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Printronix P7000 Series User Manual

Printronix P7000 Series
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Maintenance Manual
Printronix P7000 Series of Line Matrix Printers

Table of Contents

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Printronix P7000 Series Specifications

General IconGeneral
Print TechnologyLine Matrix
Resolution180 x 144 DPI
ConnectivityEthernet, Parallel, Serial
Paper HandlingFanfold paper
Noise Level55 dBA (depending on model)
DimensionsVaries by model
WeightVaries by model

Summary

1 Maintenance Overview

Printronix P7000 Printers

Introduces the P7000 printers, PSA3 architecture, controller boards, and features.

Order The Correct Spares

Guidance on ordering correct spare parts for P7000 printers.

How To Identify A P7000 Printer

Explains how to identify a P7000 printer model based on its alphanumeric code.

H-Series Printers

Details H-Series models for specific regions and their unique platens/shuttles.

HD Printers

Explains HD printers using Windows drivers and LQ1600K emulation for high-res output.

Zero Tear Pedestal (ZTP) Printers

Describes ZTP printers' special hardware/software for seamless form ejection.

Printer Configuration Code

Forms Handling

Details paper handling for pedestal and cabinet models.

Important Maintenance Notes

Notices

Explains the meaning of WARNING, CAUTION, IMPORTANT, and NOTE headings.

About This Manual

How To Use This Manual

Provides a systematic approach to maintenance tasks and understanding the manual.

Printing Conventions In This Manual

Explains how control panel keys, messages, and key combinations are highlighted.

Safety Notices

Hinweise zur Sicherheit

German safety notices regarding maintenance, cleaning, and handling.

Controls And Indicators

Electrical Controls

Details the function of each electrical control and indicator on the printer.

Mechanical Controls

Explains the function of various mechanical controls for paper handling and alignment.

Tools And Test Equipment

Plugging In The Printer

Power Cord Requirements

Outlines safety standards and requirements for the printer's power cord.

Interface Cable Requirements

Details specifications for interface cables to comply with EMC regulations.

Printronix Customer Support Center

Printronix Supplies Department

Contact information for ordering genuine Printronix supplies.

Maintenance Training For Printronix Products

2 Preventive Maintenance

Cleaning The Printer

Importance and necessity of periodic cleaning for printer life and reliability.

Cleaning The Outside Surfaces

Step-by-step instructions for cleaning the printer's exterior surfaces.

Cleaning The Shuttle Frame Assembly

Detailed steps for cleaning the shuttle frame assembly and its components.

Cleaning The Card Cage Fan Assembly

Procedures for cleaning the card cage fan assembly and surrounding areas.

3 Troubleshooting

Introduction

Lists fault messages and general symptoms for troubleshooting printer malfunctions.

Troubleshooting Aids

Lists aids within the manual to help isolate printer malfunctions.

Start Here...

Troubleshooting Display Messages

List Of Messages

Provides a table of P7000 ASCII (Spool) error messages with explanations and solutions.

Troubleshooting Other Symptoms

General Symptom List

Lists printer problems not indicated by LCD messages with troubleshooting procedures.

Communications Failures

Table 7. Communications Problems

Lists common causes and solutions for communication problems across interfaces.

Diagnostic Printer Tests

Selecting And Running Diagnostic Printer Tests

Provides steps and LCD results for selecting and running diagnostic tests.

Boot Diagnostics Menu

Activating The Boot Diagnostics Menu

Steps to access the boot diagnostics menu by holding specific keys while powering on.

Exiting The Boot Diagnostics Menu

Describes two methods for exiting the boot diagnostics menu.

Factory Menu

Entering The Factory Menu

Instructions for accessing the Factory menu by holding specific keys.

Exiting The Factory Menu

Instructions for exiting the Factory menu by pressing the ON LINE key.

Exception Menu

The exception menu is only accessible when certain faults occur.

Explains accessing the Exception Menu for fault-specific troubleshooting information.

Hex Code Printout

How To Print A Hex Dump

Step-by-step instructions on how to generate a hex dump for troubleshooting.

ASCII Character Set

Soft vs. Hard Reset

Soft Reset

Explains a software reset that clears memory and loads power-up configuration.

Hard Reset (“Cycle Power”)

Describes a hard reset as power shutdown and restart, running initialization and diagnostics.

