Printer Applicator System PAM 3600 Service Manual Edition 1/07
W.H. Brady Lindestraat 21 Industriepark C3 9240 Zele Belgium Phone: +32 52 457 811 e-mail: support@brady.be 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 All specifications about delivery, design, performance and weight are given to the best of our current knowledge and are subject to change without prior notice.
Service Manual PAM 3600 Table of Contents Table of Contents 1 1.1 1.2 1.3 1.4 1.5 1.6 Introduction................................................................................................................................................. 5 Scope of Information.................................................................................................................................... 5 Important Information.......................................................................................
Table of Contents 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 6 6.1 6.2 6.3 Service Manual PAM 3600 Adjusting the Guide Plate........................................................................................................................... 50 Adjusting the Sensors of the Peel-off Table................................................................................................ 51 Adjusting the Sensors of the Printhead.................................................................
Service Manual PAM 3600 1 Introduction 1 Introduction 1.1 Scope of Information This manual is intended for use by qualified service and maintenance personnel. The technical information included relates to hardware and mechanical parts of the Printer Applicator System PAM 3600. Information related to operation will be found in the Operator's Manual. If a problem occurs, which cannot be solved with the help of this manual, please contact the Technical Service Department. To adress see page 2. 1.
1 Introduction 1.
Service Manual PAM 3600 1.
1 Introduction 1.
Service Manual PAM 3600 1 Introduction Applicators 1 2 3 4 4 5 6 7 8 9 PAM 3602 PAM 3603 Figure 1b Overview applicators 1 2 3 4 5 6 7 8 9 Energy-chains Sensor 1 main cylinder Main cylinder Sensor 2 main cylinder (PAM 3602 only) Slide valve Lift cylinder (PAM 3603 only) Turn cylinder (PAM 3602 only) Pad holder Pad Printer Applicator System PAM 3600
1 Introduction Service Manual PAM 3600 Options 1 2 3 4 5 Figure 1c Overview options 1 2 3 4 5 10 Warning light Warning sensor, ribbon end Warning sensor, label end Antistatic burst Blow tube Printer Applicator System PAM 3600
Service Manual PAM 3600 2 Expanded Functions for Servicing 2 Expanded Functions for Servicing 2.1 The Service Key and the OEM Key There are a service key (Part No. 5540301) and an OEM key (Part No. 5540304) for accessing special service functions which are not accessible to the operator. The OEM key enables: • selecting the correct device name (Set OEM Name).
2 Expanded Functions for Servicing 2.2 Service Manual PAM 3600 Expanded Functions in the "Setup" Menu There are a variety of parameters that can be set to configure the printer to specific requirements.
Service Manual PAM 3600 2.3 2 Expanded Functions for Servicing Expanded Functions in the "Test" Menu The test functions allow the operator or the service personnel to obtain an overview of the most important printer settings and hardware configurations. The following functions can be called in the "Test" menu.
2 Expanded Functions for Servicing Service Manual PAM 3600 A B O O C D E F Figure 2b Status Print with Service Key inserted 14 Printer Applicator System PAM 3600
Service Manual PAM 3600 2 Expanded Functions for Servicing Device List The most important hardware components installed in the printer and the connected optional devices are listed in the "Device list" submenu. Please also refer to the "Test Functions" section of the Operator's Manual for the printout of the device list and further information. Proceed as follows to print the device list: 1. Insert the service key into the Master USB socket. 2.
2 Expanded Functions for Servicing Service Manual PAM 3600 Label Profile The label profile printout contains additional information with the service key inserted. Print out the label profile as follows: 1. Insert the service key into the Master USB socket. 2. Select the "Test" menu in the offline menu and confirm with the key. 3. Press the or key until you reach the "Label profile" function and confirm with the Start the printout with the pre-dispense key. The printout can be aborted with the key. key.
