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™

Stacker Position Adjustment

• Once the web has been centered in the printer or it has stabilized from running,

confirm that equal numbers of belts exist on either side of the fabric, and that
the spacing to the nearest belt is the same on each side. This is achieved by
loosening the stacker mount screw and moving the stacker forward or back
accordingly.

Stacker Label Width Adjustment

• Slide the left and right spring loaded upright rails to the desired position.

Users Manual Model 545™ Printer Operation / Adjustments • 29

Stacker Label Length Adjustment

• Loosen the “T” head thumbscrews on either side of the upright base.

• Slide the entire base to the desired position so that the cut label hangs over the

last belt roller approximately ¼” (6mm)

Stacker Angle Adjustment

• Turn the lock knob counter-clockwise to allow the stack end of the stacker to
rotate.

• Once the stack is so that the stacker rails are approximately 5° to 30° off
horizontal, tighten the lock knob by turning it clock-wise.

30 • Printer Operation / Adjustments Users Manual Model 545™

Stacker Full Level Adjustment

• To change the height at which the machine will stop, first loosen the plastic

thumbscrew located on the stacker upright and slide it up or down.

• Once the desired stop level is reached retighten the thumbscrew.

• Do not bring the thumbscrew in contact with the top of the slot. The

thumbscrew must be able to move up approximately 3/16” for the switch to be
activated and stop the printer.

• Note: Not all material and or label sizes will reach the top of the stacker. Set

the stacker full level accordingly.

Users Manual Model 545™ Printer Operation / Adjustments • 31

Replenishing Fabric at End of Roll

• The PAXAR 545 has been designed so that the fabric can be

replenished quickly.

• Cut the fabric from and remove the spent fabric roll core.

• Place a new roll on the unwind and adhere the end of the last roll still

threaded in the printer to the leader of the new roll. Make sure you
have determined the orientation to prevent any twisting in the fabric.

• The front panel START button will then automatically advance the

joint splice beyond the print stations prior to the print heads swinging
into the print position. This prevents any labels from being produced
on the joint splice.

• Remove the “advance splice stripes” containing the joint splice as they

arrive at the stacker.

CAUTION: DO NOT ATTEMPT TO PRINT ON HAND MADE SPLICES AS

PRINT MODULE DAMAGE MAY OCCUR. A SPLICE MAY
CONFLICT WITH THE PRINTHEADS OR HEAD SWING ARM
MOVEMENTS. IF A SPLICE HAS BEEN MADE FOR ANY
REASON OTHER THAN A “STOCK OUT” ERROR CONDITION
MANUALLY ADVANCE IT BEYOND THE PRINT STATIONS.

NOTE: Whenever fabric of a different width is threaded through the printer, a

sample run should be performed. If the print quality / registration is
acceptable, you can immediately begin your production run. If the print
quality / registration needs to be optimized, refer to the Printer Setup
procedure and make the necessary adjustments.

Splices

The PAXAR 545 machine and the fabric it prints on have been designed so
that factory splices can be detected. When a splice is detected, the machine
will stop with a “STOPPED FOR SPLICE “ error.

• The front panel START button will then automatically advance the

factory splice beyond the print stations prior to the print heads
swinging into the print position. This prevents any labels from being
produced that contain splicing material.

• Remove the “advance splice strips” containing the splice as they arrive

at the stacker.

CAUTION: DO NOT ATTEMPT TO PRINT ON HAND MADE SPLICES AS

PRINT MODULE DAMAGE MAY OCCUR. A SPLICE MAY
CONFLICT WITH THE PRINTHEADS OR HEAD SWING ARM
MOVEMENTS. IF A SPLICE HAS BEEN MADE FOR ANY
REASON OTHER THAN A “STOCK OUT” ERROR CONDITION
MANUALLY ADVANCE IT BEYOND THE PRINT STATIONS.

32 • Printer Operation / Adjustments Users Manual Model 545™

Print Head Operation

Each print module consists of two print heads mounted one on each side of a swing
arm. Through an electronic delay the two heads form a single print line. The arm
has two positions, the parked position and the print position. Upon the start
command the heads are rotated 90 degrees to the print position, and at the stop
command the heads are retracted back to the parked position where head
maintenance can take place if needed. A sensor located on the PCB in the print
module monitors the swing arm position. Care should be taken not to obstruct the
path of the print head swing arms as it may disrupt their travel and adversely effect
print quality.

Parked Position Print Position

Users Manual Model 545™ Printer Operation / Adjustments • 33

Printer Setup

From time to time it may be necessary or desirable to reset the printer to a known
state of print / cut. The following procedure can be used to make the necessary
changes. Only adjust the adjustments that are needed in the order that follows;

1) Clean the machine as needed.

2) Check and adjust the unwind and web guides as needed for the fabric width that is

loaded on the machine.

3) Using a 5/64” hex key adjust station 1’s head swing arm stop screw to produce

print on the back of the label that has neither a gap or overlap in the center of the
print image. Rotating the screw counter clockwise will decrease the overlap or
increase the gap. Rotating it clockwise will decrease the gap or increase the
overlap. Once adjusted properly the image on the back of the label should appear
square with no gap or overlap in the center.

4) Adjust station 2’s head swing arm stop screw the same as station 1 to produce

print on the front of the label that has neither a gap or overlap in the center of the
print image.

5) Using the print line label format adjust the mount angle of the knife as needed to

produce a square cut. Loosen the two mount screws securing the knife module
and rotate the entire module then retighten the mount screws.

6) On the front panel adjust the PRINT POSITION STATION 1 to cause the inboard

half of the feed print line on the back of the label to be at 1.0”.

NOTE: PRINT POSTION STATION 1 adjustment is opposite from all the other

adjustment. Using the module view a more negative number moves the
print to the right; a more positive number moves the print to the left.

-20 +20

7) On the front panel adjust the PRINT POSITION STATION 2 to cause the inboard

half of the feed print line on the front of the label to be at 1.0”.

34 • Printer Operation / Adjustments Users Manual Model 545™

-20 +20

8) On the front panel adjust the PRINT OFFSET STATION 1 to produce one

straight continuous feed print line on the back of the label.

-20 +20

9) On the front panel adjust the PRINT OFFSET STATION 2 to produce one

straight continuous feed print line on the front of the label.

-20 +20

10) On the front panel the CUT POSITION should be set to 0, as this is a non-sense

mark label.

Users Manual Model 545™ Printer Operation / Adjustments • 35

-10 +10

11) On the front panel adjust STATION 2 DOT SHIFT to cause station 2’s web
print line to be directly over station 1’s web print line.

-16

+16

Sensor Calibration

The optical sensors used to detect error conditions in production can be calibrated
without the use of a multi-meter via the front panel. One may need to be calibrated
if it has just been replaced or put into service. Refer to the Front Panel Mode
Descriptions under the Control Panel Operation section.

36 • Printer Operation / Adjustments Users Manual Model 545™

Control Panel Operation

Control Buttons

Start

- Starts the printer.

- ON LINE light must be GREEN.

Feed

Test

(Batches downloaded to be printed)

- If “Stopped For Splice” error condition exists: Fabric will be advanced
until the splice is beyond the print stations. Labels between the heads and
knife will be reproduced and stacked as finished labels.

- FEED and START must both be used.

- Feed will stop when the buttons are released.

- Labels between the heads and knife will be cut and stacked as finished
labels.

- Fabric moves through in one continuous strip.

- Fabric moves through without printing.

- TEST and START must both be used.

- Test will stop when the buttons are released.

- Labels between the heads and knife will be cut and stacked as finished
labels.

- Fabric moves through in one continuous strip.

Users Manual Model 545™ Control Panel Operation • 37

Indicator Lights

- Fabric moves through with test pattern printing.

Stop

- The stop button will stop the printer at the end of the current label being
printed.

The Paxar 545 has three Indicator lights. These lights are used along with the LC
display to tell the operator the current status of the printer.

On Line

OFF

After Power up Sequence:

ORANGE

GREEN

Sensor

GREEN = "C" SENSOR

- Has not been powered on.

- Is in it's power - up sequence.

- Failed the system test.

- Printer is running.

- System is operational.

- Ready for batches to be downloaded.

- Batches to print, ready to start.

- Printer is stopped - light is on - sensor is located over a fabric sensor

38 • Control Panel Operation Users Manual Model 545™

LCD Display

mark hole.

- Flashing light while the printer is running, - the sensor is in-line with
the registration HOLES.

ORANGE = REFLECTIVE SENSOR

- Flashing light while the printer is running, - the sensor is in-line with
the registration PRINTED MARKS.

Error

ORANGE

- System inter-lock triggered - see display for error.

The LCD display is a 2 line, 24 character, with back lighting feature for easy
readability. The first line of the display in most cases will be a prompt or question.
The second line is the response.

Users Manual Model 545™ Control Panel Operation • 39

Front Panel Menu Map

↑

↵

↑

↵Ð↑

↑

↵

↑

↵

Ready For

Batches

Î

Print / Cut

Positions

РРРРРР

→

Print Checkout

Format

РРРРРР

Print Position

Station 1

РРРРРР

Print Position

Station 2

РРРРРР

Print Offset

Station 1

РРРРР

Print Offset

Station 2

Ð

Change Cut

Position

ÐÐ

Station 2 Dot

Shift

↑↵

Î

→

Print Head

Cleaning Proc

Clean Station 1

Î

→

Calibrating

Sensors

Hole / Slot In

Sensor

Clean Station 2 Hole / Slot Not

In Sensor

Change Default

Cleaning Level

Top Refl Over

Mark

Station 1

Change Default

Cleaning Level

Top Refl Not

Over Mark

Station 2

Station

Activation

Bot Refl Over

Mark

Bot Refl Not

Over Mark

Stacker

Blocked

Ð

Stacker Not

Blocked

Ð

Stock Out

Blocked

Ð

Stock Out Not

Blocked

Î

Life Counts /

Î

Feature Setup

Versions

→

Label Counter

→

Cutter Enabled

(Re settable)

Total Labels

Produced

Total Inches Of

Stock

Controller

Version

Imager Version Baud Rate:

↵

Change Date

Î

Verifier Setup

→

Print Verifier

/ Disabled

Emulation

Mode:

History

Print Verifier

Setup

Language: Clear Scan

Memory

Protocol: Verifier

Enabled/
Disabled

Ð

and Time

40 • Control Panel Operation Users Manual Model 545™

Front Panel Power Up / Home Screens

POWER UP (DIAGNOSTICS TESTS)

D I AGNOST I C T ES T 1

This screen is displayed while the Front Panel is initializing and waiting for the
Thermal Control Board (TCB) response. While this screen is displayed the code
will check the functionality of the LED's and the display. Each state of the LED's
will be checked - (orange, green, amber and off). The LCD is checked by writing a
character to the display, checking for communications and then reading the character
back and comparing with the write. If an error occurs, the code will halt the
diagnostic test and blink the ERROR LED.