4 Adjustments and Tests

Introduction

Outlines the need for occasional adjustments and tests as part of maintenance.

Adjustments and Tests

Lists various adjustment and test procedures with corresponding page numbers.

Preparing The Printer For Maintenance

Returning The Printer To Normal Operation

Belt, Paper Feed Timing, Adjustment

Belt, Platen Open, Adjustment

Paper Scale Alignment

Platen Gap Adjustment

Ribbon Guide Alignment

Paper Out Adjustment

Hammer Phasing Adjustment

Loading Flash Memory

Loading Software With The Firmware Download Utility

Instructions for loading program files using the Firmware Download Utility.

Loading Through Parallel Port Using DOS

Instructions for loading software via the parallel port using DOS commands.

Loading Software If Flash Contains Only Boot Code

Steps for loading software through the parallel port using a three-key sequence.

Loading Software Through The NIC

Instructions for loading software through the Ethernet NIC.

Reprogramming the Security Key

How To Reprogram The Security Key

Procedures for reprogramming the security key using an SPX module.

Coil Temperature Adjustment

Dynamic Paper Tension Adjustment

Tractor Belt Tension Adjustment

Shuttle Electrical Short Check

Hammer Bank Power Cable Shorts Test

Cable Shorts Test

Check for shorts to ground:

Procedure to check cables for shorts to ground.

Check for pin-to-pin shorts:

Procedure to check cables for pin-to-pin shorts.

Main Wire Harness Test Diagnostic

Power Supply Operational Check

5 Replacement Procedures

Organization Of This Chapter

Explains the chapter covers removal/installation procedures for field-replaceable units (FRUs).

Replacement Procedures

General warnings and important notes regarding component replacement.

List Of Removal / Installation Procedures

Lists component replacement procedures with corresponding page numbers.

Belt, Paper Feed Timing

Belt, Platen Open

Circuit Breaker

Connector Coupling Shrouds

Control Panel Assembly

Controller Board

Removal

Details removal of V5 and V6 controller boards, with safety precautions.

Installation

Instructions for installing the controller board, including software download.

Cover Assembly, Hammer Bank / Ribbon Mask

Cover Assembly, Shuttle

Cover Assembly, Top, Pedestal Models

CT Board

Dashpot

Fan Assembly, Cabinet Exhaust

Fan Assembly, Card Cage

Fan Assembly, Hammer Bank

Hammer Spring Assembly, Version 1

Hammer Spring Assembly, Version 2

Installation Using The Short Tip Alignment Tool

Procedure for installing version 2 hammer spring assemblies using a short tip tool.

Installation Using The Long Tip Alignment Tool

Integrated Print Management Sensor

Magnetic Pickup (MPU) Assembly

Memory and Security Key

Removal

Procedures for removing memory modules and the security key.

Installation

Procedures for installing memory modules and the security key.

NIC (Network Interface Card) Assembly

Removal

Procedures for removing the NIC from V5 controller boards.

Installation

Procedures for installing the NIC on V5 controller boards.

Paper Feed Motor

Paper Ironer

Paper Path

Platen

Removal

Detailed procedures for removing the platen.

Installation

Procedures for installing the platen and related components.

Platen Open Motor

Platen Stop Assembly

Power Supply Board

Resistors, Terminating, V5 Controller Board

Removal

Procedures for removing terminating resistor packs from the V5 controller board.

Installation

Procedures for installing resistor packs in the V5 controller board.

Resistors, Terminating, V6 Controller Board

Removal

Procedures for removing resistor packs from the V6 controller board.

Installation

Procedures for installing resistor packs in the V6 controller board.

Ribbon Drive Motor

Ribbon Guide Assembly (L/R)

Shaft, Splined

Removal

Procedures for removing the splined shaft.

Installation

Procedures for installing the splined shaft.

Shaft, Support

Shuttle Frame Assembly

Removal

Procedures for removing the shuttle frame assembly.

Installation

Procedures for installing the shuttle frame assembly.

Spring, Extension, Hammer Bank

Switch Assembly, Paper Detector

Switch Assembly, Platen Interlock

Tractor (L/R)

Removal

Procedures for removing the tractors.

Installation

Procedures for installing the tractors.

Tractor Assembly Support Gate

Removal

Procedures for removing the tractor assembly support gates.

Installation

Procedures for installing the tractor assembly support gates.