Service Manual PAM 3600 2 Expanded Functions for Servicing 1. Insert the service key into the Master USB socket. 2. Switch from online mode to the offline menu by pressing the key. 3. Select the "Test" menu in the offline menu and confirm with the key. 4. Select the option "Printhead profile" by pressing the key or the key and confirm by pressing the key. NOTICE! The measurement of the resistance values can take several minutes. You will see the progress of this measurement on the display. 5.
2 Expanded Functions for Servicing Service Manual PAM 3600 Event Log The label printer stores the following events in the event log: • Hardware fault • Adjustment of the label sensor • Firmware updates • Service counters reset The event log can only be called with the service key inserted. Print out the event log as follows: 1. Insert the service key into the Master USB socket. 2. Select the "Test" menu in the offline menu and confirm with the key. 3.
Service Manual PAM 3600 2.4 2 Expanded Functions for Servicing Expanded functions in the "Service" Menu In the "Service" menu, the operator only has access to the "Firmware update" and "Firmware from card" function.
2 Expanded Functions for Servicing Service Manual PAM 3600 Adjusting the Label Edge Sensor The function "Adjust gap sensor" enables the label edge sensor to be adjusted. This is necessary when the label edge sensor itself or the CPU PCB are replaced. NOTICE! In order to avoid the influence of light from the outside, check the adjustment of the sensor with the cover closed and housing mounted! Perform the adjustment as follows: 1. Insert the service key into the Master USB socket. 2.
Service Manual PAM 3600 2 Expanded Functions for Servicing Loading the NVRAM The "Load NVRAM" function is used to reload a previously saved printer configuration from a CompactFlash memory module. This function is only accessible with the service key inserted and the CF card in the slot. Load the NVRAM as follows: The printer is switched on. 1. Insert a CF card containing the stored printer configuration into the CF slot. 2. Insert the service key into the Master USB socket. 3.
3 Maintenance 3 Service Manual PAM 3600 Maintenance The printer requires little maintenance. It is important to clean the thermal printhead regularly. This guarantees a consistently good printed image and plays a major part in preventing premature wear of the printhead. Otherwise, the maintenance work is limited to occasion cleaning of the device and the rollers. 3.1 General Cleaning Dust particles collect during operation, particularly around the printer’s mechanical parts.
Service Manual PAM 3600 3.3 3 Maintenance Cleaning the Print Roller and the Transport System If the print roller and the rollers of the transport 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.
3 Maintenance 3.4 Service Manual PAM 3600 Cleaning the Brake It is recommended to clean the brake regularly. Otherwise it is possible that the transport of the paper is adversely affected. WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 3 Figure 3c Cleaning the brake 1 Brake 2 Screw 3 Brake plate 1. Remove label stock and transfer ribbon from the printer. 2. Loosen the screw (2). 3. Remove the brake plate (3). 4.
Service Manual PAM 3600 3.5 3 Maintenance Cleaning the Pad During operation, dust particles accumulate on the pad. It is recommended to clean the pad regularly. WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 Figure 3d Cleaning the pad 1 Valve 2 Pad 1. Slightly pull the valve (1) until the bleed position is reached. So it is possible to move the pad manually. 2. Slide the pad (2) to a position where the underside of the pad is easily accessible. 3.
4 Replacing Assembly Units 4 Replacing Assembly Units 4.
Service Manual PAM 3600 4.2 4 Replacing Assembly Units Replacing the Printhead WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! CAUTION! Damages by electrostatic loading! Ground yourself to the chassis before you remove or install the printhead. This will prevent a static discharge from your body through the printhead to ground. 1 2 2 3 Figure 4a Replacing the printhead 1 Printhead locking screw 2 Plug 3 Printhead with head plate 1.
4 Replacing Assembly Units 4.3 Service Manual PAM 3600 Replacing the Print Roller and the Feed Roller WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 3 4 Figure 4b Replacing the print roller or the feed roller 1 2 3 4 Head plate 5 screws Feed roller Print roller 1. Remove label stock and transfer ribbon from the printer. 2. Loosen and remove the 5 screws (2) from the head plate (1). 3. Remove the head plate (1). 4.
