 5n Slip clutch on the ribbon supply hub

1. Turn the knurled nut (1) of the slip clutch in the counterclockwise direction.

2. Remove the knurled nut.

NOTICE ! Be careful with the six small springs inside the knurled nut, as they can easily fall out.

3. Loosen the two threaded pins (2) on the hub with a 2 mm Allen key.

4. Remove the hub and slide the new hub onto the axle.

NOTICE ! When sliding the hub on, ensure that the driver (3) is slid between the ends (4, 5) of the spring.

5. Tighten the threaded pins (2) on the hub with a 2 mm Allen key.

6. Mount the knurled nut (1) with the springs and tighten it, so that the springs are pressed.

7. Adjust the torque of the new slipping clutch as shown in section 6.6.

31Printer-Applicator-System PAM 3000

5.7.3 Replacing the Slip Clutch on the Ribbon Takeup Hub

Fig. 5o Slip clutch on the ribbon takeup hub

1. Pull out the plug (1) of the motor (2).

2. Dismantle the assembly (3) by loosening the two screws (4).

6 7

Fig. 5p Replacing the slip clutch on the ribbon takeup hub

3 4 4

3. Loosen the knurled nut (5) of the slip clutch by turning it in the counterclockwise direction.

NOTICE ! Be careful with the six small springs (6) inside the knurled nut, as they can easily fall out.

4. Loosen the two threaded pins (7) on the hub with a 2 mm Allen key.

5. Remove the hub with the disk clutches and the knurled nut.

6. Slide the new knurled nut and the new hub with the disk clutches onto the axle.

7. Tighten the threaded pins (7) on the new hub with a 2 mm Allen key.

8. Tighten the knurled nut (5) with the springs, so that the springs are pressed.

9. Mount the assembly by screwing the two screws (4).

10. Put the plug of the motor into the corresponding socket of the PCB driver electronics.

11. Adjust the torque of the new slipping clutch as shown in section 6.6.

32 Printer-Applicator-System PAM 3000

5.8 Replacing the Main Drive Motor

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 5q Preparation

1. Remove the cover on the rear side.

2. Loosen the belt (2) by taking off it from the roller (1).

Fig. 5r Replacing the motor

3 4

3. Pull out the plug (3) of the motor (5).

4. Loosen the four screws (4) at both sides of the main drive motor (5).

5. Replace the main drive motor (5).

6. Fasten the motor by tightening the four screws.

7. Put the cable of the new motor into the socket of the PCB.

8. Tighten the belt by putting it on the roller.

9. Mount the cover on the rear side.

33Printer-Applicator-System PAM 3000

5.9 Replacing the PCBs CPU and Driver Electronics

Before replacing the PC CPU, create a self test printout or note the setup parameters for further reference.

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 5s Replacing the CPU PCB

Replacing the PCB CPU

1. Remove the cover on the rear side.

2. Check the slot of the memory card and take the memory card out of the slot if necessary.

3. Pull off the centronics plug (1) from the PCB CPU.

4. Unscrew the three screws (3) holding the PCB CPU (4).

5. Take off the PCB CPU (4) from the connector (2) of the PCB electronics.

6. Replace the PCB CPU and reassemble in revers order.

7. Connect the printer to the power supply, switch on printer.

8. Restore the setup, default values and operating parameters (use the data previously recorded).

9. Adjust the label edge sensor (Internal Setup).

Fig. 5t Replacing the PCB driver electronics

Replacing the PCB driver electronics

1. Dismantle the PCB CPU (step 1 until 5).

2. Pull off all plugs from the PCB driver electronic (6).

3. Unscrew the screws (7) and loosen the screws (5) holding the PCB (6).

4. Remove the PCB driver electronics and replace it.

5. Reassemble in revers order.

6. Plug in all plug connectors.

7. Connect the printer to the power supply, switch on printer.

8. Adjust the label edge sensor (Internal Setup).

34 Printer-Applicator-System PAM 3000

5.10 Firmware-Update of the Printer Module

The printer modules firmware is stored in an EPROM. Therefore, the EPROM has to replaced when the firmware is updated.

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 5u Replacing the EPROM on the PCB CPU

1. Remove the cover on the rear side.

2. Pull the EPROM (2) out of the PCB CPU (1).

3. Press the EPROM containing the new firmware into the PCB CPU.

4. Mount the rear cover.

5. Connect the printer to the power supply, switch on printer.

35Printer-Applicator-System PAM 3000

5.11 Replacing the PCB Applicator Control and Firmware-Update of the Applicator Module

WARNING ! Disconnect power supply ! Switch off compressed air !

Fig. 5v Replacing the PCB applicator control

Replacing the PCB

1. Remove the cover on the rear side.

2. Pull off all plugs from the PCB (2).

3. Unscrew the two screws (1) holding the PCB (2).

5. Remove the PCB and replace it.

6. Reassemble in revers order.

7. Connect the printer to the power supply, switch on printer.

Fig. 5w Update of the Firmware

Firmware Update

1. Dismantle the PCB applicator control (step 1 until 5).

2. Pull off the controler (3) with a PLC-extractor and press in the controler containing the new firmware.

3. Reassemble in revers order.

4. Connect the printer to the power supply, switch on printer.

36 Printer-Applicator-System PAM 3000

5.12 Sensor Replacement

WARNING ! Disconnect power supply ! Switch off compressed air !