6 Illustrated Parts Breakdown

Organization Of This Chapter

Explains the chapter contains drawings of electrical and mechanical assemblies.

Illustrations of Printer Components

Lists illustrations of printer components with corresponding page numbers.

7 Principles Of Operation

Line Matrix Printing

Explains how line matrix printers create characters and graphics using dot patterns.

Printing Rates

Details printer speed metrics (lpm, cpm, ipm) and factors affecting them.

Printing Mechanism

Describes the three integrated subassemblies of the line matrix printing mechanism.

Shuttle Frame Assembly

Hammer Bank Assembly

Describes the hammer bank assembly and hammer spring counts.

Shuttle Drive Motor

Hammer Springs and Hammer Bank (Detail)

Details hammer springs and hammer bank components, including magnetic attraction.

Paper Transport System

Ribbon Transport System

Integrated Print Management System

Operation

Details how ribbon ink consumption is displayed and managed.

Control Panel Menus

Defines options within the ZTP SETTINGS menu.

Ribbon End Point

Explains setting the ribbon life tracking based on print density.

Ribbon Action

Defines default and alternative ribbon end point actions.

Ribbon Installation And Detection

The Ribbon Log

Describes how the printer identifies ribbons and logs depleted ribbons.

Logical Control Of The Printer

Control Panel

Explains user interaction via the control panel keys and LCD.

Controller Board

Data Controller (DC)

Lists the responsibilities of the Data Controller (DC).

Engine Controller (EC)

Lists the responsibilities of the Engine Controller (EC).

Data Controller

MPC8245 Microprocessor

Identifies the MPC8245 microprocessor as the DC unit's processor.

Flash Memory

Explains flash memory storage for code, its characteristics, and capacity.

SDRAM

Explains System SDRAM usage for program variables and buffers.

NVRAM

Describes NVRAM for storing configuration and statistical data.

V8 ASIC

Memory Access Controller

Explains how the V8 ASIC handles addresses and chip selects.

SDRAM Controller

Specifies V8 support for SDRAM banks.

Flash Controller

Specifies V8 support for flash memory banks.

DMA Channels

Describes DMA channels for direct memory access.

Control Panel Interface

Details the V8's handling of the control panel interface.

“Dot Plucking” And Adjacent Dot Checking

Explains "Dot Plucking" as a DMA function controlled by the EC.

“Cajun” Bus Interface

Ports

Lists the I/O functions controlled by the V8 ASIC.

Host I/O Drivers And Termination

Describes support circuitry for serial and parallel interfaces.

Engine Controller

80C167 Microcontroller

Describes the 80C167 microcontroller and its role as the EC.

Bus Configuration

Details the 80C167 bus configuration for address, data, and operation.

Power Reduction

Explains the 80C167 chip's power reduction modes: idle and Energy Star.

EC Flash Memory

Describes the EC's local flash memory for boot code, program code, and tables.

MECA ASIC

Explains the MECA ASIC's role in controlling printer motor functions.

Analog Drive Circuitry

Details analog drive circuits for motors and hammers, and sensor monitoring.

Power Supply Board

AC Power

Details AC voltage input tolerance and overvoltage protection.

DC Power

Explains the two DC power supply systems (+5V for logic, +48V/+8.5V for motors/hammers).

Printer Interface

Graphics

Introduces VGL and PGL programming languages for creating forms, bar codes, and graphics.

A Wire Data

Interconnection Diagram

Provides a block diagram of the printer's interconnection of subsystems.

Cable Routing, Cabinet Model

Illustrates cable routing for cabinet models.

Cable Routing, Pedestal Model

Illustrates cable routing for pedestal models.

Main Wire Harness Test Tables

Provides tables for testing continuity and shorts in main wire harness components.

Circuit Board Pinouts

Details pinouts for V5 and V6 controller boards.

Power Supply: P7X05, P7X10, P7X02H, and P7X03H

Provides a schematic for power supplies used in specific P7X00 models.

Power Supply: P7X06H and P7X15

Provides a schematic for power supplies used in specific P7X00 models.

Power Supply: P7000HD, P7X08H, and P7220

Provides a schematic for power supplies used in specific P7000 models.

CT Board

Provides a schematic for the CT board, including Twinax and Coax connections.

SureStak Power Stacker PCBA

Provides a schematic for the SureStak Power Stacker PCBA, showing motors and sensors.

