Paxar 545 User Manual

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-volatile Memory 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: 1-800-96PAXAR or [phone]

Fax: [phone]

For spare parts, requests for service or technical support

Paxar Service Group

170 Monarch Lane

Miamisburg, OH 45342

Call: [phone]

Fax: [phone] for Warranty Parts

Fax: [phone] or [phone] for 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-resolution ink 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™

Inventory of Components

The following list shows the additional parts (pieces) which should be included in
your PAXAR 545 shipping containers. If anything is missing, notify PAXAR
immediately - in the U.S.A. at 570-888-9116. In other countries please contact your
local PAXAR supplier.

- PAXAR 545 "User's Manual"

- Quick-disconnect power cord

- Serial communications cable & converter.

- Stacker assembly

- One or two print modules as ordered.

- PCMCIA Card containing special Swiss fonts for the 545 printer, also used to
store Logos or additional fonts that were special ordered.

(located in the back of the manual)

- Any optional software ordered.

- Tool kit

NOTE: Some of the above parts may be inside the envelope containing the tool kit.

PAXAR 545 TOOL KIT (#341390)

101324 7/64” Ball Driver

181301 2.5mm Ball Driver

241149 Anti-Static Gloves (2)

241132 Anti-Static Wrist Strap

351156 Chip Removal Tool

921309 Hex Key Set

921338 Printer Cleaning Kit

921352 Screwdriver

921353 Phillips Head Screwdriver

921362 Pkg. / Foam Cleaning Swabs (25)

921364 3/16" Long Ball Driver

Ink Cartridge Return Program

Empty ink cartridges can be returned to PAXAR for credit. Please contact your
sales representative for more information.

Users Manual Model 545™ Unpacking / Inventory • 9

Product Description

Printer Description

The PAXAR model 545 ink jet printer is an electronic printer that can print on fabric
rolled tape. The printer interfaces to a computer or a main frame system thus
allowing electronic data input or even custom design of labels with PAXAR’S
“Formatter / PcMate Plus" program. This printer can generate a complete label
printed on one or two sides.

♦ United States Patent Number 6,142,622

• Design your own labels on a PC

• Computer interface = IBM Compatible

• Mainframe direct interface

• RS-232 9 Pin D shell female Serial interface connector

Paxar Model 545 Label Printer

10 • Product Description Users Manual Model 545™

Printer Specification

Print
method:

Label Size Max: up to 1.5” (38.1mm) web x up to 3.5” (88.9mm) feed - cut and stacked

Print Area Max: up to 1.36" (34.54mm) web x up to 5.85" (148.5 mm) feed

Resolution 185.3 DPI across the web x 192.2 DPI in the feed direction

Fonts Scalable fonts resident: condensed, standard, and bold typefaces, upper and lower case

Logos No restriction on number or size per tag (up to maximum image area)

Care
Symbols

Justification Left, Right, and Center field selectable

Narrow web ink jet one or two sided print – Single color only – 2/0 Future

Speed – 4” (101.6mm), 6” (152.4mm) or 8” (203.2mm) per second

Up to 6" (152.4 mm) feed w/ rewind

Min: .5” (12.7mm) web x .625” (15.9mm) feed

Min: No restrictions

6 point up to 96 point

All rotations 0°, 90°, 180°, 270°

All rotations 0°, 90°, 180°, 270°

Full Ginetex Care Symbol set and full NAFTA Care Symbol Set

Fully Scaleable

All rotations 0°, 90°, 180°, 270°

Stock Support for blank and pre-printed fabrics – Roll size up to 12” (305mm) diameter

Interface PAXAR PCL via RS-232 serial port – 9 pin D-shell

Control
Panel

Dimensions 17.0" (431.8 mm) high x 31.5" (800.1 mm) wide

Weight 80 Lbs. (176kg) Shipping: Machine 92 Lbs. (202kg )

Electrical Operator selectable 90-132 or 180-265 VAC 50-60Hz 6.25Amp

Temperature

Humidity 5% to 90% non-condensing

Push-button printer function with 2 Line x 24 Character International LCD Backlite Display

Including stacker x 20.0" (508mm) deep

Stacker & Supplies – 58Lbs (128kg )

