Brady PAM 3600 User manual
Printer Applicator System
PAM 3600
Service Manual
Edition 1/07
All specications about delivery, design, performance and weight are given to the best of our current knowledge and are
subject to change without prior notice.
W.H. Brady
Lindestraat 21
Industriepark C3
9240 Zele Belgium
Phone: +32 52 457 811
e-mail: support@brady.be
Identication 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 3600
Service Manual PAM 3600 Table of Contents
Table of Contents
1 Introduction................................................................................................................................................5
1.1 Scope of Information ................................................................................................................................... 5
1.2 Important Information .................................................................................................................................. 5
1.3 General Safety Instructions ......................................................................................................................... 6
1.4 Safe Handling of Electricity .......................................................................................................................... 7
1.5 Printer Types ............................................................................................................................................... 7
1.6 Component Location ................................................................................................................................... 8
Printer .................................................................................................................................................... 8
Applicators ............................................................................................................................................. 9
Options................................................................................................................................................. 10
2 Expanded Functions for Servicing........................................................................................................ 11
2.1 The Service Key and the OEM Key ............................................................................................................11
2.2 Expanded Functions in the "Setup" Menu ................................................................................................. 12
Print Parameters .................................................................................................................................. 12
Interfaces ............................................................................................................................................. 12
2.3 Expanded Functions in the "Test" Menu .................................................................................................... 13
Status Print .......................................................................................................................................... 13
Device List ........................................................................................................................................... 15
Label Prole ......................................................................................................................................... 16
Printhead Prole .................................................................................................................................. 16
Event Log ............................................................................................................................................. 18
Print Directory of IFFS ......................................................................................................................... 18
2.4 Expanded functions in the "Service" Menu ................................................................................................ 19
Clearing the Service Counter ............................................................................................................... 19
Adjusting the Label Edge Sensor......................................................................................................... 20
Saving the NVRAM .............................................................................................................................. 20
Loading the NVRAM ............................................................................................................................ 21
Setting the Device Name ..................................................................................................................... 21
3 Maintenance.............................................................................................................................................22
3.1 General Cleaning ...................................................................................................................................... 22
3.2 Cleaning the Printhead .............................................................................................................................. 22
3.3 Cleaning the Print Roller and the Transport System ................................................................................. 23
3.4 Cleaning the Brake .................................................................................................................................... 24
3.5 Cleaning the Pad ....................................................................................................................................... 25
4 Replacing Assembly Units......................................................................................................................26
4.1 Recommended Tools ................................................................................................................................. 26
Standard Tools ..................................................................................................................................... 26
Special Tools ........................................................................................................................................ 26
4.2 Replacing the Printhead ............................................................................................................................ 27
4.3 Replacing the Print Roller and the Feed Roller ......................................................................................... 28
4.4 Replacing the Transport Locking Roller ..................................................................................................... 29
4.5 Replacing the Pinch Roller ........................................................................................................................ 30
4.6 Replacing the Label Edge Sensor ............................................................................................................. 32
4.7 Replacing the Slip Clutches ....................................................................................................................... 33
Replacing the Slip Clutch on the Ribbon Take Up Hub ........................................................................ 34
Replacing the Slip Clutch on the Ribbon Supply Hub .......................................................................... 35
Replacing the Slip Clutch on the Internal Rewinder............................................................................. 35
4.8 Replacing the Main Drive Motor ................................................................................................................ 36
4.9 Replacing the CPU PCB ............................................................................................................................ 37
4.10 Replacing the Power Unit .......................................................................................................................... 39
4.11 Replacing the Applicator Control PCB and Firmware Update of the Applicator Module ............................ 40
4.12 Replacing the Sensors .............................................................................................................................. 41
Sensors of the Printer Module ............................................................................................................. 41
Sensors of the Applicator Module ........................................................................................................ 46
4.13 Disassembling the Energy-Chains ............................................................................................................ 47
5 Adjustments.............................................................................................................................................48
5.1 Adjusting the Peel-off Table ....................................................................................................................... 48
