Brady PAM 3000 User manual

Edition 6/02

PAM 3000

Printer-Applicator-System

Service Manual

In accordance with our policy of continual product improvement, we reserve the right to alter specifications without notice

Données technique modifiables sans prévais

Technische Änderungen vorbehalten

Identification Solutions Division

6555 W. Good Hope Road

PO Box 2131

Milwaukee, WI 53201 U.S.A.

Phone: 1-800-537-8791 Fax: 1-800-292-2289

3Printer-Applicator-System PAM 3000

No part of this manual nor any translation may be reproduced or transmitted in any form or by any means,

for any purpose other than the purchaser's personal use, without the express written permission of W.H.

Brady Co.

Edition 6/02

Printer-Applicator-System

Spare Parts List

PAM 3000

Printer-Applicator-System

Spare Parts List

4 Printer-Applicator-System PAM 3000

5Printer-Applicator-System PAM 3000

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Appendices

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

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

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

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

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

6 Printer-Applicator-System PAM 3000

1 Introduction

1.1 Scope of Information

This manual is intended for use by qualified service and maintenance personnel by BRADY Co.

The technical information included relates to hardware and mechanical parts of the Printer-Applicator-System

PAM 3000.

Information related to operation will be found in the Operating Manual provided with the system.

Important information contained in this manual is marked as follows:

WARNING !

Impending danger!

May cause death or physical injuries.

CAUTION !

Dangerous situation !

May cause equipment/material damage or data loss.

NOTICE !

Helpful additional information and tips for use.

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

Service Department.

cab Produkttechnik Sömmerda GmbH

Am Unterwege 20

D - 99610 Sömmerda

Telephone: 03634/6860-111

Telefax : 03634/6860-119

1.2 General Safety Instructions

CAUTION !

Follow the general safety rules below:

Keep the area around the device clean at all times!

Avoid performing maintenance which might expose persons to danger or make the device a source of danger!

Save housing or other parts of the device removed during maintenance!

Keep tools out of the way to avoid injury to yourself or others not involved in the maintenance!

Do not wear loose clothing that could be caught in moving parts of the device. Button up your shirt or jacket

sleeves or roll them up.Tie back or put up long hair. Tuck the ends of scarves, ties and shawls into your

clothing and attach them with a non-conducting clip.

Do not wear jewelry, glasses with metal frame or clothing with metal fasteners!

WARNING !

If such metal parts contact the device, they cause an increased current flow

due to good conductivity!

Wear protective goggles at work as follows:

- while working with compressed air by cleaning the machine

- while using spring hooks or springs

- while soldering

- while using solvents, cleaners or other chemical substances

- in any case where injury to the eyes is possible.

Refit all protective devices such as covers, safety instructions, and grounding cable upon completion of the

maintenance work! Replace all faulty or defective parts!

7Printer-Applicator-System PAM 3000

1.3 Safe Handling of Electricity

Follow the additional instructions below when handling electricity:

Find out the positions of the emergency and the power switch in order to operate themquickly in an

emergency situation!

Do not work alone under dangerous working conditions or while working on devices with non-protected

voltages (over 50 V AC or 120 V DC)!

Turn off power to the printer before:

- removing or installing power units

- working near open power supply parts

- mechanical checkup of power supply parts

- changing circuit boards or electrical parts

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

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

the power in case of danger.

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

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

pocket until you have finished.

NOTICE !

A shock occurs only with a closed circuit.

By using only one hand, as described above, you would avoid a current flow

through your own body.

Do not use worn or defective tools!

Never assume that a circuit is not powered. You must always verify that there is no voltage present!

Always examine the work area for possible sources of danger, such as wet floors, defective extension cords,

faulty protective grounding connectors etc.

If you observe an accident with electricity:

- Be careful and avoid danger to yourself.

- Switch off power.

- Request medical assistance.

- Give first aid, if necessary.