41°F (5°C) to 104°F (40°C)

Users Manual Model 545™ Product Description • 11

Other
Features

Ink PAXAR wet cartridge ink

Options - Rewind Unit (115V or 230V)

- Downloading of information while printer is operating

- Sequenced Fields (Printer installed fonts)

- Time / Date Stamping (US or European format)

- Operator adjustable: print positions, cut position, baud rate

- Error Detection of: fabric out, splice, ink out, full stacker, stacker jam

- Display: labels left to print in a batch, batch ID, total life inches, total life cuts

- Self Diagnostics

- Missed sense mark detection and correction (Future)

- Slot, Notches, Hole or Reflective registration detection (Future, depending on option)

- Optical Hole / Notch Sensor (Future)

- Bottom Reflective Sensor (Back of Web Only) (Future)

- Top Contrast Sensor (Future)

- PCMate DOS

- Spare Parts Kit

- International Hardware Kit

Personal Computer Specifications

This specification describes the hardware and application software requirements for
the Personal Computer that is used to download to the PAXAR 545 Printer.

The PAXAR 545 Printer uses a DOS Version of PCMate or a Windows version of
“PcMate Plus / Formatter ”. These applications create the tag or label formats
(layouts) then fill and transfer data to the printer through the serial port of the
computer.

“PcMate Plus / Formatter ” Requires the following;

- IBM® PC or compatible

- Microsoft Windows® 95 or higher (Including Win 2000, ME, and NT)

- 16 Megabytes RAM (minimum) - 32 Megabytes recommended

- 50 Megabytes (minimum) free disk space

- Pentium or Pentium Type processor - 200 Mhz or higher

- 3-1/2" floppy drive

Refer to your specific software package for proper installation procedures.

12 • Product Description Users Manual Model 545™

Printer Assembly

Fuse Configuration

The main fuse(s) on the Paxar 545 are located inside the AC entry. The entry has a
fuse drawer that holds the fuse(s) and selects the appropriate line voltage. If the
voltage in the window DOES NOT match the AC line amplitude intended to be
supplied to the printer, DO NOT plug the power cord in. Reconfigure as follows:

1) Using a flat blade screwdriver, open the AC entry by lifting the tab just above

the voltage indicator window.

AC Entry

2) Remove the red fuse drawer.

3) Remove all fuses and the fuse jumper if it is present.

4) Insert into the fuse drawer the correct number and style of fuse(s) and fuse jumper
for your application.

Configuration Number One: Line voltage within the range of

(See 115VAC Fuse Placement) 90 - 132VAC @ 50 - 60Hz

1) Install one 990689 – 6.25A 250V Fast Acting 1/4 x 1 1/4"

2) Install one Fuse Jumper

Users Manual Model 545™ Printer Assembly • 13

115VAC Fuse Placement 230VAC Fuse

Placement

Configuration Number Two: Line voltage within the range of

(See 230VAC Fuse Placement) 180 - 265VAC @ 50 - 60Hz

1) Install two 990757 6.0A 250V Fast Acting 5 x 20MM

NOTE: The fuse jumper must be removed to install both 5 x 20mm fuses.

5 X 20MM Fuse Placement

5) Reinsert the fuse drawer into the AC entry with the desired voltage up.

6) Close the AC entry and verify the correct voltage is now visible.

Installing the Power Cord

A power cord is shipped with each printer. The cord for 115-volt printers will use
the standard three-prong plug used in the U.S.A. A 230-volt printer and some other
115-volt configurations will have the plug end of the cable removed. It is the
customer’s responsibility to have the plug alteration work done by a certified
electrician. Paxar supplies printers to many countries with many variations.
Therefore we leave this to the customer to make the proper selection for their
country.

The fuses must be between points A and B as shown, not B and C.