Service Manual PAM 3600 4.4 4 Replacing Assembly Units Replacing the Transport Locking Roller WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 3 Figure 4c Replacing the transport locking roller 1 Transport locking roller 2 E-ring 3 Knurled knob 1. Remove label stock and transfer ribbon from the printer. 2. Remove the two E-rings (2) from the axle. 3. Unlock the transport locking roller (1) by pressing the knurled knob (3) downward. 4.
4 Replacing Assembly Units 4.5 Service Manual PAM 3600 Replacing the Pinch Roller WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 3 4 5 6 7 Figure 4d Preparation 1 2 3 4 5 6 7 Gear Belt 4 screws Main motor Belt Pulley Snap ring 1. Remove label stock and transfer ribbon from the printer. 2. Unlock the transport locking roller by pressing down the knurled knob (10). 3. Remove the cover at the rear side. 4.
Service Manual PAM 3600 8 9 4 Replacing Assembly Units 10 11 12 13 14 Figure 4e Replacing the pinch roller 8 9 10 11 12 13 14 Transport locking roller Spring Knurled knob Bearing plate 4 screws Pinch roller Guide roller 8. Hang out the spring (9). NOTICE! Pay attention on the spring on the other side of the transport locking roller (8), do not hang out it by moving the roller or the knurled knob. 9. Loosen and remove the four screws (12) on the bearing plate (11). 10.
4 Replacing Assembly Units 4.6 Service Manual PAM 3600 Replacing the Label Edge Sensor WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 2 3 4 Figure 4f Replacing the label edge sensor 1 2 3 4 Cable Label edge sensor Hole Screw 1. Remove label stock and transfer ribbon from the printer. 2. Remove the cover at the rear side. 3. Pull out the cable (1) from the label edge sensor (2). 4. Remove the screw (4). 5.
Service Manual PAM 3600 4.7 4 Replacing Assembly Units Replacing the Slip Clutches The rewinders for the ribbon and the media and the brake for the ribbon supply hub are equipped with slip clutches. A slip clutch has to be replaced when it can not longer be adjusted. The assembly instructions for the clutches also have to be observed when a winder has to be replaced.
4 Replacing Assembly Units Service Manual PAM 3600 Replacing the Slip Clutch on the Ribbon Take Up Hub 6 1 1 2 3 4 7 8 9 4 5 5 Figure 4h Slip clutch on the ribbon take up hub 1 2 3 4 5 6 7 8 9 Screw Motor bracket Tappet Slip clutch Bearing on the take up hub Lugs of the clutch 2 set screws Knurled nut of the clutch Feeler gauge 1. Pull out the plug of the motor (fig. 4g, 2). 2. Remove the two screws (1) and the bracket (2) with the motor assembly and the tappet (3). 3.
Service Manual PAM 3600 4 Replacing Assembly Units Replacing the Slip Clutch on the Ribbon Supply Hub 1 2 3 7 4 6 5 5 6 4 3 2 1 7 1 2 3 4 5 6 Figure 4i Slip clutch on the ribbon supply hub 1 2 3 4 5 6 Snap ring Washer Clutch Lug Flat Spring legs 1. Remove the snap ring (1) and the washer (2). 2. Remove the clutch (3). 3. Insert the new clutch, make sure that the lug (4) is located between the spring legs (6) and that the clutch has the right position to the flat (5) on the hub. 4.
4 Replacing Assembly Units 4.8 Service Manual PAM 3600 Replacing the Main Drive Motor WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! PANEL R ibbon IEEE1284 PERI PERI HEADLOCK USB MASTER 05/N31 G-TESTED SERIAL MOTOR PRINTHEAD POMER SUPPLY GAP SENSOR 1 2 3 4 5 6 Figure 4l Replacing the main drive motor 1 2 3 4 5 6 CPU PCB Plug Gear Belt 4 screws Main drive motor 1. Remove the cover at the rear side. 2.