5.12.1 Sensors of the Printer Module

Fig. 5x Replacing the sensor printhead cylinder

Sensor printhead cylinder

1. Remove the cover on the rear side.

2. Loosen the screw on the concerning sensor (2).

3. Open the cable holder (1, 4) and remove the corresponding cable.

4. Remove the concerning cable from the connector (3) (see appendix D).

5. Replace the sensor and reassemble in revers order.

6. Connect the printer to the power supply, switch on printer and compressed air.

7. Check the replaced sensor of correct adjusting and adjust if necessary (see section 6.5).

21 42 3

Fig. 5y Replacing the sensor sled

5 5 6 7 7

Sensor sled

1. Remove label stock and transfer ribbon from the printer.

2. Remove the cover on the rear side.

3. Open the cable holder (1, 4) and remove the concerning cable.

4. Remove the respective cable from the connector (3) (see appendix D).

5. Loosen the two screws (5) on the baseplate (6) below the peel-off table.

Now it is necessary to move the whole peel-off table assembly.

6. Loosen the screw on the concerning sensor (7) and remove the sensor.

7. Pull out the cable of the sensor.

8. Replace the sensor and reassemble in revers order.

9. Connect the printer to the power supply, switch on printer and compressed air.

10. Check the replaced sensor of correct adjusting and adjust if necessary ( see section 6.4).

37Printer-Applicator-System PAM 3000

4814 9 10 11

Fig. 5z Pulling out the plug of the sensor

Sensor pinch roller

1. Remove label stock and transfer ribbon from the printer.

2. Remove the cover on the rear side.

3. Pull out the concerning plug (8, 9) on the PCB driver electronics or on the PCB applicator control.

4. Open the corresponding cable holder (1, 4, 10, 11) and remove the respective cable.

12 13 13 14

5 5 6

Fig. 5aa Preparation

5. Disassemble the motor (12) (see section 5.5).

6. Disassemble the pulley (14) (see section 5.5).

7. Loosen three screws (13).

8. Loosen the two screws (5) on the baseplate (6) below the peel-off table.

Now it is necessary to move the whole peel-off table assembly.

38 Printer-Applicator-System PAM 3000

Fig. 5ab Dismantling the bearing plate

9. Loosen the two screws (16) on the bearing plate (15).

10. Move the whole mounting forward.

1615 16

1717 18

19 2017

Fig. 5ac Replacing the sensor pinch roller

11. Loosen the four screws (17) on the bracket (18).

12. Take out the bracket with the mounted sensors.

13. Loosen the two screws (20) holding the concerning sensor (19).

14. Replace the sensor and reassemble in revers order.

15. Connect the printer to the power supply, switch on printer and compressed air.

39Printer-Applicator-System PAM 3000

5.12.2 Sensors of the Applicator Module

62 4

Fig. 5ad Unscrewing the sensors of the applicator module

1. Unscrew the concerning sensor (1, 3, 6) by loosening the correcponding screw ( 2, 4, 5).

7 8

Fig. 5ae Replacing the sensors of the applicator module

2. Pull out the plug (7).

3. Remove the cover of the plug by unscrewing the screw (8).

4. Remove the concerning cable from the connector by screwing the respective screws.

5. Replace the sensor and reassemble in revers order.

6. Connect the printer to the power supply, switch on printer and compressed air.

7. Adjust the replaced sensor if necessary (see section 6.13).

40 Printer-Applicator-System PAM 3000

6 Alignings and Adjustments

6.1 Aligning the Peel-off Table

For optimum print and applicate quality, it is important to align the front position and the back position of the peel-off table exactly. This alignment has already been performed in the factory. Nevertheless, it may become necessary to align it.

1 2 32 3 4 5 6

Fig. 6a Aligning the peel-off table

Aligning the front position

1. Switch off compressed air.

2. Loosen the nut (2) on the threaded pin (3).

3. Slide the peel-off table (1) to its front position.

4. Check the front position by measuring the distance A between the rear edge of the table (1) and the front edge of the bearing plate (4). It is recommended to set the distance A on 52,8 ± 0,2 mm.

5. Align the table to the recommended value by turning the threaded pin (3) if necessary.

6. Tighten the nut (2) on the threaded pin (3).

7. Check the function of the sensor for the front position of the peel-off table (see section 6.4).

Aligning the back position

1. Switch off compressed air.

2. Loosen the nut (5) on the threaded pin (6).

3. Slide the peel-off table (1) to its back position.

4. Check the back position by measuring the distance A between the rear edge of the table (1) and the front edge of the bearing plate (4). It is recommended to set the distance A on 26,8 52,8 ± 0,2 mm.