The keypad is also checked during DIAGNOSTIC TEST 1. Each key is tested to
see if it is stuck in the on state. If a fault condition is detected, the test is halted and
the screen will display the first error key found with the following display:

(BUT TON NAME ) KEY S TUCK

The (BUTTON NAME) will be one of the push button names on the front panel ­START, FEED, TEST, STOP, EXIT, MODE, <YES, NO>, OR ENTER.

When the code has finished the above tests, the code will attempt to communicate
with the Thermal Control Board (TCB).

D I AGNOST I C T ES T # # #
CONTROL LER VERS I ON 0 0 . 0 0

This screen will be updated with diagnostic numbers as the TCB and AT go through
different stages of PowerPC initialization.

The diagnostic test screen will also be displayed when the Diagnostic tests that are
run able from the front panel are being executed.

Once the diagnostic tests are complete, the Front Panel should display the HOME
screen.

Users Manual Model 545™ Control Panel Operation • 41

HOME SCREEN

READY FOR BATCHES

545

OR

BATCH I D QUANT I TY
PCL001 10

When the printer is powered up and all initializations are complete, if there aren’t
any Batches to print, the "HOME" screen will be "READY FOR BATCHES" and
the printer model number.

When there are Batches to be printed, the "HOME" screen will be the

"BATCH ID QUANTITY” screen. The Batch ID / Batch Qty screen displays
the currently cutting batch ID and labels remaining to be cut.

When the Batch Id/Qty screen is the home screen and the user presses the EXIT
button the Model Number is displayed briefly before the Batch Id/Qty screen is
displayed again.

If the printer is performing a FEED or a TEST pattern, the screen will show
"FEEDING" or "PRINTING TEST PATTERN" respectively on line two, the top
line will be blank

FEED I NG

PR I NT I NG TEST PATTERN

42 • Control Panel Operation Users Manual Model 545™

Pressing the MODE / Down Arrow key will take the user to the various mode
screens listed below (Refer to the Front Panel Mode Descriptions section in this
manual).

Pressing the EXIT / Up Arrow key at any time will take the user back to the
"HOME" screen.

PRINTER ADJUSTMENTS

PRESS ENTER FOR
PR I NT / CUT POS I T I ONS

PRINTHEAD CLEANING

PRESS ENTER FOR
PR I NT HEAD CLEAN I NG PROC

CALIBRATE SENSORS

PRESS ENTER FOR
CAL I BRA T I NG S ENSORS

LIFE COUNTS / VERSIONS

PRESS ENTER FOR
L I FE COUNTS /VERS I ONS

SETUP SCREEN

PRESS ENTER FOR
FEATURE SETUP

VERIFIER SETUP SCREEN

PRESS ENTER FOR
VER I F I ER SETUP

Users Manual Model 545™ Control Panel Operation • 43

Front Panel Mode Descriptions

There are six (6) main mode levels, which are selected and modified using the
following function keys:

Use the MODE ↓ key to move through the main mode screens shown below:

PRESS ENTER FOR

PRINT / CUT POSITIONS

PRESS ENTER FOR

PRINT HEAD CLEANING PROC

PRESS ENTER FOR

CALIBRATING SENSORS

PRESS ENTER FOR

LIFE COUNTS / VERSIONS

PRESS ENTER FOR

FEATURES SETUP

PRESS ENTER FOR

VERIFIER SETUP

Use the EXIT ↑ to move back to the HOME screens.

44 • Control Panel Operation Users Manual Model 545™

PRINT / CUT POSITIONS

PRESS ENTER FOR
PR I NT / CUT POS I T I ON

This screen follows the "BATCH ID / BATCH QTY" screen if there are batches to
be printed, otherwise it follows the "READY FOR BATCHES / MODEL" home
screen.

Pressing ENTER will take the user to the "PRINT / CUT POSITIONS" screens.
Pressing the MODE / Down Arrow key will take the user to the "PRINTHEAD
CLEANING PROC" screen. Pressing the EXIT / Up Arrow key will take the user
back to the "HOME" screen.

PRESS ENTER TO
PR I NT CHECKOUT FORMAT

This screen is the first screen under "PRINT / CUT POSITIONS". Pressing ENTER
will cause the printer to print the checkout format. The printer will setup to do the
checkout format and start printing. The front panel will remain on this screen so the
user can use the MODE / Down Arrow key to get to the printer adjustments. When
the EXIT / Up Arrow key is pressed the printer stops printing the checkout format
and goes back to what it was doing before the checkout was requested.

Pressing the MODE / Down Arrow key will take the user to the "PRINT POSITION
STATION 1" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

PR I NT POS I T I ON STAT I ON 1
VALUE : ±XX NEW VALUE : ±YY

This screen follows the "PRINT CHECKOUT FORMAT" screen. This screen
allows the print position of station 1 to be adjusted in the feed direction.

The <YES / NO> buttons are used to change the new print position value. The value
is displayed in a positive/negative format. The value ranges for XX and YY can be
from a -99 to a +99. Pressing ENTER will change the VALUE to the NEW
VALUE. Using the module view a more positive number will move the print of
station 1 to the left while a more negative number will move it to the right.

NOTE: Print Position Station 1 is opposite all the other adjustments.

Pressing the MODE / Down Arrow key will take the user to the "PRINT POSITION
STATION 2" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

Users Manual Model 545™ Control Panel Operation • 45

PR I NT POS I T I ON STAT I ON 2
VALUE : ±XX NEW VALUE : ±YY

This screen follows the "PRINT POSITION STATION 1" screen. This screen
allows the print position of station 2 to be adjusted in the feed direction.

The <YES / NO> buttons are used to change the new print position value. The value
is displayed in a positive / negative format. The value ranges for XX and YY can be
from a -99 to a +99. Pressing ENTER will change the VALUE to the NEW
VALUE. A more positive number will move the print of station 2 to the right while
a more negative number will it to the left.

Pressing the MODE / Down Arrow key will take the user to the "PRINT OFFSET
STATION 1" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

PR I NT OFFSET STAT I ON 1
VALUE : ±XX NEW VALUE : ±YY

This screen follows the "PRINT POSITION STATION 2" screen. This screen
allows the offset print position of station 1 to be adjusted.

The <YES / NO> buttons are used to change the new print offset value. The value is
displayed in a positive / negative format. The value ranges for XX and YY can be
from a -20 to a +20. Pressing ENTER will change the VALUE to the NEW
VALUE. A more positive number will move the outboard half of the image printed
by station 1 to the right while a more negative number will move it to the left.

Pressing the MODE / Down Arrow key will take the user to the "PRINT OFFSET
STATION 2" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

PR I NT OFFSET STAT I ON 2
VALUE : ±XX NEW VALUE : ±YY

This screen follows the "PRINT OFFSET STATION 1" screen. This screen allows
the offset print position of station 2 to be adjusted.

The <YES / NO> buttons are used to change the new print offset value. The value is
displayed in a positive / negative format. The value ranges for XX and YY can be
from a -20 to a +20. Pressing ENTER will change the VALUE to the NEW
VALUE. A more positive number will move the outboard half of the image printed
by station 2 to the right while a more negative number will move it to the left.

Pressing the MODE / Down Arrow key will take the user to the "CHANGE CUT
POSITION" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

46 • Control Panel Operation Users Manual Model 545™

CHANGE CUT POS I T I ON
VALUE : ±XX NEW VALUE : ±YY

This screen follows the "PRINT OFFSET STATION 2" screen. This screen allows
the cut position to be adjusted on sense mark formats. The <YES / NO> buttons are
used to change the new cut value. The value is displayed in a positive / negative
format. The value ranges for XX and YY can be from a -10 to a +10. Pressing
ENTER will change the VALUE to the NEW VALUE. On sense mark format a
more positive number will move the cut to the right while a more negative number
will move the cut to the left.

Pressing the MODE / Down Arrow key will take the user to the "STATION 2 DOT
SHIFT" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

STAT ION 2 DOT SHI FT
VALUE : ±XX NEW VALUE : ±YY

This screen follows the "CHANGE CUT POSITION" screen. This screen allows the
print position of station 2 to be adjusted in the web direction.

The <YES / NO> buttons are used to change the new dot shift value. The value is
displayed in a positive / negative format. The value ranges for XX and YY can be
from a -16 to a +16. Pressing ENTER will change the VALUE to the NEW
VALUE. A more positive number will move the print of station 2 to the front of the
machine while a more negative number will it to the back of the machine.

Pressing the MODE / Down Arrow key will take the user back to the "PRINT
CHECKOUT FORMAT" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.

PRINTHEAD CLEANING PROCEDURES

PRESS ENTER FOR
PR I NTHEAD CLEAN I NG PROC .

This screen follows the "PRINT / CUT POSITIONS" screen.