Service Manual PAM 3600 4.9 4 Replacing Assembly Units Replacing the CPU PCB WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 3 4 5 Figure 4m Replacing the CPU PCB 1 2 3 4 5 Fixing screw Stepper motor driver CPU PCB Heat conductor pad Cooling rib 1. If possible backup the settings of the printer configuration on a CompactFlash card as described in the chapter "Save NVRAM". 2. Pull out all interface connectors at the side of the printer. 3.
4 Replacing Assembly Units Service Manual PAM 3600 PANEL 9 R ibbon 10 IEEE1284 PERI PERI 12 HEADLOCK USB MASTER 11 13 05/N31 G-TESTED SERIAL MOTOR 14 PRINTHEAD POMER SUPPLY GAP SENSOR 6 7 8 Figure 4n Connectors at the CPU PCB 6 7 8 9 10 11 12 13 14 Label edge sensor Low-voltage input from power pack Printhead logic connector Control panel Transfer ribbon sensor Applicator control PCB Applicator control PCB (alternative) Sensor transport locking roller Motor Mounting the CPU PCB: 12.
Service Manual PAM 3600 4 Replacing Assembly Units 4.10 Replacing the Power Unit WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! WARNING! Mortal danger by electric shock! While switched-on, the power unit has a voltage of up to 380 V as a function of the capacitor. However, when the printer or power unit is switched off, this voltage falls to non dangerous levels (< 42 V) within one minute.
4 Replacing Assembly Units Service Manual PAM 3600 4.11 Replacing the Applicator Control PCB and Firmware Update of the Applicator Module WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 2 3 4 2 Figure 4p Replacing the applicator control PCB 1 2 3 4 Fixing screw Controller with firmware Applicator control PCB PLCC extractor Replacing the PCB 1. Remove the cover. 2. Dismount the CPU PCB as described in section 4.9. 3.
Service Manual PAM 3600 4 Replacing Assembly Units 4.
4 Replacing Assembly Units Service Manual PAM 3600 Sensors peel-off table C View A View B D-A93V D-A93V B A 8 9 10 10 11 12 12 View C Figure 4r Replacing the sensors peel-off table 8 9 10 11 12 Canal Cable Screw Base plate Sensor peel-off table 1. Remove label stock and transfer ribbon from the printer. 2. Remove the cover. 3. Remove the cable from the cable holder (1). 4. Remove the plug (5) from the applicator control PCB (3), loosen the screws of the concerning cable and remove it. 5.
Service Manual PAM 3600 4 Replacing Assembly Units Sensor transport locking roller 13 14 Figure 4s Preparation 13 Head plate 14 5 screws 1. Remove label stock and transfer ribbon from the printer. 2. Remove the cover. 3. Pull out the concerning plug (fig. 4q, 7) on the CPU PCB (fig. 4q, 6). 4. Loosen the five screws (14) and remove the head plate (13). 5. Move the whole mounting forward.
4 Replacing Assembly Units Service Manual PAM 3600 Sensors printhead cylinder 19 19 Figure 4u Replacing the printhead cylinder sensors 19 Printhead cylinder sensor 1. Remove the cover. 2. Loosen the screw on the concerning sensor (19). 3. Remove the cable from the cable holder (fig. 4q, 2). 4. Remove the plug (fig. 4q, 5) from the applicator control PCB (fig. 4q, 3), loosen the screws of the concerning cable and remove it. 5. Replace the sensor and reassemble in reverse order. 6.
Service Manual PAM 3600 4 Replacing Assembly Units 20 21 22 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE VACUUM BLOWAIR Switch paper end 23 Figure 4v Replacing switch paper end 20 21 22 23 Switch paper end 3 screws Plate Screw 1. Remove label stock and transfer ribbon from the printer. 2. Remove the cover. 3. Remove the flange and the adapter from the media supply hub. 4. Remove the three screws (21) and the plate (22) from the media supply hub. 5.