5. Align the table to the recommended value by turning the threaded pin (6) if necessary.

6. Tighten the nut (5) on the threaded pin (6).

7. Check the function of the sensor for the back position of the peel-off table (see section 6.4).

41Printer-Applicator-System PAM 3000

6.2 Aligning the Printhead

For optimum print quality, the line of heating elements on the printhead must be parallel and aligned correctly to the print roller. This alignment has already been performed in the factory. Nevertheless, it may become necessary to adjust it.

A misaligned printhead causes a poor quality which appears as described below :

 the print image looks generally light, spotted, and irregular

 the print image appears uneven from one side to the other.

When these errors occur it is recommended to align the printhead.

Fig. 6b Aligning the printhead

Aligning the printhead parallel to the print roller

1. Leave the material inside the printer.

2. Loosen the screw (1).

3. Loosen the nut (3).

4. Adjust the printhead by screwing the screw (4).

5. Perform a test print, for instance a wide black line over the whole width of the label.

6. Go on adjusting if necessary.

7. Tighten the nut (3) and the screw (1) if the adjustment is finished.

Aligning the printhead parallel to the label edge

1. Leave the material inside the printer.

2. Release the printhead mounting screw (2).

3. Adjust the printhead by screwing both screws (5) by turns.

4. Perform a test print.

5. Go on adjusting if necessary.

6. Tighten the printhead mounting screw (2) if the adjustment is finished.

3 5542

42 Printer-Applicator-System PAM 3000

6.3 Aligning the Guide Plate

It is possible that the guide plate become loose by the movement during the operating process. For that reason it is necessary to readjust the guide plate to guarantee a proper print image.

Fig. 6c Readjusting the guide plate

1. Switch off the printer, switch off compressed air.

2. Remove the cover on the rear side.

3. Check the clearance of the guide plate (2) by moving the four guide wheels (1, 3) on both sides of the plate manually. When the clearance is too large it is possible to move the wheels lightly.

4. Tighten the two guide wheels (1) on the left side by screwing the respective hexagon adapter bushing (4) to readjust the guide plate.

5. Mount the cover.

6. Switch on the printer, switch on compressed air.

1 4 13 3

43Printer-Applicator-System PAM 3000

6.4 Adjusting the Sensors of the Peel-off Table

After replacing a sensor and sometimes after making the mechanical adjustments it is necessary to align the sensors of the peel-off table. By watching the concerning LEDs on the PCB applicator control the correct adjustment of the peel-off table can be checked (see appendix D). If one of the LEDs do not shining during the table movement the sensor has to adjust.

Fig. 6d Checking the LEDs

1. Remove the cover on the rear side.

2. Release a movement of the table (4) by pressing the integrated key (1) on the concerning valve.

3. Check the LEDs (2, 3). LED8 (3) should be shining if the front position of the table is adjusted. LED7 (2) should be shining if the back position of the table is adjusted.

2 3

5 6

Fig. 6e Setting the peel-off table position

4. Loosen the screw on the concerning sensor (5, 6) by using a 1 mm allen key. The lower senor (6) recognizes the back position of the peel-off table. LED7 (2) is shining The upper sensor (5) recognizes the front position of the table. LED8 (3) is shining

5. Shift the respective sensor (5, 6).

6. Release a movement of the table (4) by pressing the integrated key (1) on the concerning valve.

7. Check the LEDs (2, 3).

8. Repeat the adjustment if necessary.

9. Tighten the screw on the sensor if the table is adjusted correct.

10. Mount the cover.

44 Printer-Applicator-System PAM 3000

6.5 Adjusting the Sensors of the Printhead

After replacing a senor it is necessary to align the concerning sensor of the printhead. By watching the concerning LEDs on the PCB applicator control the correct adjustment of the printhead can be checked (see appendix D). If one of the LEDs do not shining during the printhead movement the sensor has to adjust.

Fig. 6f Checking the LEDs

1. Remove the cover on the rear side.

2. Release a movement of the printhead by pressing the integrated key (1) on the concerning valve.

3. Check the LEDs (2, 3).

Fig. 6g Setting the printhead position

2 3

4. Loosen the screw on the concerning sensor (4, 5). The left senor (4) recognizes the upper position of the printhead. The right sensor (5) recognizes the lower position of the printhead.

5. Shift the respective sensor (4, 5).

6. Release a movement of the printhead by pressing the integrated key (1) on the concerning valve.

7. Check the LEDs (2, 3).

8. Repeat the adjustment if necessary.

9. Tighten the screw on the sensor if the printhead is adjusted correct.

10. Mount the cover.

45Printer-Applicator-System PAM 3000

6.6 Adjusting the Torques at the Hubs

The rewinders for the transfer ribbon and the label liner are equipped with slip clutches. The transfer ribbon supply hub is braked during printing by another slip clutch. The slip clutches are used to adjust the torque of the hubs. The rotation is characterized by the torque. The torque results from the traction F which works vertical to the rotary axis and the distance l between the working line of the traction and the rotary axis. So the physical relation between torque and traction is as follows :

M = F x l M = torque

F = traction l = distance

The correct adjustment of the torques of the hubs is essential for : a) the exact transport of the transfer ribbon during label transport ® adjust the torque at the

ribbon takeup hub

b) a good rewinding quality of the silicon liner ® adjust the torque at the internal rewinder

c) avoiding wrinkles in the transfer ribbon ® adjust the torque at the ribbon supply hub.