Pressing ENTER will take the user to the "PRINTHEAD CLEANING
PROCEDURES" screens. Pressing the MODE / Down Arrow key will take the user
to the "CALIBRATING SENSORS" screen. Pressing the EXIT / Up Arrow key will
take the user back to the "HOME" screen.

PRESS ENTER FOR
CLEAN I NG STAT ION 1

This screen is the first screen under "PRINTHEAD CLEANING PROC." screen.
This screen allows the user to initiate a cleaning cycle for station 1. Pressing
ENTER will initiate a cleaning procedure on station 1 based on it’s default cleaning
level setting.

Pressing the MODE / Down Arrow key will take the user to the "CLEANING
STATION 2" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

Users Manual Model 545™ Control Panel Operation • 47

PRESS ENTER FOR
CLEAN I NG STAT ION 2

This screen follows the "CLEANING STATION 1" screen. This screen allows the
user to initiate a cleaning cycle for station 2. Pressing ENTER will initiate a
cleaning procedure on station 2 based on it’s default cleaning level setting.

Pressing the MODE / Down Arrow key will take the user to the "CHANGE
DEFAULT CLEANING LEVEL STATION 1" screen. Pressing the EXIT / Up
Arrow key will take the user back to the "HOME" screen.

CHANGE DEFAULT CL EAN I NG
LEVEL FOR STAT I ON 1 : XX

This screen follows the "CLEANING STATION 2" screen. This screen allows the
user to adjust the default cleaning level for station 1.

The ENTER button is used to change the cleaning level value. The value is
displayed in a positive format. The value for XX can be either 3 or 4. Pressing
ENTER will toggle between the two values. The higher the value - the more
extensive the cleaning procedure will become.

Pressing the MODE / Down Arrow key will take the user to the "CHANGE
DEFAULT CLEANING LEVEL STATION 2" screen. Pressing the EXIT / Up
Arrow key will take the user back to the "HOME" screen.

CHANGE DEFAULT CL EAN I NG
LEVEL FOR STAT I ON 2 : YY

This screen follows the "CHANGE DEFAULT CLEANING LEVEL STATION 1"
screen. This screen allows the user to adjust the default cleaning level for station 2.

The ENTER button is used to change the cleaning level value. The value is
displayed in a positive format. The value for XX can be either 3 or 4. Pressing
ENTER will toggle between the two values. The higher the value - the more
extensive the cleaning procedure will become.

Pressing the MODE/Down Arrow key will take the user to the "STATION
ACTIVATION" screen. Pressing the EXIT / Up Arrow key will take the user back
to the "HOME" screen.

STAT I ON ACT I VAT I ON XX
CLOSE HEADS PRESS ENTER

This screen follows the "CHANGE DEFAULT CLEANING LEVEL STATION 2"
screen. This screen allows the user to enable or disable the print stations.

The ENTER button is used to change the value. The value is displayed in a positive
format. The values are 1, 2, or 12. Pressing ENTER will continuously cycle though
the values.

Pressing the MODE / Down Arrow key will take the user back to the "CLEAN
STATION 1" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

48 • Control Panel Operation Users Manual Model 545™

CALIBRATE SENSORS

PRESS ENTER TO
CAL I BRA T E SENSORS

This screen follows the "PRINT HEAD CLEANING PROC" screen.

Pressing ENTER will take the user to the "CALIBRATE SENSORS" screens.
Pressing the MODE / Down Arrow key will take the user to the "LIFE
COUNTS/VERSIONS" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.

HOL E / S LOT I N S ENSOR
VALUE: 000 NEW VALUE: 000

This screen is the first screen under "CALIBRATING SENSORS" screen. Place the
fabric hole/slot sense mark under the sensor. Slowly move the fabric under the
sensor until the NEW VALUE reading is its lowest value then press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "HOLE/SLOT NOT
IN SENSOR" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

HOL E / S LOT NOT I N S ENSOR
VALUE: 000 NEW VALUE: 000

This screen follows the "HOLE/SLOT IN SENSOR" screen. Place the fabric under
the sensor so that it blocks the sensor and when NEW VALUE is at its highest value
press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "TOP REFL OVER
MARK" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

TOP RE FL OVER MARK
VALUE: 000 NEW VALUE: 000

This screen follows the "HOLE / SLOT NOT IN SENSOR" screen. Place the fabric
under the top reflective sensor so that the reflective mark is under the sensor and
when NEW VALUE is at the highest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "TOP REFL NOT
OVER MARK" screen. Pressing the EXIT / Up Arrow key will take the user back
to the "HOME" screen.

TOP RE FL NOT OVER MARK
VALUE: 000 NEW VALUE: 000

This screen follows the "TOP REFL OVER MARK" screen. Place the fabric under
the top reflective sensor so that the fabric is under the sensor but the reflective mark
is not under the sensor and when NEW VALUE is at the lowest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "BOT REFL OVER
MARK" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

Users Manual Model 545™ Control Panel Operation • 49

BOT RE FL OVER MARK
VALUE: 000 NEW VALUE: 000

This screen follows the "TOP REFL NOT OVER MARK" screen. Place the fabric
over the bottom reflective sensor so that the reflective mark is over the sensor and
when NEW VALUE is at the highest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "BOT REFL NOT
OVER MARK" screen. Pressing the EXIT / Up Arrow key will take the user back
to the "HOME" screen.

BO T REF L NOT OVER MARK
VALUE: 000 NEW VALUE: 000

This screen follows the "BOT REFL OVER MARK" screen. Place the fabric over
the bottom reflective sensor so that the fabric is over the sensor but the reflective
mark is not over the sensor and when NEW VALUE is at the lowest value press
‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "STACKER
BLOCKED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

STACKER BLOCKED
VALUE: 000 NEW VALUE: 000

This screen follows the "BOT REFL NOT OVER MARK" screen. Place the fabric
in the stacker jam sensor so that the fabric is within the sensor site path and when
NEW VALUE is at the highest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "STACKER NOT
BLOCKED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

STACKER NOT BLOCKED
VALUE: 000 NEW VALUE: 000

This screen follows the "STACKER BLOCKED" screen. Remove any fabric from
the stacker jam sensor so that no fabric is within the sensor site path and when NEW
VALUE is at the lowest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "STOCK OUT
BLOCKED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

STOCK OUT BLOCKED
VALUE: 000 NEW VALUE: 000

This screen follows the "STACKER NOT BLOCKED" screen. Place the fabric in
the stock out sensor so that the fabric is within the sensor site path and when NEW
VALUE is at the highest value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user to the "STOCK OUT NOT
BLOCKED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

50 • Control Panel Operation Users Manual Model 545™

STOCK OUT NOT BLOCKED
VALUE: 000 NEW VALUE: 000

This screen follows the "STOCK OUT BLOCKED" screen. Reposition the fabric so
that a splice is within the sensor site path and when NEW VALUE is at the lowest
value press ‘Enter’.

Pressing the MODE / Down Arrow key will take the user back to the "HOLE /
SLOT IN SENSOR" screen. Pressing the EXIT / Up Arrow key will take the user
back to the "HOME" screen

LIFE COUNTS/VERSIONS

PRESS ENTER FOR
L I FE COUNTS /VERS I ONS

This screen follows the "CALIBRATE SENSORS" screen. Pressing ENTER will
take the user to the "LIFE COUNTS/VERSIONS" screens.

Pressing the MODE / Down Arrow key will take the user to the "FEATURE
SETUP" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

LABEL COUNTER: 000000
PRESS ENTER TO RESET

This screen is the first screen under "LIFE COUNTS / VERSIONS". This screen
shows total labels produced since the last counter reset. Pressing the ENTER key
will reset the counter to zero.

Pressing the MODE / Down Arrow key will take the user to the "TOTAL LABLES
PRODUCED" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

TOTAL LABE LS PRODUCED

0000000000

This screen follows the "LABEL COUNTER" screen. This screen displays the total
labels produced since the printer was built. This counter is NOT resettable by the
user.

Pressing the MODE / Down Arrow key will take the user to the "TOTAL INCHES
OF STOCK" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

TOTAL I NCHES OF STOCK

0000000000

This screen follows the "TOTAL LABELS PRODUCED" screen. This screen
displays the total inches since the printer was built. This value is NOT resettable by
the user.

Pressing the MODE / Down Arrow key will take the user to the "CONTROLLER
VERSION" screen. Pressing the EXIT / Up Arrow key will take the user back to the
HOME screen.

Users Manual Model 545™ Control Panel Operation • 51

CONTROL LER VERS I ON
XXXXX

This screen follows the "TOTAL INCHES OF STOCK" screen. This screen shows
the operating system version for the controller (TCB). Pressing the MODE / Down
Arrow key will take the user to the "IMAGER VERSION" screen. Pressing the
EXIT / Up Arrow key will take the user back to the HOME screen.

IMAGER VERS ION

XX . XX

This screen follows the "CONTROLLER VERSION" screen. This screen shows
operating system version for the imager (AT).

Pressing the MODE / Down Arrow key will take the user back to the "LABEL
COUNTER" screen.

Pressing the EXIT / Up Arrow key will take the user back to the HOME screen.

FEATURE SETUP SCREEN

PRESS ENTER FOR
FEATURE SETUP

This screen follows the "LIFE COUNT/VERSIONS".

Pressing ENTER will take the user to the "FEATURE SETUP" screens. Pressing
the MODE / Down Arrow key will take the user to the "VERIFER SETUP" screen.
Pressing the EXIT / Up Arrow key will take the user back to the "HOME" screen.

CUT TER I S ENABL ED
PRESS ENTER TO D I SABLE

OR

CUTTER I S D I SABLED
PRESS ENTER TO ENABLE

This screen is the first screen of the "FEATURE SETUP". This screen allows the
cutter to be enabled or disabled. Pressing ENTER will toggle from ENABLED to
DISABLED and vice versa. Pressing the MODE / Down Arrow key will take the
user to the "EMULATION MODE" screen. Pressing the EXIT / Up Arrow key will
take the user back to the "HOME" screen.