4 Replacing Assembly Units Service Manual PAM 3600 Sensors of the Applicator Module 1 1 1 Figure 4w Unscrewing the sensors of the applicator module 1 Sensors 1. Unscrew the respective sensor (1) by loosening the corresponding screw. 7 3 4 5 6 2 1 2 8 530 9 913 3_0 2 3 Figure 4x Replacing the sensors of the applicator module 2 Plug 3 Screw 2. Pull out the plug (2). 3. Remove the cover of the plug by loosen the screw (3). 4.
Service Manual PAM 3600 4 Replacing Assembly Units 4.13 Disassembling the Energy-Chains If a cable contained in the energy-chains is to be changed, proceed as follows: 1 2 3 Figure 4y Disassembling the energy-chains 1 2 screws 2 Holder 3 First track link 1. Loosen the two screws (1) of one of the holders (2) and take the chains from the holder. 2. Zip the outer side of the chains open by pulling out the first track link (3). 3. Change the respective cable and reassemble the chains in reverse order.
5 Adjustments Service Manual PAM 3600 5 Adjustments 5.1 Adjusting the Peel-off Table For optimum print and application quality, it is important to adjust the front position and the back position of the peeloff table exactly. This adjustment has already been performed in the factory. Nevertheless, it may become necessary to adjust it.
Service Manual PAM 3600 5.2 5 Adjustments Adjusting the Printhead For optimum print quality, the line of heating elements on the printhead must be parallel and adjusted correctly to the print roller. This adjustment has already been performed in the factory. Nevertheless, it may become necessary to adjust it.
5 Adjustments 5.3 Service Manual PAM 3600 Adjusting the Guide Plate It is possible that the guide plate (2) becomes loose by the movement during the operating process. For that reason it is necessary to readjust the guide plate to guarantee a proper print image. WARNING! Mortal danger by electric shock! Disconnect power supply! Switch off compressed air! 1 1 2 3 3 4 1 5 Figure 5c Adjusting the guide plate 1 2 3 4 5 Guide wheel Guide plate Guide wheel Bushing Nut 1. Remove the cover. 2.
Service Manual PAM 3600 5.4 5 Adjustments Adjusting the Sensors of the Peel-off Table After replacing a sensor ore after mechanical adjustments it is necessary to adjust the sensors of the peel-off table. LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE VACUUM BLOWAIR The correct adjustment of the peel-off table can be checked by watching the concerning LEDs on the applicator control PCB. If one of the LEDs does not shine during the table movement the sensor has to be adjusted.
5 Adjustments 5.5 Service Manual PAM 3600 Adjusting the Sensors of the Printhead After replacing a sensor it is necessary to align the concerning sensor of the printhead. By watching the concerning LEDs on the applicator control PCB the correct adjustment of the printhead can be checked. If one of the LEDs is not shining during the printhead movement the sensor has to be adjusted. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR VACUUM 1 LIFT CYL.
Service Manual PAM 3600 5.6 5 Adjustments Adjusting the Torques at the Hubs The rewinders for the transfer ribbon and the media are equipped with slip clutches. The transfer ribbon supply hub is braked during printing by another slip clutch. The slip clutches are used to adjust the torques of the hubs.
5 Adjustments Service Manual PAM 3600 Measuring the Traction at the Ribbon Take Up and the Ribbon Supply Hub The traction at the ribbon take up and at the supply hub is measured by using a test collar (Part no. 5534199). In this case the distance l results from the radius of the test collar (30 mm). 1 2 3 1 Bereit 4 2 Bereit Figure 5i Measuring the traction at the hubs of the transfer ribbon 1 2 3 4 Spring scale, 10 N Test collar Ribbon take up hub Ribbon supply hub 1.
Service Manual PAM 3600 5 Adjustments Adjusting the Torques If the measured values differ from the set values proceed the adjustment as follows.