6.6.1 Measuring the Traction at the Ribbon Takeup and the Ribbon Supply Hub

The traction at the takeup and at the supply hub is measured by using a test collar (item no. 5534199). In this case the distance l results from the radius of the test collar (30 mm).

Set values: Transfer ribbon take up hub

® F

= 4,5 - 5 N (value to use)

take up

Transfer ribbon supply hub

® F

= 1,0 - 1,2 N (value to use)

supply

3 4

3 5 4

Fig. 6h Measuring the traction at the hubs of the transfer ribbon

1. Remove the transfer ribbon from the printer.

2. Attach the test collar (4) to the appropriate hub (3 or 5).

3. Clamp the test collar (4) with the spreading mechanism (turn the knurled nut in counterclockwise

direction).

4. Wind the string (2) attached to the test collar (4) several times around it.

NOTICE ! Pay attention to the direction of winding during measuring.

5. Attach the spring scale (1), 10 N, to the end of the string and move it vertically upwards until the hub

starts to rotate.

6. Read the measured traction value.

If the readings differ from the set values as stated above, the concerning clutch has to be adjusted.

46 Printer-Applicator-System PAM 3000

6.6.2 Measuring the Traction at the Media Takeup Hub

The traction is measured by using a string which is wound around the rewinder. In this case the distance l results from the radius of the rewind hub (20 mm).

Set value : F

takeup

= 10 - 11 N (value to use)

Fig. 6i Measuring the traction at the media rewind hub

1. Remove all label stock from the printer.

2. Wind the string (2) several times around the hub (6).

NOTICE ! Pay attention to the direction of winding during measuring.

3. Attach the spring scale (7), 25 N, to the end of the string and move it vertically upwards until the hub starts to rotate.

NOTICE ! Hold tight the hub during the measurement.

4. Read the measured traction value.

If the reading differs from the set value as stated above, the clutch has to be adjusted.

47Printer-Applicator-System PAM 3000

6.6.3 Adjusting the Torques

If the measured values differ from the set value make the adjustment as follows.

WARNING ! Disconnect power supply ! Switch off compressed air !

8 9 10

Fig. 6j Adjusting the torques

1. Remove the rear cover.

2. Adjust the winding torque by turning the knurled nut of the corresponding clutch (8, 9, 10).

· Turning it clockwise increases the torque

· Turning it counterclockwise decreases the torque

NOTICE ! The numbers on the knurled nut are not setting values, they are for orientation only.

3. Repeat the measuring.

4. Mount the cover on the rear side.

5. Connect the printer to the power supply, switch on printer, switch on compressed air.

48 Printer-Applicator-System PAM 3000

6.7 Adjusting the Brake at the Media Supply Hub

The media supply hub is equipped with a brake system. The torque of this system can be adjusted by positioning the swing arm. This system of brake and swing arm make it possible :

 to speed up the media supply hub soft when also using heavy label stock and high print speed  to guarantee a nearly constant torque at the media regardless of the diameter of the label stock.

A misaligned system can cause several errors as follows :

 The swing arm hits the upper limitation, from this it follows that it can form a loop of media and the media

runs sidewards, so it can cause damages of the media.

 The swing arm hits the lower limitation, from this it follows that it can cause a faulty media transport

mainly when speeding up heavy label stock.

6 7

2 3 4 5

Fig. 6k Preparation

1. Remove labels and transfer ribbon from the printer.

2. Unscrew the two screws (2) on the cover (3) and remove it.

3. Loosen the screw (1) on the hub and remove the knurled nut, the rewinder end cap, the shells and the plate.

4. Unscrew the three screws (4) on the plate (5) and remove it.

Fig. 6l Aligning the brake

5. Align the length of the spring (8) by turning the nut (9). The swing arm (7) is closed to the arm stop clip (6). It is recommended to set the length A of the spring to the value 100 mm.

6. Reassemble the printer in the revers order.

49Printer-Applicator-System PAM 3000

6.8 Adjusting the Label Edge Sensor

The label edge sensor is adjusted by using the internal setup.

6.9 Setting the Speed of the Compressed Air Driven Assemblies

6.9.1 Setting the Speed of the Peel-off Table Movement

The speed of the peel-off table movement can be set via two valves. Those valves regulate the speed with which the compressed air flows.

Fig. 6m Setting the speed of the peel-off table movement

1. Remove the cover on the rear side.

2. Turn one of the valves (1, 2) to regulate the speed.

Turning clockwise will close the valves. A wider opening of the top valve (1) speeds-up the table moving forward. A wider opening of the bottom valve (2) accelerates the backward movement.

3. Check the speed by releasing a movement of the table. For that purpose press the integrated key (3)

on the concerning valve.

4. If the setting is correct mount the cover.

50 Printer-Applicator-System PAM 3000

6.9.2 Setting the Speed of the Printhead Movement

The speed of the printhead movement can be set via two valves. Those valves regulate the speed with which the compressed air flows.