8 Printer-Applicator-System PAM 3000

1.4 Component Location

Fig. 1a Front view

Printer

1 - Display

2 - Function keys with indicator LEDs

3 - Ribbon take up hub

4 - Ribbon supply hub

5 - Print mechanism

6 - Guide roller

7 - Media rewind hub

8 - Knurled knob

9 - Flange

10 - Adapter

11 - Media supply hub

12 - Swing arm with guide roller

13 - Pre-dispense key (for applicator)

14 - Electronic connector for the applicator

15 - Air connectors for the applicator

1

2

3

4

5

67 8

9

10

1112131415

9Printer-Applicator-System PAM 3000

Fig. 1b Detailed view of the print mechanism

1 - Adjusting plate

2 - Printhead

3 - Print roller

4 - Feed roller

5 - Pinch roller

6 - Transport locking lever

7 - Peel-off table

8 - Label edge sensor

9 - Brake

10 - Media guide axle

11 - Media guide

1

2

3

4

5

67 981011

10 Printer-Applicator-System PAM 3000

Fig. 1c Side view

1 - Connector for the compressed air

2 - Power connector with power switch

3 - Parallel interface port

4 - Serial interface port

5 - Scanner connector

6 - Connector warning sensor transfer ribbon end

7 - Connector warning sensor label end

8 - PLC interface port

9 - DIP switches

10 - Connector warning light

11 - Silencer

12 - Memory card module slot

1

2

3

4

5

12

10

9

7

8

6

11

11Printer-Applicator-System PAM 3000

Applicator

Fig. 1d Front view

1 - Connector for the electronics

2 - Pad holder

3 - Pad

4 - Turn cylinder

5 - Slide valve

6 - Lift cylinder

12

3

4

5

6

12 Printer-Applicator-System PAM 3000

2 Self Test

2.1 Self Test Preparation

The PAM 3000 Label Printer has a built-in self test, which makes troubleshooting easier and gives information

about the configuration of the device.

In order to make a self test printout please load material (labels, continuous paper) which covers the entire

printing width.

If you wish to make a test printout in thermal transfer mode, use transfer ribbon of maximum width.

NOTICE !

The test printout is made regardless of label gaps, and is about 230 mm long.

Continuous media would be best suited for test prints, otherwise, a normal sheet of

paper which is cut to a width of 115 mm can be used in thermal transfer mode, too.

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

OFF (see Operators Manual). The self test is initiated by either pressing the key when switching on the

printer and keep them pressed until the system test is completed. The display will show Testprint. You may start

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

pressing the key.

Firmware version

2.2 Self Test Explanation

Bar code with test information

Setup and status information

Fig. 2a Self test printout

Available character sets

Test pattern

13Printer-Applicator-System PAM 3000

3 Internal Setup

3.1 General Information

In addition to the setup facilities that can be accessed by the user (see Operating Manual), the printer has an

internal setup which is to be used by service personnel only.

In order to use the internal setup you need a terminal application. Therefore you can use Windows-Terminal

on a Windows-PC, ZTERM on a Macintosh, connect on an ATARI or KERMIT under UNIX.

This example describes the use of the Windows Terminal application.

It is recommended to remove the machine out of the production line while using the Internal Setup.

3.2 Starting the Internal Setup

For preparation, set the parameter "Interface" in the user setup of the printer to specify RS-232, baud rate 9600.

Now start the Windows terminal program on the PC.

Select "Transfer" from the menu "Preferences" and adjust the terminal program to the printer setup (baud rate

etc.).

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

1. Hold the keys

ONL

and

CAN

when switching on

or

2. Hold the keys

ONL

and

CAN

longer than 5 seconds.

The message Setup is shown on the display of the printer, followed by Country.

In this printer condition, enter the characters secret into the terminal program on the PC.

RS232Setup is displayed and the terminal program shows the following menu on screen :

SETUP PAM 3000 2.67 (Nov 29 2001) - SETUP

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

2) Print head test pattern

3) Reset counters - Hours Transfer Thermal

Total 0 0 m 0 m

Since Service 0 0 mm 0 mm

4) Save as default values

5) Adjust label gap sensor

9) Main motor current: 16/16

A) Delay for peel off: On

B) Backfeed on power-on: Off

C) Paper-end lever build-in: Yes

D) Peel-off edge at 13 mm

E) Ignore protocol error: Off

F) Additional offset gap sensor : 0

Z) Quit

(15.03.02 13:15:57) ? _

14 Printer-Applicator-System PAM 3000

1) Complete system test

By selecting 1, a detailed internal selftest will be activated (This includes more detail than the self test

which runs after powering on the printer).