5 Adjustments 5.7 Service Manual PAM 3600 Adjusting the Brake at the Media Supply Hub The media supply hub is equipped with a brake system. The torque of this system is depending by the position of the swing arm (1).
Service Manual PAM 3600 5.8 5 Adjustments Adjusting the Label Edge Sensor To adjust the label edge sensor see section 2.4. 5.9 Setting the Speed of the Compressed Air Driven Assemblies Setting the Speed of the Peel-off Table Movement 1 2 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE VACUUM BLOWAIR The speed of the peel-off table movement can be set via two valves. Those valves regulate the speed of the compressed air.
5 Adjustments Service Manual PAM 3600 Setting the Speed of the Printhead Movement 2 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR 1 VACUUM The speed of the printhead movement can be set via two valves. Those valves regulate the speed of the compressed air. 3 Figure 5n Setting the speed of the printhead movement 1 Valve for upward movement 2 Valve for downward movement 3 Valve key printhead 1. Remove the cover. 2. Turn one of the valves (1, 2) to regulate the speed.
Service Manual PAM 3600 5 Adjustments Setting the Speed of the Turn/Lift Cylinder Movement LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR VACUUM The speed of the turn cylinder (PAM 3602) respective the lift cylinder (PAM 3603) movement also can be set via two valves.
5 Adjustments Service Manual PAM 3600 Setting the Speed of the Main Cylinder Movement The speed of the lift cylinder movement can be set via two throttle valves which are mounted on the cylinder. Those valves regulate the speed with which the compressed air escapes the two air containers. 2 3 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR 1 VACUUM The valves are adjustable by turning the respective throttle screws.
Service Manual PAM 3600 5 Adjustments 5.10 Pneumatic Setting of the Printhead Pressure 1 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR VACUUM If there are problems with the print quality the pressure of the printhead can be measured and adjusted to the recommended value. 2 3 4 2 5 6 Figure 5q Setting the printhead pressure 1 2 3 4 5 6 Screw Tube Valve key printhead Tube T-fitting Manometer 1. Switch off the printer, switch off the compressed air. 2. Remove the cover.
5 Adjustments Service Manual PAM 3600 5.11 Pneumatic Setting of the Brake 1 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR VACUUM If there are problems with the brake during operation the pressure of the brake can be measured and adjusted to the recommended value. 2 3 2 4 5 Figure 5r Setting the pressure on the brake 1 2 3 4 5 Screw Tube Tube T-fitting Manometer 1. Switch off the printer, switch off the compressed air. 2. Remove the cover. 3.
Service Manual PAM 3600 5 Adjustments 5.12 Pneumatic Setting of the Supporting Air If a blow tube is installed sometimes it is necessary to set the strength of the supporting air. 1 LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR VACUUM It is dependent from the size and the format of the label. 2 Figure 5s Setting the strength of the supporting air 1 Screw 2 Valve key supporting air 1. Remove the cover. 2.
5 Adjustments Service Manual PAM 3600 5.13 Pneumatic Setting of the Table If there are problems with the table during operation the pressure of the table can be measured and adjusted to the recommended value. LIFT CYL. ROTATE CYL. PRINT HEAD TABLE SUPPORT AIR BRAKE BLOWAIR VACUUM View A A 8 6 4 12 psi 14 2 bar 0 1 2 10 100 150 H5/06 50 200 1bar=0,1MPa 16 3 4 5 6 4 Figure 5t Setting the pressure on the table 1 2 3 4 5 6 Screw Tube Valve key table Manometer T-fitting Tube 1.
Service Manual PAM 3600 5 Adjustments 5.14 Adjusting the Sensors of the Applicator Module Normally the sensors are adjusted by the factory. But it can be necessary to adjust the sensors e.g. after replacing one of the sensors. Adjusting the Sensor Turn/Lift Cylinder The sensor checks the movement of the turn respective the lift cylinder. PAM 3602: Sensor (1) recognizes if the turn cylinder is in the 90°-position (away from the peel-off edge).