Fig. 6n Setting the speed of the printhead movement

1. Remove the cover on the rear side.

2. Turn one of the valves (1, 2) to regulate the speed. Turning clockwise will close the valves. A wider opening of the top valve (1) speeds-up the printhead moving upwards. A wider opening of the bottom valve (2) accelerates the downward movement.

3. Check the speed by releasing a movement of the printhead. For that purpose press the integrated key (3) on the concerning valve.

4. If the setting is correct mount the cover.

6.9.3 Setting the Speed of the Turn Cylinder Movement

The speed of the turn cylinder movement can be also set via two valves.

321

4 5

Fig. 6o Setting the speed of the turn cylinder movement

1. Remove the cover on the rear side.

2. Turn one of the valves (1, 2) to regulate the speed. Turning clockwise will close the valves. A wider opening of the top valve (1) speeds-up the pad (4) moving outwards (90°-position to the dispense edge (5) of the printer, see picture above). A wider opening of the bottom valve (2) accelerates the inward movement of the pad (4) (0°-position to the dispense edge (5) of the printer).

3. Check the speed by releasing a movement of the turn cylinder. For that purpose press the integrated key (3) on the concerning valve.

4. If the setting is correct mount the cover.

5. Check the time for the turning movement (see section 6.14).

51Printer-Applicator-System PAM 3000

6.9.4 Setting the Speed of the Lift Cylinder Movement

The speed of the lift cylinder movement can be set via two throttle valves which are mounted on the cylinder. Those valves regulate the speed with which the compressed air escapes the two air containers. The valves are adjustable by turning the respective throttle screws.

Fig. 6p Setting the speed of the lift cylinder movement

1. Switch off the printer.

2. Remove the cover on the rear side.

3. Turn the screw into the bottom valve (1) to set the speed of the downward movement. Turn the screw into the top valve (2) to set the speed of the upward movement. Turning clockwise will close the valves. A wider opening of the bottom valve (1) speeds up the pad moving down. A wider opening of the top valve (2) accelerates the upward movement.

3 4

Fig. 6q Checking the set speed

4. Check the speed by releasing a movement of the lift cylinder. For that purpose press the integrated key (3, 4) on the concerning valve. Pressing the key (4) the downward movement is carriing out. Pressing the key (3) the upward movement is carriing out.

5. If the setting is correct mount the cover.

52 Printer-Applicator-System PAM 3000

6.10 Pneumatic Setting of the Printhead Pressure

If there are problems with the print quality the pressure of the printhead can be measured and adjusted to the recommended value.

31 2154

Fig. 6r Measuring the pressure on the printhead

1. Switch off the printer, switch off the compressed air.

2. Remove the cover on the rear side.

3. Pull the tube 11 (1) out of the pressure regulator (2) of the printhead valve.

4. Push the tube (5) of the manometer (3) into the regulator (2) of the printhead valve.

5. Push the tube 11 (1) into the push-in-T-fitting (4) of the manometer (3).

Fig. 6s Setting the pressure on the printhead

6. Switch on the printer, switch on the compressed air.

7. Release a printhead movement by pressing the integrated key (7) on the valve.

During pressing the key it is possible to measure the value of the compressed air on the printhead cylinder.

The recommended value is 3,5 bar.

8. If necessary set the compressed air value to the recommended value by turning the screw (6)

on the pressure regulator of the printhead valve.

· Turning the screw clockwise increases the value.

· Turning the screw counterclockwise decreases the value.

9. Switch off the printer, switch off the compressed air.

10. Restore the normal tube connection.

11. Mount the cover.

53Printer-Applicator-System PAM 3000

6.11 Pneumatic Setting of the Brake

If there are problems with the brake during operation the pressure of the brake can be measured and adjusted to the recommended value.

Fig. 6t Setting the pressure on the brake

1. Switch off the printer, switch off the compressed air.

2. Remove the cover on the rear side.

3. Pull the tube 14 (2) out of the valve (3) of the brake.

4. Push the tube (5) of the manometer (6) into the valve (3) of the brake.

5. Push the tube 14 (2) into the push-in-T-fitting (4) of the manometer (6).

6. Switch on the printer, switch on the compressed air.

7. Measure the value of the compressed air on the brake.

8. If necessary set the compressed air value to the recommended value by turning the screw (1) on the valve (3).

The recommended value is 2 bar.

9. Switch off the printer, switch off the compressed air.

10. Restore the normal tube connection.

11. Mount the cover.

41 2

6.12 Pneumatic Setting of the Supporting Air

When a blow tube is installed sometimes it is necessary to set the strength of the supporting air. It is dependent from the size and the format of the label.

1 2

Fig. 6u Setting the strength of the compressed air

1. Remove the cover on the rear side.

2. Set the supporting air by turning the screw (1) on the concerning valve.

3. Check the supporting air on the blow tube by pressing the integrated (2) key of the valve.

4. Mount the cover.

54 Printer-Applicator-System PAM 3000

6.13 Mechanical Adjustments of the Sensors on the Applicator

Normally the sensors are adjusted by the factory. But it can be necessary to adjust the sensors e.g. after replacing one of the sensors.