EMULAT ION MODE : NONE
NEW EMULAT I ON MODE : NONE

This screen follows the "CUTTER ENABLE / DISABLE" screen. This screen
allows the EMULATION MODE to be changed. Use the <YES and NO> keys to
move between NONE, 630, and 650 modes. Pressing ENTER will update the
emulation mode with the selection after new emulation mode. Pressing the MODE /
Down Arrow key will take the user to the "LANGUAGE" screen. Pressing the
EXIT / Up Arrow key will take the user back to the "HOME" screen.

52 • Control Panel Operation Users Manual Model 545™

LANGUAGE : XXXXXX

NEW LANGUAGE : YYYYYY

This screen follows the "EMULATION MODE" screen. This screen allows the
front panel display language to be changed. Use the <YES and NO> keys to move
between the supported languages on the printer. Any number of front panel
languages can be stored on the optional PCMCIA card (dependent on available
space). If no additional languages other than the default are available on the printer
XXXXXX and YYYYYY will be the same value. Pressing ENTER will update the
display language with the selection. Pressing the MODE / Down Arrow key will
take the user to the "PROTOCOL" screen. Pressing the EXIT / Up Arrow key will
take the user back to the "HOME" screen.

Warning: Mis-matched communication protocols may result in the inability to

communicate with the printer and/or loss of data.

PROTOCOL : XON / XOFF
NEW PROTOCOL : XON / XOF F

This screen follows the "LANGUAGE" screen. This screen allows the
communications protocol to be changed between the supported types. Use the <YES
and NO> keys to move between the supported protocols – RTS / CTS is considered
hardware handshaking and XON / XOFF is considered to be software. Pressing
ENTER will update the communications protocol with the selection. Pressing the
MODE / Down Arrow key will take the user to the "BAUD RATE" screen. Pressing
the EXIT / Up Arrow key will take the user back to the "HOME" screen.

BAUD RATE : XXXXXX

NEW BAUD RATE : YYYYYY

This screen follows the "PROTOCOL" screen. This screen allows the serial
communications speed to be changed. Use the <YES and NO> keys to move
between the supported speeds – typical is 9600 dependent on serial communication
cable length. Pressing ENTER will update the communications speed with the
selection. Pressing the MODE / Down Arrow key will take the user to the
"CHANGE DATE AND TIME" screen. Pressing the EXIT / Up Arrow key will
take the user back to the "HOME" screen.

CHANGE DAT E AND T I ME
MM / D D / Y Y HH : MM XM

This screen follows the "BAUD RATE" screen. This screen allows the machine date
and time stamp to be changed / set. Use the <YES and NO> keys to change the
flashing field. Pressing ENTER will update the present field and move to the cursor
to the next. Pressing the MODE / Down Arrow key will take the user back to the
"Cutter Enabled / Disabled" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.

Users Manual Model 545™ Control Panel Operation • 53

VERIFIER SETUP

PRESS ENTER FOR
VER I F I ER SETUP

This screen follows the "FEATURE SETUP" screen.

Pressing ENTER will take the user to the "VERIFIER SETUP" screens. Pressing
the MODE / Down Arrow key will take the user back to the "PRINT / CUT
POSITIONS" screen. Pressing the EXIT / Up Arrow key will take the user back to
the "HOME" screen.

PRESS ENTER TO
PR I NT VER I F I ER H I STORY

This screen is the first screen under "VERIFIER SETUP". Pressing ENTER will
cause the printer to print a verifier history report containing bar code information for
all the problem scans since the scan memory was last cleared.

Pressing the MODE / Down Arrow key will take the user to the "PRINT VERIFIER
SETUP" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

PRESS ENTER TO
PR I NT VER I F I ER SETUP

This screen follows the "PRINT VERIFIER HISITORY" screen. Pressing ENTER
will cause the printer to print a report containing the present verifier setup.

Pressing the MODE / Down Arrow key will take the user to the "CLEAR SCAN
HISTORY" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

PRESS ENTER TO
CL EAR SCAN MEMORY

This screen follows the "PRINT VERIFIERP SETUP" screen. Pressing ENTER will
clear the verifier scan memory.

Pressing the MODE / Down Arrow key will take the user to the "VERIFIER
ENABLE" screen. Pressing the EXIT / Up Arrow key will take the user back to the
"HOME" screen.

VER I F I ER I S ENABLED
PRESS ENTER TO D I SABLE

OR

VERIFIER IS DISABLE
PRESS ENTER TO ENABLE

This screen follows the "CLEAR SCAN HISTORY" screen. This screen allows the
verification process to be enabled or disabled. Pressing ENTER will toggle from
ENABLED to DISABLED and vice versa.

Pressing the MODE / Down Arrow key will take the user back to the "PRINT
VERIFIER HISTORY" screen. Pressing the EXIT / Up Arrow key will take the
user back to the "HOME" screen.

54 • Control Panel Operation Users Manual Model 545™

Maintenance

Print Module Handling

Warning

Print heads contained in the print modules can be damaged easily, and are subject to
premature failure if not properly handled. Careful handling must be exercised so as
not to damage the nozzle plate. Please follow the procedures carefully to help
ensure print module life and print quality. Because print modules may be damaged
through a number of ways, Paxar has developed the following recommendations;

Handling

ESD

Electro Static Discharge is very detrimental to print heads and PCBs. To avoid
damaging the components of a print module follow these simple procedures:

- Do not touch any terminals extending from the print modules.

- Do not touch the print head nozzle plates.

- Store the print modules near the printer to reduce the distance traveled

thereby reducing the risk of mechanical and electrical damage.

- Store the print modules in a low static environment.

- Store the print modules upright as ink spillage may occur otherwise.

Users Manual Model 545™ Maintenance • 55

Print Module Replacement / Height Adjustment

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

print module(s).

DUE TO THE TOLERANCES IN THE PRINT MODULES AND OF THE

PRINT HEADS THEMSELVES, THE ENTIRE PRINT MODULE MUST
BE REPLACED - ONCE A PRINT HEAD HAS REACHED ITS END OF
LIFE.

1) Remove the ink cartridge from the printer in order to remove the print module.

2) Remove the print module by holding the release lever to the right and lifting the
print module from the printer using its handle.

3) Insert a replacement print module in the reverse order.

4) If the replacement print module does not function properly by swinging the print
heads out to the print position, the module stop block may need to be adjusted.
These stop blocks are located beneath the print module under the front nose
cover of the machine. With the power off remove the cover by removing four
screws, two on either end of the cover then while holding the active unwind
pinch roller down slide the cover forward far enough to unplug the front panel
PCB. Once the PCB is unplugged - remove the cover and set aside. Adjust the
print module stop block as needed to cause the pinion gears (B) to fully mesh
without binding. This is achieved by loosening the two screws (A) securing the
stop block to the frame and then moving the stop block right or left to cause it to
raise or lower. Retighten the screws once the proper height is reached.

5) Replace the cover and perform the auto cleaning until the print heads are filled
with ink and printing a full image.

6) As a final test of the print module installation, run a test pattern to check the print
quality. You should observe an even grid of rectangles.

56 • Maintenance Users Manual Model 545™

Print Head Swing Arm Stop Adjustment

If a gap or overlap appears in the image on the front or back of the label it may be
necessary to adjust the print head swing arm stop screw A for that print station.

A

Using a 5/64” hex key - adjust screw A for the station needing the adjustment.
Rotating the screw counter clockwise will decrease the overlap or increase the gap.
Rotating it clockwise will decrease the gap or increase the overlap. Once adjusted
properly - the image should appear square with no gap or overlap in the center.

Users Manual Model 545™ Maintenance • 57

Automated Print Head Cleaning

Before performing the Automated Print Head Cleaning procedure check the print
head guard slots for any foreign objects that maybe deflecting or blocking the ink
while in flight.

Automated Print Head Cleaning is performed on operator command from the front
panel. From time to time it may become necessary to perform a cleaning routine to
purge air or clear clogged print head nozzles.

There are two cleaning levels to choose from for each print station. Level 4 is more
aggressive than level 3 cleaning and it will therefore take longer to perform and
consume more ink. They are:

Level 3 - Med. Level Cleaning – 15 Cycles.

Level 4 - High Level Cleaning – 20 Cycles. (Also used for priming a new

print module).

NOTE: Each cycle moves 0.3mL of ink from the supply bag into the waste

bag. A new supply bag has 110mL of ink. The machine will shut
down the module pump when 30mL of ink has been pumped into
an ink cartridge waste bag. The balance of new ink in that
cartridge’s supply bag can be consumed by printing.

See the Front Panel Menu map for the location of the default cleaning levels.

WHAT LEVEL TO USE:

• Level 3 - is used when few nozzles will not print.

• Level 4 - is used when level three will not clear all nozzles, and for new print

modules, to purge the heads of analog / air and fill them with ink.

Once the default level of your choice has been selected for the print station to be
cleaned return to its Clean Station screen and press the Enter button. The machine
will then generate a vacuum on the print heads in that print station. This will cause
ink to flow from the supply bag through the print heads and into the waste bag
purging the print heads of air / foreign objects.

58 • Maintenance Users Manual Model 545™

Manual Manifold Seal Cleaning

CAUTION: The print head nozzle plates are very delicate, use extreme

care not to contact the print head nozzle plates while the print
heads are in the print position. Use nothing other than foam
tips with minimal pressure while cleaning the manifold seals.

From time to time depending on the amount of dust and debris in the printing
environment the manifold seals may need to be cleaned by wiping. This will
maintain the module’s ability to form a seal between the print heads and the
manifold. Use the following procedure to position the print module swing arms to
the print position for cleaning purposes, and then back to the parked position when
done.