5 Adjustments Service Manual PAM 3600 Adjusting the Labeling Position Sensor This sensor checks if the main cylinder reaches the application position. If the pad is in the position to apply the label (lower end position) the integrated LED is switched on. The labeling pressure for stamping the label onto the product can be altered by moving the labeling position sensor. 1 2 Figure 5v Adjusting the labeling position sensor 1 Screw 2 Sensor 1. Switch off the compressed air. 2. Loosen the screw (1). 3.
Service Manual PAM 3600 5 Adjustments Adjusting the Sensor 1 Main Cylinder The sensor checks if the main cylinder reaches its upper end position. If the sensor is adjusted exactly the integrated LED is switched on. 1 2 3 Figure 5w Adjusting the sensor 1 main cylinder 1 Sensor 2 Screw 3 Holder 1. Switch off the compressed air. 2. Check the integrated LED. The LED is switched on if the sensor (1) is adjusted correctly in the upper end position. 3.
5 Adjustments Service Manual PAM 3600 Adjusting the Sensors 2 Main Cylinder (PAM 3602 only) There are two sensors 2 main cylinder to check if the pad reaches the intermediate position correctly. At the intermediate position the turn cylinder carries out the swing movement of the pad. It is very important that the pad swings without damage. For that reason the area for the swing movement has to be free.
Service Manual PAM 3600 6 Problem Solution 6 Problem Solution 6.1 Errors During Printing Error Cause and Solution The printer has a print job but does not print 1. The input signals to start the print of every single label is not connected or not used; check the connections at the PLC interface. Transfer ribbon wrinkles 1. Printhead balance is not correctly adjusted; re-adjust the printhead balance (see Operator‘s Manual). 2. Transfer ribbon is too wide; use transfer ribbon which is max.
6 Problem Solution Service Manual PAM 3600 Error Cause and Solution Table is not in its front position; error message "Table not in frt" is shown in the display.. 1. 2. 3. 4. PAM 3602: Turn cylinder has not left the 90°/180°-position. PAM 3603: Small lift cylinder has not left the retracted position. Error message "Nozzle 0° error" is shown in the display. 1. Loss of compressed air, check all connections. 2. Sensor turn/lift cylinder defective, replace it. 3.
Service Manual PAM 3600 6.2 6 Problem Solution Failure of Device Functions Error Possible Solutions No movement of material 1. Mechanical check of the gears and belts, replace damaged gears or belts. 2. Replace CPU PCB. 3. Replace stepper motor. No printing (no printed image) 1. 2. 3. 4. No display and navigator pad function 1. Check whether LED1 (green) on CPU PCB is on. If LED1 is off --> Power unit or CPU PCB is defective.
6 Problem Solution 6.3 Service Manual PAM 3600 Permanently Displayed Hardware Errors Error Message Possible Solutions ADC malfunction Error of CPU PCB; replace PCB. dRAM malfunction Error of CPU PCB; replace PCB. FPGA malfunction Error of CPU PCB; replace PCB. Head open Error of sensor transport locking roller; check sensor, adjust switch lever, replace sensor if necessary. Invalid setup Error of CPU PCB; carry out a firmware update, replace PCB.