6.13.1 Sensor Turn Cylinder

The sensor checks the movement of the turn cylinder. It recognizes if the cylinder is in the 90°-position or in the 0°-position.

1 2

Fig. 6v Adjusting the sensor turn cylinder

1. Switch off the compressed air.

2. Remove the cover on the rear side.

3. Check the concerning LED (2, LED1) on the PCB applicator control. The LED is switched on if the sensor (1) is adjusted correctly in the 90°-position.

4. If the sensor (1) is not adjusted correctly, loosen the screw on the sensor using a 1,2 mm allen key, slide the sensor (1) until the LED (2) is switched on and tighten the screw.

5. Move the pad by hand and check if the LED (2) is switched on and off correctly.

6. Repeat the adjustment if necessary.

7. Mount the cover.

8. Switch on the compressed air.

55Printer-Applicator-System PAM 3000

6.13.2 Labelling Position Sensor

This sensor checks if the lift cylinder reachs the position to applicate the label. If the pad is in the position to applicate the label (lower end position) the LED 4 on the PCB applicator control (see appendix D) is switched on. The labelling pressure for stamping the label onto the product can be altered by moving the labelling position sensor.

1 2 3

Fig. 6w Adjusting the labelling position sensor

1. Switch off the compressed air.

2. Loosen the screw (2).

3. Move the sensor (1) on the cable (3). Moving the sensor (1) upwards will reduce the labelling pressure.

4. Tighten the screw (2).

5. Switch on the compressed air.

6.13.3 Sensor Lift Cylinder 1

The sensor checks if the lift cyliner reachs its upper end postion. If the sensor is adjusted exactly the LED 3 on the PCB applicator control is switched on (see appendix D).

1 2

Fig. 6x Adjusting the sensor lift cylinder 1

1. Switch off the compressed air.

2. Remove the cover on the rear side.

3. Check the concerning LED (2, LED3) on the PCB applicator control. The LED is switched on if the sensor (1) is adjusted correctly in the upper end position.

4. If the sensor (1) is not adjusted correctly, loosen the screw on the sensor using a 1,2 mm allen key, slide the sensor (1) until the LED (2) is switched on and tighten the screw.

5. Slide the manual valve on the applicator to the bleed-position.

6. Move the cylinder by hand and check if the LED (2) is switched on and off correctly.

7. Repeat the adjustment if necessary.

8. Mount the cover.

9. Slide the manual valve on the applicator to the operate-position.

10. Switch on the compressed air.

56 Printer-Applicator-System PAM 3000

6.13.4 Sensor Lift Cylinder 2

There are two sensors lift cylinder 2 to check if the pad reaches the intermediate position correctly. At the intermediate position the turn cylinder carries out the swing movement of the pad. It is very important that the pad swings without damage. For that reason the area for the swing movement has to be free. The upper sensor recognizes this position during the movement downwards and the lower sensor during the movement upwards. If the sensors are adjusted right the LED 2 on the PCB applicator control (see appendix D) is switched on and off during the cylinder movement. The sensor has to adjust corresponding to the special requirements.

2 31

Fig. 6y Adjusting the sensor lift cylinder 2

1. Switch off the compressed air.

2. Remove the cover on the rear side.

3. Slide the manual valve on the applicator to the bleed-position.

4. Move the cylinder by hand downward. Check on which position it is posssible to swing the pad without collision with the putting up area or any other componets.

5. Adjust the upper sensor (2) by turning the screw and sliding it into the required position so, that it could recognize this position.

6. Move the cylinder up and down and check if the LED2 (3) is switched on and off.

7. Move the cylinder by hand upward. Check on which position it is posssible to swing the pad without collision with the putting up area or any other components.

8. Adjust the lower sensor (1) so, that it could recognize this position.

9. Move the cylinder up and down and check if the LED2 (3) is switched on and off.

10. Slide the manual valve on the applicator to the operate-position.

11. Switch on the compressed air.

12. Release a labelling process by alternately pressing the

key and the pre-dispense key on the

printer.

13. Check the movement of the lift and the turn cylinder and if the LED2 (3) is switched on and off.

14. Readjust the respective sensor if necessary.

Attend : - Upper sensor (2) checks the Stop during the movement downwards

- Lower sensor (1) checks the Stop during the movement upwards

15. Mount the cover.

57Printer-Applicator-System PAM 3000

6.14 Setting of Delay Times during Operation

For best adaptation, the applicator offers possibilities to adjust to the whole system and, therefore, to the required needs. There are two potentiometers on the PCB applicator control to adjust the labelling process by changing certain time delays. If any one of the settings is changed the actual value is briefly shown in the printer display.

Fig. 6z Setting times

Potentiometer R19 (1) : Delay time

This parameter determines the time period between the start signal and the start of the labelling process. With this delay it is possible to release the start of the labelling process sensor controlled, for instance, when a sensor is located on an assembly line in front of the labelling place. The default value for this time is 0 ms.