Positioning Swing Arms for Seal Cleaning

• Go to the PRINT HEAD CLEANING PROC menu on the front panel

and press "enter".

• From either of the first two sub menu items:

(PRESS ENTER FOR / CLEANING STATION 1 (or 2)).

• Press the “YES (←)” button to swing the (active) print station(s) to the

print position.

Users Manual Model 545™ Maintenance • 59

Cleaning

• Take a new foam tip swab (not a cotton swab) and clean any excess ink and

debris from both of the manifold seals for each print module present as shown.

• Use a wiping action across the seals to avoid pushing any debris down into the

manifold seal holes.

• When done cleaning, press the “NO (→)” button to swing the (active)

print station(s) to the home / park position.

60 • Maintenance Users Manual Model 545™

General Machine Cleaning

The machine should be cleaned every eight hours of use or as needed. With the
exception of the print heads and the optical sensors, the machine can be cleaned
using an alcohol base solution. Simply apply a liberal amount of alcohol to a clean
rag and wipe down the machine components starting at the unwind and ending at the
stacker.

Printheads

Refer to the Automated Print Head and Manual Manifold Cleaning sections for
cleaning the print heads.

NOTE: The print head guards can be cleaning with alcohol.

Optical Sensors

When an erroneous interlock condition occurs or print registration in reference to a
sense mark becomes inconsistent or erratic - a sensor may need to be cleaned.
Always use clean supplies when cleaning sensors. Never use anything abrasive on
any of the sensors. Never use an alcohol based solution on any of the sensors. Dry
air or a foam swab are the recommended supplies to use when cleaning a sensor.
Either blow the dust / debris from the sensor using dry clean compressed air or wipe
the sensor with a dry clean swab.

Knife Adjustment

The knife has an adjustment to square the cut to the fabric. To make
the adjustment, loosen the two cap screws, one on top of the knife and
one below the knife, using the 3/16” ball driver. Move the knife in
the direction desired to square the cut and retighten.

Feed Open Interlock Switch Adjustment

With the machine rear cover removed - while turning the feed lever knob back and
forth you should heard the switch clicking. If not, the switch bale is adjusted by
carefully bending it as needed.

Users Manual Model 545™ Maintenance • 61

Lubrication Procedure

General

The 545™ series printers are factory equipped with pre-lubricated bronze bearings
that do not require lubrication. The one exception is the rub cams on either end of
the rotary knife. Periodic cleaning of the printer and removal of dust will greatly
enhance the length of the time the printer will function.

Cam - Lubrication Procedure

1) Clean any dust and residue from cams (using alcohol or other suitable solvent) as
needed, or approximately every 100,000 cuts. Use any good quality general­purpose oil to keep the oilers from drying out. Excess oil may migrate onto the
blades and cause jamming.

2) If lubrication is omitted, the knife will squeak and draw attention to required
lubrication.

No other printer lubrication should be required in normal use.

62 • Maintenance Users Manual Model 545™

Changing Stacker Belts

8-32 CAP SCREWS

FULL STACKER
CONNECTOR

FIGURE 1

1. Remove stacker rail assembly by removing full stacker connector and (2) 8-32 cap
screws from stacker mounting plate. (See figure 1)

Users Manual Model 545™ Maintenance • 63

RIVETS

JAM SENSOR

HARNESS

SNAP RING

FIGURE 2

2. Remove upper conveyor roller assembly by removing jam sensor harness
connector, snap-rings and rivets.

REMOVE

8-32 SCREW

(SEE ITEM 5)

3. Remove the drive belt cover.

LOOSEN

6-32 SET SCREWS

DRIVE BELT

COVER

FIGURE 3

4. Loosen 6-32 set screws in ends of main drive roller. (See figure 3)

64 • Maintenance Users Manual Model 545™

5. Insert an 8-32 screw into the threaded hole in the front side of the roller pin and
remove the pin. (See figure 3)

6. Remove the thumbscrew on the front side of the stacker rail base and let the
square nut on the underside fall out. Loosen the thumbscrew on the far side to
allow slack for the belts to slide on. (See figure 3)

FIGURE 4

7. Pull the drive away from the frame enough to allow the roller / belts to be lifted
out of the frame. This will allow removal of the center roller / bearing assembly
from the frame and provide “slack” sufficient to remove front roller from bearing
blocks. (It is not necessary to loosen or remove the drive pulley to accomplish
this step.) (See figure 4)

Users Manual Model 545™ Maintenance • 65

SMALL DUAL

DRIVE BELTS

(SEE ITEM 8)

8. Remove small dual drive belts from one side of front roller to allow assembly of

9. To re-assemble, reverse procedure above.

FIGURE 5

new belts.

66 • Maintenance Users Manual Model 545™

Electrical Trouble Shooting

Power Up / Sign On / Communications

Problem Probable Cause Corrective Action

Printer fails to power up. 1) Incorrect power amplitude. 1) Confirm that the AC entry is configured for the

line voltage intended to be applied to the
printer. Failure to do so can damage the
printer's internal power supplies.

2) Lack of power to printer. 1) Check that both ends of the power cord are
plugged in securely.

2) Confirm that the outlet the printer is plugged
into has power.

3) Missing or blown fuse(s) 1) Check that the fuse(s) located inside the AC
entry are present and intact. Replace as
needed.

Front panel displays no text

or nothing at all.

4) Unconnected cable / connector

inside printer.

5) Thermal Control Board

unplugged from the Mother Board

1) Front panel cable unplugged. 1) Power off and remove the power cord from the

1) Power off and remove the power cord from the
AC entry. Remove the back cover and inspect
the cables and connectors to and from the
power supplies.

1) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat
the Thermal Control Board.

AC entry. Remove the back cover and inspect
the cable and connectors to and from the front
panel.

Users Manual Model 545™ Electrical Trouble Shooting • 67

Problem Probable Cause Corrective Action

Front panel does not complete

diagnostics test 2.

Printer does not receive

batches.

1) One or more PC board(s)
unplugged from the Mother
Board.

2) PCMCIA cartridge not inserted
correctly in PCMCIA slot.

1) Serial communications cable
loose or unconnected.

2) Printer not powered on or has
not completed diagnostics tests.

3) Data sent to wrong printer. 1) In PcMate change to the printer that the data is

4) Configuration incorrect in
PcMate.

5) Batch Que data flow interrupted. 1) Purge all batches in batch Que. power cycle the

6) Faulty Thermal Control Board. 1) Replace Thermal Control Board.

7) Jumpers not configured
correctly.

1) Power off and remove the power cord from the
AC entry. Remove the back cover and reseat
the offending board.

1) Insert a PCMCIA cartridge with the arrow up
and towards the front of the printer so that the
ejector button pops out.

1) Check and secure both ends of the serial cable
with the thumbscrews.

1) Power printer on and wait until front panel
displays "Ready for batches". Re-download
data.

intended to be sent.

1) Reconfigure PcMate for Paxar PCL printer as
per your PcMate manual.

printer and re-download.

1) Contact Paxar Service.

68 • Electrical Trouble Shooting Users Manual Model 545™

Fabric Advance

Problem Probable Cause Corrective Action

Fabric does not advance

when the start button is
depressed.

1) No batches to be printed. 1) Download batch (if batch downloaded uses the
same format as a previously downloaded batch
the printer with start automatically).

2) An interlock condition exists. 1) Determine the number and type of interlock(s)
by reading the front panel display. As each is
corrected the number of errors will decrease
(Example "Error 910 Feed Open" close feed).

3) Feed roller(s) not gripping the

fabric.

4) Feed rollers bound. 1) With power off - check that all rollers turn

5) Fabric bound. 1) With the feed open and the pressure roller held

6) Feed motor(s) unplugged or

faulty.

7) Thermal Control Board

unplugged or faulty.

8) Finishing Interface Board

unplugged or faulty.

1) Clean the feed rollers in the active unwind and
the feed module.

freely.

open in the active unwind - check that the
fabric will pull through the printer with little to
no resistance.

1) Check the feed motor cable(s) and or replace
the active unwind or feed motor.

1) Check Thermal Control Board / AT board
connection and or replace Thermal Control
Board.

1) Check Finishing Interface Board connections
and or replace Finishing Interface Board.

Users Manual Model 545™ Electrical Trouble Shooting • 69

Print

Problem Probable Cause Corrective Action

Printer advances fabric but

does not print.

Printer stops after ever

third label.

Print registration is off in

the feed direction.

1) If sense mark format fabric
registration sensor miss aligned.

2) Print station(s) inactive. 1) Using the front panel - activate the needed print

3) Print module not fully engaged. 1) Remove the ink cartridge and reinsert the

4) Print module void of ink. 1) Perform a level 4 clean level to purge the print

5) Print module cable unconnected
or faulty.

6) Head Driver Board unplugged or
faulty.

1) Fabric registration sensor miss
aligned.

2) Fabric registration sensor
uncalibrated.

1) Printer incorrectly threaded. 1) Check and rethread the fabric as needed.

1) Adjust sensor position so that the sensor light
on the front panel flashes as a sense mark /
hole passes under the sensor.

station(s).

offending print module.

module of air and fill with ink.

1) Power off the printer and reinsert the offending
connector or replace cable.

1) Check Head Driver Board / AT board
connection and or replace Head Driver Board.

1) Adjust sensor position so that the sensor light
on the front panel flashes as a sense mark /
hole passes under the sensor.

1) Calibrate the sensor.

Print registration is off in

the web direction.

2) Printer print position(s) are
incorrect.

3) Field(s) position incorrect in the
format.

4) Bound roller(s). 1) Check that all rollers turn freely on their shafts.

1) Printer incorrectly threaded. 1) Check and rethread the fabric as needed.

2) Web guides incorrectly adjusted. 1) Check and adjust as needed.

3) Unwind incorrectly adjusted. 1) Check and adjust as needed.

4) Printer station 2 dot shift is
incorrect.