14 • Printer Assembly Users Manual Model 545™

P.C. Board Identification

D

C

A

B

A – Mother Bd. (371170) - Horizontal on bottom of printer

B – Head Driver Bd. (341106) - AT Slot 1(From Rear Of Printer)

C – Memory Card Bd. (350016) - AT Slot 4

D – Thermal Control Bd. (371105IJ) - AT Slot 2

E – Front Panel Bd. (511108) - User interface system located on front

TCB Dip Switch Settings

1 PRINTHEAD RESOLUTION OFF = 192 DPI ON =

2 UNDEFINED OFF = Default ON =

3 PRINTER TYPE OFF = Default ON =

4 PRINTER TYPE OFF = ON = Default

5 STACKER JAM SENSOR OFF = DISABLED ON = ENABLED

6 UNDEFINED OFF = Default ON =

of Machine (Not Shown)

7 UNDEFINED OFF = Default ON =

8 LOKPRINT / DOWN STACKER OFF = LP ON = DS

Users Manual Model 545™ Printer Assembly • 15

Inserting a PCMCIA Card

A PCMCIA card can be used to store fonts, logos, and operating system upgrades.
To insert the card, make sure that the manufacturer’s name is facing the front of the
machine. Insert the card so that the end with the holes goes in first. Slide the card in
until it reaches the back of the slot and the eject button pops out. To eject the card
push in the eject button and then pull the card out. Some machines will ship with a
double slotted card option. If using a single IC card, the card must be inserted into
the slot closest to the rear of the printer.

NOTE: The printer loads the data from the PCMCIA card at power up, after

inserting a PCMCIA - power cycle the machine.

Eject
Button

16 • Printer Assembly Users Manual Model 545™

Print Module Insertion and Removal

CAUTION: Turn off the power to the printer before removing or inserting the

print module. Hot swap of the print module has been built into the
design. However, a dirty connector from ink etc could prevent it from
protecting the head. Therefore, we recommend that all print module
removal and replacement be done with the power off.

NOTE: An ink cartridge must not be present in the print station before a print

module can be installed or removed. The print module(s) must be in
the parked position.

Remove the print module(s) from the separate packaging. Remove the packaging
from around the print module and save with the rest of the printer packing supplies.
Swing open the top cover to the printer. In order to install or remove the print
modules the ink cartridges MUST be out of the machine. To install the print module
push the module release lever (A) to the right and with your other hand align the
module between the mount rails. Slide the module down until it makes contact.
After the module makes contact continue pushing until the module moves down
approximately 3/8” more. Then release the lever to hold the module in place.

Users Manual Model 545™ Printer Assembly • 17

Print Module Handling

g

CAUTION: Do not lay the print module flat on the sides, back, or front if removed

Installing the Stacker

Remove the stacker from the separate packaging. Remove the packaging from
around the stacker and save with the rest of the printer packing supplies. Swing
open the top cover to the printer. Make sure that the stacker bed is in the most
upright position by loosening the locking knob and rotating the bed up and then re
tightening the locking knob. Locate the clearance hole as shown below in the center
of the knife’s mounting bracket. Place the stacker into position by inserting the
screw in the stacker’s mounting plate into the clearance hole and making sure that
the stacker is resting on the two leveling pins. Using a 3/16” long handled ball
driver tighten the screw until the stacker is secured in place. Adjusting the stacker
position is covered later.

from the printer. The unit must stand on end as shown below.

3/16” Lon
Handled Ball

Clearance

Driver

Hole

18 • Printer Assembly Users Manual Model 545™

Install the stacker up-right rails. Remove one of the spring-loaded screws. Insert the
spring-loaded screw through the mating hole in the up-right rail assembly. Thread
the spring-loaded screw into the mounting block. Repeat the above procedure for
the other rail. Remove the spring-loaded screw and washer from the top of the inner
stacker rail. Place the threaded stud into the slot of the outer rail and reattach the
washer, spring and nut.

Users Manual Model 545™ Printer Assembly • 19

Cable Installation

Stacker Cable

There is a cable with a connector leading from the back of the stacker that plugs into
a socket on the TCB (refer to the P.C. Board Identification section in this manual).
The socket and plug are polarized. Rotate the plug until the polarized keyway and
socket align and push the stacker connector into the socket.

PC Interface Cable

The 545 requires a 9-pin RS-232 cable which is provided with the printer. If the
cable was not found it can be ordered from PAXAR - (Part no. 351124).