Potentiometer R20 (2) : Lock time

This parameter determines the time period for the movement of the turn cylinder. The default value for this time is 600 ms.

To alter the set values proceed as follows :

1. Remove the cover.

2. Turn the integrated screw of the concerning potentiometer (1, 2).

The actual value is briefly shown in the printer display.

Fig. 6aa Set times on the display

3. Check the set time on the display.

4. Mount the cover.

Information about the set times can also be recalled in the printer info display (see also Operator's Manual PAM 3000 section 11).

58 Printer-Applicator-System PAM 3000

6.15 Level Adjustment of the Applicator Module

The basic adjustments which are necessary for the operation of the device have been carried out. But it may be useful to do some more fine tuning for example after replacing a sensor of the applicator module or after changing the pad. This refers mainly to mechanical parameters, which are depending on the format of the labels.

Fig. 6ab Level adjustment

There are three screws at the front side of the applicator to adjust the level of the cylinder unit.

1. Loosen the two screws (1) at the carrier plate of the applicator. But they may not be removed.

2. Move the whole unit within the longish holes (2) by screwing the screw (3). The pad has to be located slightly above the dispense table of the printer.

3. Tighten the screws (1).

59Printer-Applicator-System PAM 3000

6.16 Mechanical Alignment of the Pad

It is very important to align the pad exactly to guarantee a trouble-free processing. There are several possibilities to alter the position of the pad. The pad can be alingned by turning the pad holder sidewards slightly. That way the pad can be adjusted parallel to the dispense edge of the printer (0°-position) and otherwise it can also be adjusted exactly in the 90°-position. Moreover the pad can be aligned forward or backward by sliding itself. It is recommended to align the pad so that it is located vertically above the label to be applicated.

Fig. 6ac Aligning the pad holder sideward

Aligning the pad holder sideward

1. Switch off the compressed air.

2. Remove the cover (1) by loosen the screw (2) at the underside of it.

3. Slide the pad (5) sideward by turning the cam (3). For it loosen the screw at the underside of the cam (3), turn the cam and then tighten the screw. For adjusting the 90°-position turn the cam (4).

4. Turn the pad (5) to the printer and check the position.

5. Repeat the alignment if necessary.

6. Mount the cover (1).

7. Switch on the compressed air.

32 4

5 5

Fig. 6ad Aligning the pad forward or backward

Aligning the pad holder forward or backward

1. Switch off the compressed air.

2. Loosen the screw at the underside of the pad (1).

3. Slide the pad (1) forward or backward to the wanted position slightly.

4. Turn the (1) pad to the printer and check the position.

5. Repeat the aligning if necessary.

6. Tighten the screw.

7. Switch on the compressed air.

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7 Problem Solution

7.1 Problems during Printing and Applicating

Problem

Print image has smears or voids

Print image is irregular, one side is lighter

Vertical white lines in the print image

Printer does not print; error message: "Paper out" or No label found

Cause and Solution

Printhead is dirty, clean printhead;

Temperature too high, decrease heat level via software;

Unsuitable combination of ribbon and label media, choose different type of ribbon;

Printhead is dirty, clean printhead;

Printhead is not correct adjusted, adjust printhead;

Printhead is defective, replace printhead;

Printhead is dirty, clean printhead;

Printhead is defective (failure of heat elements), replace printhead (service);

Label is not inserted in the label edge sensor, correct label path;

Label edge sensor is dirty, clean it;

Printer transports label media, but the ribbon does not move

Thermal transfer ribbon creases

Printer does not stop after transfer ribbon runs out

Error message "Ribbon out", though ribbon is loaded

Printer only prints each second label

Label edge sensor is not adjusted (e.g. after replacing PCB CPU or PCB Driver Electronics), carry out the adjustment;

Label edge sensor is defective, replace it;

Transfer ribbon is wrong inserted. Check, if the inked side faces the label

The combination of ribbon and media is unsuitable Choose different type of ribbon

Transfer ribbon too wide. Use transfer ribbon which is max. 10% wider than the label media.

Direct thermal printing is chosen in the software. Choose to thermal transfer printing mode in the software.

Transfer ribbon is not locked at the supply hub, supply hub does not turn, tighten the ribbon.

Setting of the size in the software is too large, correct the setting.

Table 7.1 Errors during printing and applicating

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Problem

Cause and Solution

Printed image is too light after repalcing the printhead

Printhead is not in its upper position; error message Head not top is shown in the display.

Printhead is not in its lower position; error message Head not down is shown in the display.

Table is not in its behind position; error message Table not at the back is shown in the display.

Printhead out of adjustment, readjust the printhead;

Printhead parameter set incorrectly, change heat level in the Setup;

Loss of compressed air, check all connections;

Sensor printhead cylinder not adjusted, adjust it;

Sensor printhead cylinder defective, replace it;

PCB applicator control defective, replace it;

Loss of compressed air, check all connections;

Sensor printhead cylinder not adjusted, adjust it;

Sensor printhead cylinder defective, replace it;

PCB applicator control defective, replace it;

Loss of compressed air, check all connections;

Sensor sled not adjusted, adjust it;

Table is not in its front position; error message Table not in front is shown in the display.