5) Incorrect DIP switch settings on
the Thermal Control Board.

1) Enter the Print / Cut Positions Mode on the
front panel and readjust the Print Position
setting(s) as needed.

1) Using Formatter / PcMate Plus, check and
readjust the field(s) position(s) as needed.

If not – repair / replace.

1) Enter the Print / Cut Positions Mode on the
front panel and readjust Station 2 Dot Shift
setting as needed.

1) Check and reset DIP switches as needed.

70 • Electrical Trouble Shooting Users Manual Model 545™

Problem Probable Cause Corrective Action

Voids in print image in the

feed direction.

Printer continually stops

with an erroneous
interlock condition.

Cut / Stack

Problem Probable Cause Corrective Action

Printer fails to cut labels

(the rotary knife does
not rotate).

1) Nozzles clogged or void of ink. 1) Enter the Print Head Cleaning Mode and clean

the print module.

2) Print head swing arm stop
misadjusted.

3) Faulty print head. 1) After cleaning head and running the test pattern

1) Sensor uncalibrated. 1) Determine which sensor and re-calibrate as

2) Sensor position misadjusted. 1) Determine which sensor and relocate

1) The cut is disabled in the Feature
Setup mode.

1) Adjust the swing arm stop position as needed to
prevent any gap or overlap in the center of the
image.

to confirm that a void still exists, replace the
print module.

needed.

accordingly.

1) Enter the Feature Setup Mode on the front panel
and Enable the knife.

2) Knife cable unconnected. 1) Power off and remove the power cord from the
AC entry. Remove the back cover and inspect
the cable and connector to the knife module.

3) Knife jammed causing auto

resetting fuse to trip on the
Thermal Control Board.

4) Faulty knife motor. 1) Replace the knife motor.

5) Faulty knife motor drive circuit

on the Thermal Control Board.

The stacker fails to run. 1) The stacker cable is unconnected. 1) Power off and insert the stacker cable in the

2) Stacker jammed causing auto

resetting fuse to trip on the
Thermal Control Board.

3) Faulty stacker motor. 1) Replace the stacker motor.

4) Faulty stacker motor drive circuit

on the Thermal Control Board.

1) Remove cause of jam at the knife.

1) Replace the Thermal Control Board.

stacker socket on the Thermal Control Board.

1) Remove cause of jam at the stacker.

1) Replace the Thermal Control Board.

Users Manual Model 545™ Electrical Trouble Shooting • 71

Mechanical Trouble Shooting

Fabric

Problem Probable Cause Corrective Action

Fabric will not roll or jumps 1) Incorrect adjustment of unwind

web guides

Fabric jams in bridge blade

rollers or knife area.

Will not stack. 1) Stacker not operating. 1) See step 3 above.

Knife will not cut or partial

cut

1) Knife mounted bridge blade too
close to stationary bridge blade.

2) Knife not cutting full width of
fabric.

3) Stacker not operating or nip rollers
not turning.

3) Incorrect rail position or stacker
bed angle.

1) Incorrect pre-load on clutch pawl. 1) With back cover removed and power off -

1) Be sure fabric roll is as flat as possible and does
not extend over core.

2) Adjust the web guides to touch the fabric roll
without pinching the core.

1) Loosen screws in upper knife securing bridge
blade roller assembly and slide up (holes in
blade are slotted) until rollers just contact
fabric. Tighten screws.

1) Loosen knife shear adjustment screws and move
outer end of knife until full cut is accomplished.

1) Be sure the nip roller is free to rotate and moves
easily in the bearing slots.

1) Using a cut label, position stacker rails so that
approximately 3/8" (9.5mm) overhangs the
second grooved roller. Loosen quick-turn
handle on stacker clamp and raise or lower
stacker bed until opening between 1st label
overhang and belt surface will allow entry of
next label.

operate solenoid by hand. When lever is
moved, clutch pawl should move counter­clockwise about 1/32" (0.79mm) with the "pac­man" in home position. If not - loosen "pac­man" set screws and readjust "pac-man" to stop
with spring in detent.

2) Partial cut 1) Loosen shear adjustment screws and move outer
end of knife until full cut is obtained.

72 • Mechanical Trouble Shooting Users Manual Model 545™

Ink

Print

Problem Probable Cause Corrective Action

Problem Probable Cause Corrective Action

Users Manual Model 545™ Mechanical Trouble Shooting • 73

Sensor Locations

A

A – Fabric Out / Splice Sensor – Detects when the fabric is depleted or a splice is

present.

B – Active Unwind Loop Sensor – Detects the fabric to maintain a predetermined

amount of slack in the active unwind.

C – Jam Sensor – Detects a jam in the stacker.

D – Full Stacker – Detects when the stacker is full.

E – Ink Cartridge Status – Detects if an ink cartridge is inserted into the machine

and also gives information about the ink cartridge

F – Feed Open Sensor – Detects if the feed lever is open.

B

E

D

C

F

74 • Mechanical Trouble Shooting Users Manual Model 545™

Non-volatile Memory Reset

It may be necessary from time to time to reset the non-volatile SRAM in the machine. This
can be done by using the DIP switch setting of the TCB at power up. Use the following steps
to perform this function:

1) Power off the machine.

2) Change switch number 2 from its present position.

3) Power on the machine, wait at least 30 seconds, then turn power off.

4) Change switch number 2 back to its original position.

5) Power on the machine and reset the front panel adjustments as needed.

Users Manual Model 545™ Mechanical Trouble Shooting • 75

Electrical Drawings

Printer Wiring

76 • Electrical Drawings Users Manual Model 545™

Electrical System Schematic

115V 230V

AC ENTRY

341111

LINE

LINE CORD

GROUND

181134

NEUTRAL

115V OPERATION
ONE 6.25A 250V
1/4 X 1 1/4 FUSE 990689

230V OPERATION
TWO 6.0A 250V
5 X 20MM FUSES 990757

MACHINE COOLING

FAN 511120

NOTES:

1. ALL AC WIRE 18AWG 600V INTERNATIONAL
COLOR CODE:

LINE BROWN
NEUTRAL LT. BLUE
EARTH GROUND GREEN W/YELLOW STRIP

2. DC OUTPUTS OF POWER SUPPLY:
+5V RED
+12V YELLOW
+24V GRAY
RETURN BLACK

A

B

C

D

DO NOT POWER ON WITHOUT

CONN 4

ONE OF FOUR

MOUNT STAND-OFFS/NUTS

SUFFICIANTLY SECURED

GROUND

CONN 6

HARNESSED 24V
POWER SUPPLY

L

N

115V STRAP

115V STRAP

G

L

N

POWER SUPPLY

341116

RETURN

5V/12V

341118

RETURN

+24V

+12V

J6

J7

+5V

J4/J5

HEAD

DRIVER

BOARD

341106IJ

CONN 4

J2

J1

J3

12

N.C.

5V/12V

HARNESS

341141

3

45678910

MOTHER BOARD

371170

PROCESSOR

FAN

ASSY, PRINT MODULE

CABLE 341128

J2

PRINTHEAD

MODULE

CABLE 341123

BOARD 1

J5

341105

J3

J1

J2

J1

MODULE

J5

BOARD 2

341105

J3

11 12

AT
BUS

VL
BUS

PRINT MODULE
345090 X 2

STATION #1

INBOARD PRINTHEAD

341101

INK CARTRIDGE

OUTBOARD

STATION #2

INBOARD

INK CARTRIDGE

OUTBOARD

J6

J7

J3/J4

THERMAL CONTROL

J7

TCB TO HDB

351121

FINISHING

INTERFACE

BOARD
341107

OPTIONAL

PCMCIA

BOARD
351181

FRONT PANEL

351108

J1

TCB TO FP
CABLE
371119

J1

BOARD

371105IJ

J2 J5

SYSTEM

HARNESS

341139

JX

J8

J1

J13

J8

J11

J10

J12

J9

J6

CONN 4

CONN 3

CONN 2

CONN 4

CONN 4

CONN 3

SYSTEM HARNESS
ASSEMBLY 341126

STEPPER MOTOR CABLE

351132

STACKER HARNESS

351125

SERIAL CABLE

EXTERNAL 351124

TCB TO VERIFIER
HARNESS 371158

351132

LOOP SENSOR
341137

SPLICE/STOCKOUT SENSOR
HARNESSED 371133

FEED OPEN
SWITCH 191120

LIGHT-BAR 371120 (OPTIONAL)

TOP REFLECTIVE REGISTRATION
SENSOR 371128 (STANDARD)

BOTTOM REFLECTIVE REGISTRATION
SENSOR 371128 (OPTIONAL)

TOP CONTRAST REGISTRATION
SENSOR 341120 (OPTIONAL)

FEED MOTOR
351141

KNIFE MOTOR
HARNESSED 351171

KNIFE SOLENOID
HARNESSED 351123

CONN 2

CONN 3

CONN 3

OPTIONAL IN LINE VERIFIER 351144

VERIFIER
PCB
351184

HARNESS 351159

HEAD MOTOR
341132

HEAD MOTOR
341132

VERIFIER

ACTIVE UNWIND MOTOR

351141

STACKER MOTOR
HARNESSED 351161

FULL STKR SWITCH
HARNESSED 351160

JAM SENSOR
HARNESSED 371133

SCANNER
351144

Users Manual Model 545™ Electrical Drawings • 77

Motherboard Power Connectors

The power supply connector on any PC / XT or PC / AT compatible motherboard is
made up of dual six-pin male connectors. Two female connectors from the power
supply plug directly onto these male connectors. The following diagrams illustrate
the proper method of attaching the connectors.

Ensure that the black wires are located next to each other in the center of the two
connectors (as shown in the diagram below), and that the clamps on the back side of
the connectors are secured along the PCB header. All pins should be covered.

Warning: Connecting the power supply incorrectly may cause irreversible

(unwarranted) damage! Ensure that the power is turned off before
connecting the power supply. Make certain that the 115 / 230VAC fuse
drawer is in the correct position.