5.2 Adjusting the Printhead ............................................................................................................................. 49
4Printer Applicator System PAM 3600
Service Manual PAM 3600Table of Contents
5.3 Adjusting the Guide Plate .......................................................................................................................... 50
5.4 Adjusting the Sensors of the Peel-off Table ............................................................................................... 51
5.5 Adjusting the Sensors of the Printhead ..................................................................................................... 52
5.6 Adjusting the Torques at the Hubs ............................................................................................................. 53
Measuring the Traction at the Internal Rewinder ................................................................................. 53
Measuring the Traction at the Ribbon Take Up and the Ribbon Supply Hub ....................................... 54
Adjusting the Torques .......................................................................................................................... 55
5.7 Adjusting the Brake at the Media Supply Hub ........................................................................................... 56
5.8 Adjusting the Label Edge Sensor .............................................................................................................. 57
5.9 Setting the Speed of the Compressed Air Driven Assemblies ................................................................... 57
Setting the Speed of the Peel-off Table Movement .............................................................................. 57
Setting the Speed of the Printhead Movement .................................................................................... 58
Setting the Speed of the Turn/Lift Cylinder Movement ........................................................................ 59
Setting the Speed of the Main Cylinder Movement.............................................................................. 60
5.10 Pneumatic Setting of the Printhead Pressure ............................................................................................ 61
5.11 Pneumatic Setting of the Brake ................................................................................................................. 62
5.12 Pneumatic Setting of the Supporting Air .................................................................................................... 63
5.13 Pneumatic Setting of the Table .................................................................................................................. 64
5.14 Adjusting the Sensors of the Applicator Module ........................................................................................ 65
Adjusting the Sensor Turn/Lift Cylinder................................................................................................ 65
Adjusting the Labeling Position Sensor ............................................................................................... 66
Adjusting the Sensor 1 Main Cylinder .................................................................................................. 67
Adjusting the Sensors 2 Main Cylinder (PAM 3602 only) .................................................................... 68
6 Problem Solution.....................................................................................................................................69
6.1 Errors During Printing ................................................................................................................................ 69
6.2 Failure of Device Functions ....................................................................................................................... 71
6.3 Permanently Displayed Hardware Errors .................................................................................................. 72
Appendix A: Block Diagram............................................................................................................................. A-1
Appendix B: Circuit Diagrams......................................................................................................................... B-1
PCB CPU: CPU, Clock Timer, Clock, BDM..........................................................................................................B-1
PCB CPU: Centronics, Interface Slot, RS-232 ....................................................................................................B-2
PCB CPU: dRAM, Flash ......................................................................................................................................B-3
PCB CPU: Printhead Connection ........................................................................................................................B-4
PCB CPU: FPGA, History RAM ...........................................................................................................................B-5
PCB CPU: Power Supply, Motor Driver ...............................................................................................................B-6
PCB CPU: Sensors, AD Converter ......................................................................................................................B-7
PCB CPU: USB Host ...........................................................................................................................................B-8
PCB 1 Control Panel ............................................................................................................................................B-9
PCB Control Panel .............................................................................................................................................B-10
PCB Applicator Control: Controller.....................................................................................................................B-11
PCB Applicator Control: Inputs/Outputs .............................................................................................................B-12
PCB Valve Connection .......................................................................................................................................B-13
PCB Ribbon Sensor ...........................................................................................................................................B-13
Appendix C: Layout Diagrams......................................................................................................................... C-1
PCB CPU: Components side .............................................................................................................................. C-1
PCB CPU: Soldering side ................................................................................................................................... C-2
PCB 1 Control Panel: Components side ............................................................................................................. C-3
PCB 1 Control Panel: Soldering side .................................................................................................................. C-3
PCB Control Panel .............................................................................................................................................. C-3
PCB Applicator Control: Components side ......................................................................................................... C-4
PCB Applicator control: Soldering side ............................................................................................................... C-4
PCB Valve Connection ........................................................................................................................................ C-5
PCB Ribbon Sensor: Components side .............................................................................................................. C-5
PCB Ribbon Sensor: Soldering side ................................................................................................................... C-5
Appendix D: Pneumatic Diagrams .................................................................................................................. D-1
PAM 3600 with Applicator 3602 .......................................................................................................................... D-1
PAM 3600 with Applicator 3603 .......................................................................................................................... D-2
Index I-1
5
Printer Applicator System PAM 3600
Service Manual PAM 3600 1 Introduction
1 Introduction
1.1 Scope of Information
This manual is intended for use by qualied 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.