Service Manual PAM 3600 Appendix A: Block Diagram Appendix A: Block Diagram Printer Applicator System PAM 3600 A-1
Appendix A: Block Diagram A-2 Service Manual PAM 3600 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams Appendix B: Circuit Diagrams PCB CPU: CPU, Clock Timer, Clock, BDM Printer Applicator System PAM 3600 B-1
Appendix B: Circuit Diagrams Service Manual PAM 3600 PCB CPU: Centronics, Interface Slot, RS-232 B-2 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams PCB CPU: dRAM, Flash Printer Applicator System PAM 3600 B-3
Appendix B: Circuit Diagrams Service Manual PAM 3600 PCB CPU: Printhead Connection B-4 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams PCB CPU: FPGA, History RAM Printer Applicator System PAM 3600 B-5
Appendix B: Circuit Diagrams Service Manual PAM 3600 PCB CPU: Power Supply, Motor Driver B-6 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams PCB CPU: Sensors, AD Converter Printer Applicator System PAM 3600 B-7
Appendix B: Circuit Diagrams Service Manual PAM 3600 PCB CPU: USB Host B-8 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams PCB 1 Control Panel Printer Applicator System PAM 3600 B-9
Appendix B: Circuit Diagrams Service Manual PAM 3600 PCB Control Panel B-10 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams PCB Applicator Control: Controller Printer Applicator System PAM 3600 B-11
Appendix B: Circuit Diagrams Service Manual PAM 3600 PCB Applicator Control: Inputs/Outputs B-12 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix B: Circuit Diagrams PCB Valve Connection PCB Ribbon Sensor Printer Applicator System PAM 3600 B-13
Appendix B: Circuit Diagrams B-14 Service Manual PAM 3600 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix C: Layout Diagrams Appendix C: Layout Diagrams PCB CPU: Components side Printer Applicator System PAM 3600 C-1
8 9 7 4 5 1 3 C-2 6 2 1 - GND 2 - 3,3 V 3-5V 4 - VMOT 5 - 24 V 6 - 1,8 V 7 - 2,5 V 8 - 24 V ext.
Service Manual PAM 3600 Appendix C: Layout Diagrams PCB 1 Control Panel: Components side PCB 1 Control Panel: Soldering side PCB Control Panel Printer Applicator System PAM 3600 C-3
Appendix C: Layout Diagrams Service Manual PAM 3600 PCB Applicator Control: Components side PCB Applicator control: Soldering side C-4 Printer Applicator System PAM 3600
Service Manual PAM 3600 Appendix C: Layout Diagrams PCB Valve Connection PCB Ribbon Sensor: Components side PCB Ribbon Sensor: Soldering side Printer Applicator System PAM 3600 C-5
Appendix C: Layout Diagrams C-6 Service Manual PAM 3600 Printer Applicator System PAM 3600
Printer Applicator System PAM 3600 14 PRINTER MANIFOLD ASSY. 2 Support air 5 1 3 4 Support air 12 14 2 14 Printhead 2 14 5 1 3 4 12 Vacuum 5 1 3 4 Printhead 12 14 2 Brake 5 1 3 4 Brake 2 Blow air 5 1 3 4 12 14 2 12 Table 14 5 1 3 4 2 5 1 3 4 2 5 1 3 4 12 Main cyl. Turn cylinder 12 14 Table 1 5 84 82 12 1 2 3 EXHAUST GAS SUPPLY VE1 P E V VIDE VACUUM SENSOR ASSY.
D-2 14 PRINTER MANIFOLD ASSY. 2 Support air 5 1 3 4 Support air 12 14 2 14 Printhead 2 14 5 1 3 4 12 Vacuum 5 1 3 4 Printhead 12 14 2 Brake 5 1 3 4 Brake 2 Blow air 5 1 3 4 12 14 2 12 Table 14 5 1 3 4 2 5 1 3 4 Lift cylinder 12 14 Table 2 12 Main cyl. 5 1 3 4 1 5 84 82 12 1 2 3 EXHAUST GAS SUPPLY VE1 P E V VIDE VACUUM SENSOR ASSY.
Service Manual PAM 3600 Index Index A L Adjust gap sensor................................................................20 Label edge sensor, adjusting...............................................20 Antistatic burst.....................................................................10 Label edge sensor, replacing..............................................32 Applicator control PCB, replacing........................................40 Labeling position sensor, adjusting.........................
Index Service Manual PAM 3600 R Ribbon supply hub.................................................................8 Ribbon supply hub, measuring the traction.........................54 Ribbon supply hub, slip clutch.............................................35 Ribbon take up hub...............................................................8 Ribbon take up hub, measuring the traction........................54 Ribbon take up hub, slip clutch...........................................34 S Save NVRAM......