78 • Electrical Drawings Users Manual Model 545™

Appendix A

Error Messages

On the Machine's detection of error(s), the display will show the first error
encountered and allow the displaying of any other errors with the <YES / NO> keys,
which will "Scroll" through additional errors if any.

XX is the total number of errors at the time of error detection.

ERROR SCREENS:

XX ERROR ( S )
STOPPED FOR SPL I CE 9

XX ERROR ( S )

I NK OUT STAT I ON 1 90 4

The screen advances to next error with each depression of the "NO>" key

The screen retreats to prior error with each depression of the "<YES” key

The screen reverts back to the first error when the “EXIT” key is pressed.

XX ERROR ( S )

I NK OUT STAT ION 2 90 5

XX ERROR ( S )
FEED OPEN 9 1 0

XX ERROR ( S )
MI SSED SENSE MARK 7O1

XX ERROR ( S )
CHECK S TACKER 9 0 2

XX ERROR ( S )
VERI F I ER HALT 912

Users Manual Model 545™ Appendix A • 79

Appendix B

Chip Upgrade Positions / Jumper Settings

15
30

R2

D45

D33

D48

D36

D24

D12

D29

D41

D3

D15

D37

D25

PN.341106 REV0
PAXAR SN.

R14

U2

C9

JP2

PIN 1

J2

J1

1
16

C1

R4

D46

D34

D21

D9

D32

D44

D7

D19

D4

D13

D38 D16

D11D35

D47 D23

D22

D10

D8

D39

D2

D1

R5

D27 D20

D26 D14

U 17

A58

C2

R56

R55

R54

R42

R41

R53

R52

R51

R50

C4

U17

J6

A45

R49

C6

U13

C8

C5

R43

U11

K1

R33

R47

R46

R35

R34

R48

R45

R44

U12

C7

A1

R36

C23

U10

+

C15

J7

R38

R39

R37

R20

R40R31

R32

R30

R29

R28

R27

R26

R25

U15

J5

Q1

R23

R24

R7

R1

4321

R17

U3

C13C12

U5

R9

R8R6

R10

R18R16 R15

C14

C10

U6

C11

U9

C3

R21R19

R22

R3

R13R12

R11

U4

C16

U8U7

U1

D40

D28

D17

D5D42

U 1

R62

R63

R61

D31

D18

D30

J4

R60 R59

D6 D43

C20

C19

C18

C17

R64

J3

C22

R57

U 14

U16

A1

JP1

U14

C21

JP1

Head Driver Board P/N 341106

(Use chip removal tool P/N. 351156 for square I.C removal)

HEAD DRIVER BOARD, Upgradeable software I.C.'s include U1, U14, U17.

PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow.

JUMPER SETTING

JP1 Off
JP2 2 to 3

80 • Appendix B Users Manual Model 545™

U42

C91

PAXAR 371105

REV 3.9

SN.

J5

Q8

C92

C90

R54

R55

C88

C85

C22

U24

D7

D9

D11

R56

D22

D23

R52

R2

R53

C84

Q5

Q6

R47

R48

R46

WT2 WT3

C16

U39

+

D20

K3

R45

C46

+

+++

C89

+

C87

Q1

K1

K2

R6

R5

C86

U 3 U 4

U1

U2

C18

C19

U3 U4

J1

L3

SIP4

F1

D51

D61

D62

D63

D64

Q7

D66

R51

D65

D60

R18

U7

R50

R49

C23

Y1

C20

C83

D55D58 D53

D57

R60 R43

U38

C3

C2

C21

U6

C47

C26

U23

D54D56 D52

R44

D59

C41

U 23

SIP5

+

D67

8

1

J15

D43

D45

U33 D68

R30

R31

R29

C66

C70

C72

C52

C24

C53

U22

C49

C48

U21

R39R40

J13

1

C79

C64

D44

D46

U35

R34

R35

C42

C78

C74

R28

U34

R61R33

U 22

U 21

J11

L2

D49

R36

Q4

U37

R42

SIP1

1

C82

D50

C80

C81

D41

U30

R22

R41

R23

U29

C45

R38

C25

C50

U 36

C75

C4

C27

Y2

+

C7

C51

J10

F3

+

C69

D39

C71

R26

C65

R27

C43

R21

C76 R37

C67

SIP3

U28

R16

C32

U36

C73

U18

C28

18

C54

U 18

J7

21

4

3

+

D42

D40 D35

C68

R20 R8

U31

R24R25

C1

C57

C29 U19 C30

C33

J3

J14

R1

U5

5

C55

D33

C56

D15

D14D17

U9

1A31

4

C61

R14

R17
C44

D19

D13

D18

U20

C34

1

U32

U25

R9

R10

C62

R19R11

D36

U 20U 19

U11

++

C93

J12

231

D47

D48+

U27

R7

U26

R13

D26

D30

D25

D24
D28
D29

U14

U15

C31

C35

C94

D34

C63

D21

D12

D5

R12

D1

JP12
JP14

JP9

JP1

5

6

JP2 JP8

JP4

10

JP3

C8

Q9

C36

C59

R57

C95

C97

U43

C96

+

+

C98

SEE DETAIL "A"

D6

Q3

D2

JP13
JP15

JP11

JP7

D38

Q2

C38

C37

D32

+

C10

C58

D37

C39

C11

R15

R59

R58

C40

C15

D31

J2

F2

D10

D8

D3

D4

S1

D16

D27

C9

U12

R3
R4

U16

C14

A1

J4

J9

C60

SIP2

C12

J6

L1

U13

U17

C13

Thermal Control Board P/N 371105IJ

(Use chip removal tool P/N. 351156 for square I.C removal)

THERMAL CONTROL BOARD, Upgradeable software I.C.'s include U3, U4, U18 - U20, U36.

PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow.

DIP CHIPS align notch on chip with the notch on the socket (U3 & U4 chips are four pins smaller than U3 & U4 sockets, position chips towards top of socket so

that the unused socket pins are at the bottom closest to the notch.

Users Manual Model 545™ Appendix B • 81

Front Panel Board P/N 511108

(Use chip removal tool P/N. 351156 for square I.C removal)

FRONT PANEL BOARD, Upgradeable software I.C.'s include U1.

PLCC CHIPS align angled corner of chip with angled corner of socket that is counter clockwise to the arrow.

Front Panel Diagnostic Descriptions

Diagnostic
Numbers

1 Front panel initialization
2 TCB Opsys initialization
5 Attempting Serial Host Initialization
6 Initializing Verifier
7 Executing Protected Mode Imaging Code
8 Checking PCMCIA Card

9 Attempting to read in scalable fonts.
10 Initializing Font Scaler
11 Attempting to load code pages
12 Attempting to read in logos
13 Attempting to read in care symbols
14 Waiting for Machine Definition from TCB
15 Attempting to create test pattern
16 Attempting to create strobe tables
17 Attempting to read in formats
18 Protected Mode Imaging Code initialization complete
19 Serial Communications Activated

0 Power up complete

Descriptions

82 • Appendix B Users Manual Model 545™

Appendix C

Ink Management / Shelf Life

The liquid ink contained in the ink cartridges has a shelf life of one year. It is
therefore recommended that any inventory supply be rotated on a regular basic to
prevent exceeding its expiration date.

Caution: Expired ink may damage print heads. Check the expiration date on the

cartridge label. Do not use expired ink. Contact your Paxar
representative for instructions on returning expired cartridges.

Users Manual Model 545™ Appendix C • 83

Appendix D

Knife MFG Guidelines

Solenoid Trigger Setting

+.000

-.020

1. After the clutch and actuator is mounted to the knife, attach the solenoid

assembly to the inside support using two 6-32 x 3/8 cap screws, flat washers,
and lock washers. Make sure the plunger moves freely and does not bind.
Motor and faceplate must be mounted also.

Check the gap between the actuator and the top of the pin on the clutch as

2.
shown in drawing. The plunger should be pushed in to make the measurement.

Other hints if there is still a problem:

• If the gap is greater then .047”, an old solenoid bracket is being used. Replace
(P/N 357003) or slot the bracket.

If plunger binds, the solenoid is not parallel with the base of the bracket that

•

mounts to the knife support, and/or the actuator slot is bottoming out on the roll
pins that are on the plunger. Make adjustment or replace the bracket.

84 • Appendix D Users Manual Model 545™

Appendix E

Material Safety Data Sheet

======================== SECTION I - GENERAL INFORMATION ========================

PRODUCT NAME: IJ1111 DATE PREPARED: September 28, 1998
MANUFACTURER'S NAME: PAXAR CORPORATION, Systems Group

MANUFACTURER'S ADDRESS: PAXAR CORPORATION

1595 Cedar Line Drive
Rock Hill, SC 29730

EMERGENCY TELEPHONE NUMBER: [phone]

CHEMICAL NAME: Pigmented liquid ink
SYNONYMS: None
FORMULA: Mixture

================= SECTION II - HAZARDOUS INGREDIENT INFORMATION =================

COMPONENT Weight % C.A.S# OSHA PEL ACGIH TLV
Hydrocarbon solvent 70 - 80 200 ppm 200 ppm
Alcohol 10 - 30 143-28-2 N/A N/A
Pigment 10 – 20 N/A N/A

=========================== SECTION III - PHYSICAL DATA ===========================

BOILING POINT (°F): >250°C SPECIFIC GRAVITY (H2O=1): 0.88
VAPOR PRESSURE: <0.01 kPA @ 38
EVAPORATION RATE: (BUTYL ACETATE=1): N/A WEIGHT PER GALLON: 7.3
SOLUBILITY IN WATER: Dispersible but immiscible % VOLATILES PER VOLUME: <80%
APPEARANCE AND COLOR: Solvent based ink; mild hydrocarbon odor

===================== SECTION IV - FIRE AND EXPLOSION HAZARD =====================

FLASHPOINT: >120°C

FLAMMABLE LIMITS: LEL: Not Known UEL: Not Known

RECOMMENDED EXTINGUISHING MEDIA: Dry chemical, carbon dioxide, waster mist, foam

RECOMMENDED SPECIAL FIRE FIGHTING PROCEDURES: None required

UNUSUAL FIRE AND EXPLOSION HAZARD: N/A

°C FREEZING POINT: <10°C

Users Manual Model 545™ Appendix E • 85

=========================== SECTION V - REACTIVITY DATA ===========================

STABILITY: Stable

INCOMPATIBILITY: Strong oxidizing agents

HAZARDOUS DECOMPOSITION PRODUCTS: None known to exist.