1.2 Important Information
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.
In special cases a second symbol is additionally used to characterize the kind of danger.
See a sample for the risk of electric shock:
WARNING!
Mortal danger by electric shock!
Unplug power cord before opening the cover!
6Printer Applicator System PAM 3600
Service Manual PAM 36001 Introduction
1.3 General Safety Instructions
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!
Keep housing or other parts of the device removed in a safe place 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!
Mortal danger by electric shock!
If such metal parts contact the device, they cause an increased current ow due to
good conductivity!
Wear protective goggles at work as follows:
while driving pins or similar parts in or out with a hammer,
while working at an electric drilling machine,
while using spring hooks or springs,
while releasing or using of springs, snap rings and grip rings,
while soldering,
while using solvents, cleansers or other chemical substances,
in any case where injury to the eyes is possible.
Ret all protective devices such as covers, safety instructions, and grounding cable upon completion of the
maintenance work!
Replace all faulty or defective parts!
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Printer Applicator System PAM 3600
Service Manual PAM 3600 1 Introduction
1.4 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 them quickly 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 in the immediate vicinity of 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 nished.
NOTICE!
A shock occurs only with a closed circuit. By using only one hand, as described above, you
would avoid a current ow through your own body.
Do not use worn or defective tools!
Never assume that a circuit is not powered. Always verify that there is no voltage present!
Always examine the work area for possible sources of danger, such as wet oors, 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 rst aid if necessary.
1.5 Printer Types
There are two printers for the PAM 3600 systems available:
PAM 3630 with a printhead resolution of 300 dpi and
PAM 3660 with a printhead resolution of 600 dpi.
Both printers can be equipped with one of the applicator types
PAM 3602, tamp-blow applicator with vertical lift (main) cylinder and turn cylinder and
PAM 3603, tamp-blow applicator with vertical lift (main) cylinder and horizontal lift cylinder.
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8Printer Applicator System PAM 3600
Service Manual PAM 36001 Introduction
1.6 Component Location
Printer
Figure 1a Overview printer
1 Ribbon take up hub
2 Control panel and display
3 Ribbon supply hub
4 Swing arm with guide roller
5 Guide roller
6 Media supply hub
7 Internal rewinder
8 Power connector
9 Power switch
10 Compressed air connector
11 Silencers
12 Frame
13 Sensor connector for the applicator
14 Compressed air connectors for the applicator
15 Printhead
16 Print roller
17 Peel-off table
18 Guide roller
19 Slot for an additional interface card
20 Connector warning sensor ribbon end
21 Connector warning sensor label end
22 PLC interface port
23 Connector warning light
24 RS-232 interface
25 USB master interface
26 Bi-directional parallel interface
27 Cover
21 22 23 24 25 26 272019
17 18
1 3 4 5 6 7 89
21110 12 1413
1615
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Printer Applicator System PAM 3600
Service Manual PAM 3600 1 Introduction
Applicators
PAM 3602 PAM 3603
Figure 1b Overview applicators
1 Energy-chains
2 Sensor 1 main cylinder
3 Main cylinder
4 Sensor 2 main cylinder (PAM 3602 only)
5 Slide valve
6 Lift cylinder (PAM 3603 only)
7 Turn cylinder (PAM 3602 only)
8 Pad holder
9 Pad
1
2
4
3
4
5
8
9
7
6
10 Printer Applicator System PAM 3600
Service Manual PAM 36001 Introduction
Options
Figure 1c Overview options
1 Warning light
2 Warning sensor, ribbon end
3 Warning sensor, label end
4 Antistatic burst
5 Blow tube
1
2
3
4
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