The printer will clear the memory completely after finishing the detailed selftest, by issuing a RESET at the

end.

The display shows:

By pressing Y, the selftest will be initiated.

In the Terminal program, the following (or similar) text will be displayed:

Fill memory with $00

Test memory for $00

Fill memory with $FF

Test memory for $FF

Fill memory with mux test values

Test memory for mux test values

Test RTC

Test ROM for mirroring

Test ROM checksum

Clear memory using movem

Test lower memory

Test upper memory

Test refresh

Test lower memory

Test upper memory

Clear memory

Writing single byte access (16K)

Reading single byte access (16K)

Test remainder for $00

Test internal sRAM

Test QSPI and ADC

Test watchdog

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

Adjust printhead ? (Y/..)

Every line represents a selftest stage. If an error occurs, the next line shows the message >>>ERROR. If

this occurs, you should replace the CPU PCB.

2) Printhead test pattern

This part of the Internal Setup supports the printhead alignment. There will be a grid test pattern printed by

selecting this option.

After keying a 2 in Terminal, the following message will appear:

After pressing Y on the keyboard of your PC you have to press the pre-dispense key on the printer to get

the test pattern.

You can now adjust the position of the printhead until the quality of the printed image is optimum. During

adjustment you have to repeat the whole procedure to get some more test pattern.

In order to cancel the operation, press the

CAN

-key.

15Printer-Applicator-System PAM 3000

3) Reset counters

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

working time

transfer printing total length

thermal printing total length

The first counter set reflects the totals over the lifetime of the printer.

The second counter set is intended to show totals for the interval since last technical service. Having

completed the maintenance work, you can reset this second set of counters as follows:

After keying a 3, the following prompt will display on your monitor:

Enter the password CARRY to reset the service counter and the result of the system test (test printout,

status display) to 0000.

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

RESLT.

4) Save as default values

By selecting option 4 you can specify as defaults the parameters you have set up using operator setup.

This will store your current values for the following as defaults:

- country

- transfer print

- label edge sensor

- interface

- cut position

- peel position

- heat level

- character set

- brightness

Generally, you will only need to save new setup parameters as defaults when components have been

replaced (e.g. printhead), the tolerances of which differ from those of the old components.

Mode ?

Save defaults ? (Y/..)

5) Adjust label gap sensor

Use option 5 to adjust the label gap sensor. This will be necessary when the label gap sensor itself or the

CPU PCB have been replaced. Once initiated, follow the prompts, removing and reinserting label stock, as

indicated below.

NOTICE !

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

16 Printer-Applicator-System PAM 3000

7) Print adjustment

This option is not valid for PAM 3000-printer. It is only valid for devices which are offered as left-handed

and right-handed types.

The left-handed-position should be selected.

Adjust label gap sensor? (Y/..)

Please remove label stock (any key)

Using 5/64 : 0

Using 6/64 : 0

Using 7/64 : 0

Using 8/64 : 0

Using 9/64 : 0

Using 11/64 : 0

Using 12/64 : 1

Using 13/64 : 3

Using 14/64 : 7

Using 15/64 : 15

Using 16/64 : 23

Using 17/64 : 34

Using 18/64 : 46

Using 19/64 : 58

Using 20/64 : 71

Using 21/64 : 84

Using 22/64 : 98

Using 23/64 : 111

Using 24/64 : 125

Using 25/64 : 139

Using 26/64 : 153

Using 27/64 : 166

Using 28/64 : 180

Using 29/64 : 193

Using 30/64 : 205

Using 31/64 : 208

Please insert label liner (any key)

Using 31/64 : 170

Using 32/64 : 181

Using 33/64 : 192

Using 34/64 : 202

Finished adjustment, Values 31 - 34 (any key)

17Printer-Applicator-System PAM 3000

9) Main motor current

Several types of motors are available as main drive motors.