Cable Assembly, Centronics I/O (P/N 152439-901)

Details the Centronics I/O cable assembly specifications and important notes.

Cable Assembly, Centronics-to-Dataproducts Adapter (P/N 154695-001)

Provides a diagram and pinout for the Centronics-to-Dataproducts adapter cable.

Cable Assembly, Twinax Auto-Termination (P/N 140752-002)

Provides a schematic and resistance chart for the Twinax Auto-Termination cable.

Cable Extension, Smart-T (P/N 204806-901)

Illustrates the Smart-T cable extension.

Cable Assembly, 2-Pin Jumper, 0.1 Ctr (P/N 154470-901)

Illustrates a 2-pin jumper cable assembly.

Cable Assembly, AC In, Power Supply (AC Kit P/N 153502-901)

Illustrates the AC input power supply cable assembly.

Cable Assembly, AC Power Input (AC Kit P/N 153502-901)

Illustrates the AC power input cable assembly.

Cable Assy, PS I/O (P/N 176601-901)

Illustrates the PS I/O cable assembly and its applicability.

Cable Assembly, Card Cage Fan (P/N 152422-901)

Illustrates the cable assembly for the card cage fan.

Cable Assembly, Control Panel (P/N 152440-901)

Illustrates the cable assembly for the control panel.

Cable Assembly, Exhaust Fan (P/N 152424-901)

Illustrates the cable assembly for the exhaust fan.

Cable Assembly, Hammer Bank Logic (P/N 152421-901)

Illustrates the cable assembly for the hammer bank logic.

Cable Assy, Hammer Bank Power (P/N 164805-901)

Illustrates the hammer bank power cable assembly and its usage.

Cable Assy, Dual Hammer Bank Power (P/N 173215-901)

Illustrates the dual hammer bank power cable assembly for the P7220 printer.

Cable Assembly, MPU (P/N 152425-901)

Illustrates the cable assembly for the Magnetic Pickup Unit (MPU).

Cable Assembly, Ribbon Guide, P7000

Illustrates the cable assembly for the ribbon guide.

Cable Assembly, Ribbon Motor, Extension (P/N 154067-901)

Illustrates the extension cable assembly for the ribbon motor.

Cable Assembly, Shuttle Motor Drive (P/N 152420-001)

Illustrates the cable assembly for the shuttle motor drive.

Frame Cable, Power Stacker (P/N 173824-001)

Provides a wiring diagram for the power stacker frame cable.

Logic Cable, Power Stacker (P/N 176029-001)

Illustrates the logic cable for the power stacker.

Power Cable, Power Stacker (P/N 174414-001)

Illustrates the power cable for the power stacker.

Rail Cable, Power Stacker (P/N 173823-001)

Provides a wiring diagram for the power stacker rail cable.

Elevator I/O Cable, Power Stacker (P/N 174759-001)

Illustrates the elevator I/O cable assembly for the power stacker.

Fan Assembly, Hammer Bank (P/N 152416-901)

Illustrates the cable assembly for the hammer bank fan.

Magnetic Pickup (MPU) Assembly (P/N 150281-901)

Illustrates the MPU assembly and its wire table.

Switch Assembly, Paper Detector (P/N 152415-901)

Illustrates the paper detector switch assembly and its wire table.

Switch Assembly, Platen Interlock (P/N 152417-901)

Illustrates the platen interlock switch assembly and its wire table.

D SureStak™ Power Stacker

Introduction

Introduces the SureStak Power Stacker as an option for printers.

Stacker Operation

Describes the mechanical operation of the power stacker.

Setting Up The Power Stacker

Instructions for setting up the power stacker.

Loading And Starting The Power Stacker

Steps for loading paper and starting the power stacker.

Stacker Problems

Lists common stacker problems and refers to troubleshooting.

Stacker First Inspection

Initial inspection steps for the power stacker.

Stacker Confidence Check

Procedures to verify proper connection and operation of stacker components.

Stacker Motor Check

Checks stacker motors and cables.

Removing The Power Stacker

Procedures for removing the power stacker assembly.

Installing The Power Stacker

Procedures for installing the power stacker assembly.

Replacement Procedures

Procedures for replacing the constant force spring.

Replacing The Timing Belts

Procedures for removing and replacing the timing belts.

Replacing The Roller Drive Shaft

Procedures for replacing the roller drive shaft.