Pad has not reached the 0°-position; error message Nozzle 0° is shown in the display.

Pad has not reached the 90°-position; error message Nozzle 90° is shown in the display.

Sensor sled defective, replace it;

PCB applicator control defective, replace it;

Loss of compressed air, check all connections;

Sensor sled not adjusted, adjust it;

Sensor sled defective, replace it;

PCB Applicator Control defective, replace it;

Loss of compressed air, check all connections;

Sensor turn cylinder not adjusted, adjust it;

Sensor turn cylinder defective, replace it;

PCB Applicator Control defective, replace it;

Loss of compressed air, check all connections;

Sensor turn cylinder not adjusted, adjust it;

Sensor turn cylinder defective, replace it;

PCB applicator control defective, replace it;

Table 7.1 Errors during printing and applicating (continuation)

62 Printer-Applicator-System PAM 3000

Problem

Cause and Solution

Pad has not reached the upper end position; Error message Upper end position is shown in the display.

Insufficient vacuum on pad

Loss of compressed air, check all connections;

Sensor lift cylinder not adjusted, adjust it;

Sensor lift cylinder defective, replace it;

PCB applicator control defective, replace it;

Loss of compressed air, check all connections;

Sensor lift cylinder not adjusted, adjust it;

Sensor lift cylinder defective, replace it;

PCB applicator control defective, replace it;

Loss of compressed air, check all connections;

In cyclical operation, the vacuum control valve is not controlled (red LED in the valve Vacuum on the manifold assy. does not come on); Applicator control PCB defective, replace PCB;

Too little under-pressure at the outlet of the vacuum generator; vacuum generator/silencer on vacuum generator dirty/defective; clean or replace vacuum generator/silencer ;

Fault in cylinder movement (lift or turn cylinder)

Error in the transfer of the label to the pad Error message Vacuum plate empty is shown in the display.

Too little under-pressure at the outlet of the vacuum tube; vacuum tube defective, replace vacuum tube;

Too little under-pressure at the pad; Suction holes or channels on the pad blocked, clean pad;

In cyclical operation the cylinder control valves are not controlled (red LED in valve Lift Cyl. or in valve Rotate Cyl. do not light up); PCB applicator control defective; replace PCB;

Cylinder movement not switched over despite intact applicator control PCB; cylinder control valve defective, replace control valve;

Cylinder movement is very slow; throttle valves are defective or badly out of adjustment, replace or readjust the valves;

Incorrect setting of the pad in the upper end position; Readjust the pad height or the rotary movement of the pad;

Table 7.1 Errors during printing and applicating (continuation)

63Printer-Applicator-System PAM 3000

7.2 Failure of Device Funstions

Problem

Loss of all applicator functions

No movement of material

No printing (no printed image)

No display function

Cause and Solution

Loss of compressed air, check all connections;

PCB applicator control defective, replace it;

Mechanical check of the gears and belts, replace damaged gears or belts;

Check fuses 1 and 2 on PCB driver electronics, replace any blown fuses, if fuse blows again, replace PCB;

Check main drive motor, replace motor if defective;

Check the printhead cable, reseat if necessary

Check printhead cable for damage, replace printhead cable if necessary;

Replace printhead

Replace CPU PCB

Check voltage selection in the power module (115V/230V), be sure it is set for the correct input voltage;

No I/O function

Check primary fuse in the power module, replace fuses if necessary, if replaced fuses blow, replace the transformer or power module;

Check 5V on driver electronics, replace driver PCB or fuses on PCB if necessary;

Check fuse 4 (8A time-delay), replace fuse if necessary; If replaced fuse blows, then replace the driver PCB

Check voltage at the output of the rectifier (approx. 38V), if not 38V, replace the rectifier

Unplug all plug connectors (also CPU PCB) from PCB driver electronics, check 5V again; If still not 5V, replace the PCB. Plug in plug connectors one by one until 5V is shorted and the voltage drops below 5V.; Replace part causing the short

Replace CPU PCB, check display function If still no display, replace the PCB control Panel / display

Check if ports of printer and computer are configured identically, configure ports if necessary;

Check interface cable, replace bad I/O cable;

If function fails completely in parallel interface mode, replace centronics plug or CPU PCB; If function fails completely in serial interface mode, replace PCB driver electronics;

Table 7.2 Failure of device functions

64 Printer-Applicator-System PAM 3000

7.3 Permanently Displayed Hardware Errors

Error

ADC malfunction

dRAM malfunction

FPGA malfunction

Head error

LCD malfunction

Invalid setup

Voltage error

sRAM malfunction

Cause and Solution

Error of PCB driver electronics, replace PCB;

Error of CPU PCB, replace PCB;

Thermal printhead faulty, replace printhead;

Error in the operating panel display, replace LCD display;

Error of CPU PCB, replace PCB;

Error of PCB driver electronics, replace PCB;

Error of CPU PCB, replace PCB;

Table 7.3 Permanently displayed hardware errors

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66 Printer-Applicator-System PAM 3000