Following menu item #9, you can adjust the motor current of the main drive motor to one of the several

types of motors (e.g.after motor replacement).

The standard motor is the type Nanotec 4T5718L5208. The adjusted value for this type is 16/16.

It is recommended from the producer to use this standard motor.

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

Upon entering "9" the display will change to:

9) Main motor current : 16/16

Value : 10+/-/ENTER ?+

Using the keys "+" and "-" you can alter the motor current value. Having setup the required value you can

return to the internal setup main menu by pressing the "ENTER" key.

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

Value: 10 +/-/ENTER?+

Value: 11 +/-/ENTER?+

Value: 12 +/-/ENTER?+

Value: 13 +/-/ENTER?+

Value: 14 +/-/ENTER?+

Value: 15 +/-/ENTER?+

Value: 16 +/-/ENTER? <ENTER>

A) Delay for peel-off

This option is not valid for PAM 3000-printer.

The ON position should be selected.

B) Backfeed on power-on

This option is not valid for PAM 3000-printer.

The OFF position should be selected as standard.

C) Paper-end lever build in

The printer is equipped with a sensor which recognizes the end of material.

This parameter is set on "Yes" when the sensor should be active. That means the printer will be stopped

when the paper is out and the display is shown a message.

Otherwise the sensor would be disregarded.

Button C allows the user to switch yes or no and the display indicates.

C) Paper-end lever build in : No

C) Paper-end lever build in : Yes

The YES position must be selected as standard.

18 Printer-Applicator-System PAM 3000

E) Ignore protocol error

The printer is equipped with a comprehensive self diagnostic system which will indicate errors in the

display of the printer. Also, the operator will be informed by the LEDs whether a protocol error occurs and

will be able to correct it and to continue the current print job after corrections, or to cancel the current print

job.

When this parameter is On the printer ignores the protocol error and no message is shown at the display.

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

The OFF position should be selected as standard.

CAUTION !

This parameter should only be set "ON" if the configuration of the computer requires

this setting.

It is possible that data are lost when the setting "ON" is active and therefore faults

will be ignorized.

Z) Quit

By keying Z, you can leave the internal setup.

A prompt inquiring whether changes should be saved will be displayed as follows:

Having completed the internal setup, the printer will now perform a reset and will be placed in the ONLINE

mode. You can now exit the Windows Terminal Program, if desired.

Save changes ? (../N)

E) Ignore protocol error : On

E) Ignore protocol error : Off

D) Peel-off edge at 13 mm

This option is not valid for PAM 3000-printer.

The setting 13 mm must be selected as standard.

F) Additional offset gap sensor

This option is not valid for PAM 3000-printer.

The setting 0 mm must be selected as standard.

19Printer-Applicator-System PAM 3000

4.1 General Cleaning

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

cleaner.

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

NOTICE !

Do not use abrasive cleaners or solvents.

4 Maintenance

4.2 Cleaning the Printhead

After extensive printer operation or if poor quality paper or ribbon has been used, foreign particles may collect on

the printhead. They cause characters or bar codes to appear light or faded, and can cause continuous light

streaks to always appear in the same physical position.

When this happens, you must clean the printhead.

We recommend cleaning the printhead every time changing the ribbon.

To clean the printhead, proceed as follows:

WARNING !

Disconnect power supply !

Switch off compressed air !

1

Fig. 4a Cleaning the printhead

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

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

CAUTION !

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

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

20 Printer-Applicator-System PAM 3000

4.3 Cleaning the Print Roller and the Transport System

If the print roller and the rollers of the tranport system become contaminated with dirt, label adhesive, ink or rest

of labels, the movement of the media and print quality may also be adversely affected.

WARNING !

Disconnect power supply !

Switch off compressed air !

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

Fig. 4b Opening the transport system

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

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

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

the transport system and from the print roller (5).

1

5

4

32

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Brady PAM 3000 User manual

Brady PAM 3000 User manual

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