HAZARDOUS POLYMERIZATION: Will not occur.

======================== SECTION VI - HEALTH HAZARD DATA ========================

ROUTES OF EXPECTED ENTRY: INHALATION - Not likely

INGESTION - Yes
SKIN - Yes

HEALTH HAZARDS: ACUTE - None to mild skin irritation

CHRONIC - No known chronic hazards are expected from this product

CARCINOGENICITY: None known

FIRST AID PROCEDURES: Eyes: Wash eyes immediately with large amounts of water until no
evidence of material remains (at least 15 minutes).

Get medical attention immediately.

Inhalation: Symptomatic treatment.

Skin: Remove contaminated clothing and wash affected area with mild

soap and large amounts of water. If irritation or rash develops,

get medical attention.

Ingestion: Symptomatic treatment.

======================= SECTION VII -HANDLING PROCEDURES =======================

SPILL OR LEAK: Contain spill with inert material (sand, earth, etc.). Transfer liquids and solid material to

separate containers for recovery or disposal. Keep spills and runoff out of municipal
sewers and open bodies of water.

DISPOSAL METHOD: Material is currently not considered to be a hazardous waste material. Waste material

may be disposed of through routine handling for any sanitary / municipal waste
material in accordance with federal, state and local laws.

HANDLING AND STORAGE: Use is accordance with good industrial workplace practices. Store in a dry area

away from excessive heat or cold.

86 • Appendix E Users Manual Model 545™

======================== SECTION VIII - CONTROL MEASURES ========================

RESPIRATORY PROTECTION:None is specifically recommended for handling this product.

VENTILATION: None required. Respiratory exposure to material in aerosol form

should be avoided.

EYE PROTECTION: None required. Avoid contact with eyes. Use glasses or face shield

when transferring large quantities.

SKIN PROTECTION: None required. Avoid contact with skin. Use gloves when

transferring large quantities.

OTHER PROTECTIVE EQUIPMENT: None is specifically recommended for handling this product.

OTHER PRECAUTIONS: This product is intended for industrial use only.

======================== SECTION IX - SPECIFIC INFORMATION ========================

HMIS RATING: HEALTH 1

FLAMMABILITY 1
REACTIVITY 0

The information contained herein is furnished without warranty of any kind. It is
compiled with the best information available to Paxar at the time of its preparation.
Users should consider these data only as a supplement to other information gathered
by them and must make independent determinations of the suitability and
completeness of the information from all sources to assure proper use and disposal
of these materials and the safety and health of employees and customers.

Users Manual Model 545™ Appendix E • 87

Assembly Drawings

Users Manual Model 545™ Assembly Drawings • 89

Frame Assembly Cover Drawing

16

16

16

3

12

13

15

14

7

6

7

11

10

10

8

9

2

8

9

12

13

17

18

1

17

14

19

18

12

7

7

14

10

10

8

9

4

14

14

5

14

14

90 • Assembly Drawings Users Manual Model 545™

Frame Cover Parts List

Item Part # Description Qty

1 341203 560 Base Pan 1
2 341206 Frame, Upright 1
3 341202 Back Cover 1
4 341204 Hinged Cover 1
5 341201 Front Cover 1
6 341216 Mounting Block, Triangle 1
7 990053 8-32 x ¾ Cap Screw 4
8 341210 Feet, 1 ½” Dia. Rubber 4

9 991079 8-32 ½ Thread Forming Screw 4
10 341215 10-32 x ½ Sem Screw 4
11 341111 AC Entry With Switch 1
12 511209 Bracket, Angle 3
13 990051 8-32 x 3/8 Cap Screw 2
14 991054 8-32 x 3/8 Btn. Hd. Socket Screw 7
15 990456 8-32 x ½ Flat Head Socket Screw 1
16 990055 8-32 x 3/8 Flt. Hd. Socket Screw 3
17 341209 Hinge, 101 Invisible 2
18 990023 6-32 x ½ Flat Head Socket Screw 8
19 341213 Brace, Upright 7

Users Manual Model 545™ Assembly Drawings • 91

Frame Assembly Drawing

92 • Assembly Drawings Users Manual Model 545™

Frame Parts List

Item Part # Description Qty

1 341206 Frame, Upright 1

2 341128 Assembly, Print Module Cable 1

3 345046 Chase Way, Trailing 2

4 345108 Actuator, Shroud Lock 2

5 341203 #10 Lock Washer 10

6 990082 10-32 x 5/8 Cap Screw 10

7 345037 Knob, Chase 2

8 345043 Mount, Chase Bar 2

9 345038 Bar, Chase 2
10 991115 ¼-20 x 1 ¼ Flt. Hd. Socket Screw 4
11 990102 #10 Washer 2
12 990091 10-32 x ½ Button Head Screw 2
13 990081 10-32 x ½ Cap Screw 5
14 990243 Roll Pin, 3/16 x ½ 2
15 143027 Spring, Brake Press 6
16 341132 Motor, Stepper Harnessed 2
17 990448 Washer, .125 x .313 x .031 Fl. 4
18 991033 4-40 x 3/16 Cap Screw 4
19 345022 Pinion, Head Drive Motor 2

Users Manual Model 545™ Assembly Drawings • 93

Sub - Frame Assembly Drawing

94 • Assembly Drawings Users Manual Model 545™

Sub - Frame Parts List

Item Part # Description Qty Item Part # Description Qty

1 341206 Frame, Upright 1 16 343038 Spindle .65 1

2* 343045 Shaft, ABC Spindle 2 17 343110 Bracket, “F” Post 1

3 343044 Spacer, Outer Race 1 18* 343058 Roller, Convex 2
4 343041 Standoff, Partition Short 4 19 343055 Spacer, .65 Spindle 3
5 343040 10-32 x 3/8 Flat Head Screw 7 20 343035 “C”- Ring 3
6 343102 Bracket, Adjuster 2 21* 344062 Spring, Compression 2
7 343103 Standoff, Adjuster 2 22* 343101 Bearing, Retainer Spindle 3
8 990023 6-32 x ½ Flat Head Screw 4 23 990053 8-32 x ¾ Cap Screw 1

9 991125 8-32 x 3/16 SK Set Screw Soft Tip 2 24 345116 Standoff Static Brush 1
10 991137 3-48 x ½ Cap Screw 2 25 345115 Static Brush 1
11 990145 ¼ Lock Washer 6 26 990066 8-32 x ¼ Button Head Screw 2
12 990121 ¼-20 x 5/8 Cap Screw 6 27 346407 Bracket, Nozzle Guard 2

13* 990016 6-32 x 3/5 Cap Screw 3 28 990019 6-32 x ¼ Button Head Screw 2

14 343039 Shaft, D-G Spindle 4 29 343059 Spindle, .75 1

15* 343048 Bearing, Ball Spindle 12 30 990097 10-32 x 5/8” Set Screw 1

* Items Marked with an Asterisk Make up ABC Spindle Assembly - Part # 344091P.

Users Manual Model 545™ Assembly Drawings • 95

Power Unwind Assembly Drawing

96 • Assembly Drawings Users Manual Model 545™

Power Unwind Parts List

Item Part # Description Qty Item Part # Description Qty

1 341206 Frame, Upright 1 20 989966 Washer, 4 Star 1

2 343135 Ass’y, Bracket Unwind 1 21 990001 4-40 x 5/8 Cap Screw 1

3 990486 E-ring 3/8 1 22 990122 ¼-20 x ¾ Cap Screw 3

4 343120 Shaft, Capstan 1 23 990145 ¼ Lock Washer 3

5 343122 Stud, Barrel Idler 1 24 990080 10-32 x 3/8 Cap Screw 6

6 991067 8-32 x 5/16 Knuckle Cup Set 2 25 351141 Ink Motor 1

7 343150 Roller, Drive 1 26 990724 Standoff 3

8 343193 Ass’y Spindle Idler 1 27 343057 Belt, Timing 1/5 1

9 990329 E-ring 7/32 1 28 990102 #10 Washer 3
10 343208 Bracket, Sensor Mount 1 29 424022 Pulley, 1/5, 12T, ¼” I.D. .37 3
11 371133 Sensor Harness 1 30 343056 Pulley, 14 Tooth 1
12 343118 Shaft, Web Guide 1 31 990053 8-32 x ¾ Cap Screw 2
13 343117 Guide, Web Outside 1 32 990082 10-32 x 5/8 Cap Screw 2
14 154020 Web Guide Shaft 1 33 343146 Stripper, Active Unwind 1
15 343116 Guide, Web Inside 1 34 990728 Washer, #10 lock 2
16 990273 #10 Bellville Washer 2 35 990028 6-32 x 3/8 Flat Head Socket Screw 2
17 343115 Bracket, Outer Web Guide 1 36 344094 Assembly, Nip Roll, Active Unwind 1
18 343141 6-32 x 3/8 Sem Screw 2 37 344095 Assembly, Snubber 1
19 343126 Knob, Web Guide 1 38 343151 Drive, Tubing 1

Users Manual Model 545™ Assembly Drawings • 97

Unwind Support Assembly Drawing

98 • Assembly Drawings Users Manual Model 545™