The male end of the cable should be connected to the 9-pin D-shell female connector
that is located on the right side of the printer at the TCB (refer to the P.C. Board
Identification section in this manual). The female end of the cable is made to fit a 9­pin male RS-232 connector on the back of a PC. In case a 9 pin serial port is not
available, a 9 to 25 pin converter is also shipped with the printer.

Keyboard

An optional keyboard can be connected to the printer for diagnostic purposes to be
used by PAXAR service representatives only.

20 • Printer Assembly Users Manual Model 545™

Installing the Applications Software

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

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

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

Users Manual Model 545™ Printer Assembly • 21

Printer Operation / Adjustments

Installing and Removing Ink Cartridges

CAUTION: NEVER INSERT YOUR HAND IN THE INK CARTRIDGE SLOTS

AS THE PRINT MODULE NEEDLES ARE UNPROTECTED
WHILE THE PRINT MODULES ARE IN THE PRINTER.

The individual ink cartridges are color specific and are identified accordingly. To
achieve maximum performance from the 545 the color of a print module may not be
changed. Changing the color on a print module may contaminate the head. Using
ink not tested and approved by PAXAR may also damage the print heads. Use the
procedure and diagram below for loading the ink.

1) Determine the color of the print module that needs an ink cartridge. The print
module in the left position prints the bottom of the label if the 545 is printing
one over one.

2) Remove an ink cartridge of the same color from its shipping package and insert it
into the slot below the print module. The end with the two round holes goes
into the slot with the label up. Align the cartridge so that the guide rail at the
bottom of the slot opening slides into the groove molded in the bottom of the
cartridge. Push the cartridge in until it comes to a stop

.

22 • Printer Operation / Adjustments Users Manual Model 545™

3) Remove the ink cartridges by pulling them straight out from their current position.

Users Manual Model 545™ Printer Operation / Adjustments • 23

Adjusting the Unwind

Before loading fabric for the first time and anytime the fabric width changes - the
unwind position must be adjusted - as the 545 is a center justified machine.

• Loosen the unwind back plate locking thumbscrew A.

• Rotate the back plate B clockwise to increase or counter clockwise to

decrease the web width until the desired width is indicated on scale C.

• Retighten the locking thumbscrew.

Loading Fabric for the First Time

• Once the unwind position has been adjusted for the job width load a roll of
fabric on the unwind core support so that the fabric pulls off the top clockwise.

• While holding the unwind from spinning - tighten the core by turning the center
knob clockwise. Confirm that the core is against the back stop.

• Pull the tab on leader to release the end of fabric and cut off all fabric that has
any tape or adhesive remaining. Pull off about 2 feet (.5m) of fabric to thread
through the printer.

NOTE: The pull-tab / adhesive will be used on the subsequent rolls loaded at a

Stock Out Error to accelerate the reloading process.

24 • Printer Operation / Adjustments Users Manual Model 545™

Threading Diagram

• Open the hinged cover to the printer and thread the fabric through the splice /

fabric out sensor (B drawing two), the active unwind, the barrel rollers, the head
guards (A drawing two), the feed module, the knife, and then the stacker as
shown.

2/0 AND 1/0 THREADING PATH

NIP ROLL

FEED ROLL

Users Manual Model 545™ Printer Operation / Adjustments • 25

B

A

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

.250

26 • Printer Operation / Adjustments Users Manual Model 545™

Web Guide Adjustment

The Paxar 545 printer has been designed with crowned rollers to maintain center
tracking. The only web guides in the printer are located on the active unwind block.
These web guides are adjustable without the use of tools. The only other web width
adjustment is the stacker up-right rails (refer to the Stacker Label Width
Adjustment).

• To increase the web guide width, turn the adjustment knob counter-clockwise.

• Turn the adjustment knob clockwise so the web guides are holding the fabric

without deforming the sides.

Users Manual Model 545™ Printer Operation / Adjustments • 27

• Open the feed roller by turning the feed lever counterclockwise.

• Once the fabric is beyond the last roller - continue straight into the feed rollers,

through the knife module and then through to the stacker belts. You will need
to lift the pre-feed rollers between the feed and knife in order to push the fabric
through the knife.

• After the fabric is pulled through the knife, continue feeding through to the
stacker belts.

28 • Printer Operation / Adjustments Users Manual Model 545™