Illustrated Parts Breakdown

Refers to illustrations and part lists for the power stacker.

E Zero Tear Pedestal (ZTP) Printer

Overview

Provides an overview of the ZTP printer's capabilities.

Operation

Covers ZTP printer operation, including paper loading and setup.

Load Paper And Set Up The Tractors

Instructions for loading paper and setting up tractors on the ZTP printer.

Remove Paper

Instructions for removing paper from the ZTP printer.

Adjust The Paper Guides

Procedures for adjusting the paper guide leaves.

Position The Paper Out Sensor

Instructions for positioning the paper out sensor for optimal performance.

Set The Tear Bar Distance

Procedure to set the tear bar distance for proper form ejection.

Set The Top Of Form

Procedure to set the top-of-form position for accurate printing.

Control Panel Menus

Defines options within the ZTP SETTINGS menu.

Performance Limitations

Lists specified continuous form paper types and their ranges.

Adjustments And Tests

Lists procedures for ZTP printer adjustments and tests.

Preparing The ZTP Printer for Maintenance

Steps to prepare the ZTP printer for maintenance.

Returning The Printer To Normal Operation

Steps to return the ZTP printer to normal operation.

Barrier Panel

Procedures for removing and installing the barrier panel.

Belt, Paper Feed Timing, Adjustment

Procedures for adjusting the paper feed timing belt.

Paper Guide Leaf, Front, Center, Outer

Procedures for adjusting paper guide leaves.

Paper Out Sensor, Adjustment

Procedure for adjusting the paper out sensor.

Paper Tension, Horizontal

Procedure for adjusting horizontal paper tension.

Replacement Procedures

Lists component replacement procedures with corresponding page numbers.

Belt, Paper Feed Timing

Procedures for replacing the paper feed timing belt.

Control Panel Assembly

Procedures for replacing the control panel assembly.

Cover Assembly, Top, Pedestal Models

Procedures for replacing the top cover assembly.

Paper Feed Motor

Procedures for replacing the paper feed motor.

Paper Guide Leaf, Center

Procedures for replacing the paper guide leaf, center.

Paper Guide Leaf, Front

Procedures for replacing the paper guide leaf, front.

Paper Guide Leaf, Outer

Procedures for replacing the paper guide leaf, outer.

Paper Out Sensor, Adjustment

Procedure for adjusting the paper out sensor.

Shaft, Splined

Procedures for replacing the splined shaft.

Shaft, Support

Procedures for replacing the support shaft.

Tractor (L/R)

Procedures for replacing the left/right tractors.

Tractor Assembly Support Gate

Procedures for replacing the tractor assembly support gate.

F Paper Specifications And Forms Design

Introduction

Divides the appendix into paper specifications and form design sections.

General Paper Specifications

Describes minimum paper specifications for best printer performance.

Environmental Considerations

Advises on proper storage conditions for forms.

Form Types

Lists the three kinds of continuous form paper specified for use.

Form Weight

Specifies the recommended form weight range.

Form Thickness

Specifies the maximum form thickness allowed.

Form Evenness

Specifies maximum acceptable evenness variation.

Tractor Pin Engagement

Refers to specifications for tractor pin engagement.

Paper Guidelines

Terms And Definitions

Provides definitions for terms related to continuous form paper.

Storage And Handling

Summary

Recommends paper conformity to specifications for best printer performance.

Packaging

Advises on using fillers in cartons to protect paper during handling.

Storage

Guidelines for storing cartons to prevent paper damage.

Preconditioning Forms

Advises on protecting paper from temperature and humidity extremes for stabilization.

G Maintenance Manuals For P5000 Printers

Table 12. Early P5000 Single Hammer Bank Printers: Maintenance Manual 164253-001

Provides details for early P5000 single hammer bank printers.

Table 14. P5000 PSA3 Single Hammer Bank Printers: Maintenance Manual 176475-001

Provides details for P5000 PSA3 single hammer bank printers.

Table 15. P5220D and P5224D Dual Hammer Bank Printers: Maintenance Manual 173843-001

Provides details for P5220D and P5224D dual hammer bank printers.

H Customer Support

Printronix Customer Support Center

Information required before calling Printronix Customer Support.

Printronix Supplies Department

Contact information for ordering genuine Printronix supplies.

Corporate Offices

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