Printronix P8000 SERIES Maintenance Manual
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Printronix P8000 SERIES Maintenance Manual

Cartridge ribbon printer series of line matrix printers
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Table of Contents

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Download this manual See also: Administrator's Manual

Maintenance Manual

Printronix P8000 Cartridge Ribbon Printer Series
of Line Matrix Printers

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Do you have a question about the P8000 SERIES and is the answer not in the manual?

Questions and answers

Billy Corts
April 30, 2025

Device not printing parts of document.

0
1 comments:
Mr. Anderson
May 16, 2025

The Printronix P8000 SERIES may not be printing parts of the document due to the following reasons:

1. The forms thickness lever is set too loose or too tight.
2. The paper tension between the tractors is incorrect.
3. The shuttle frame assembly has print chaff, debris, or ink residue.
4. The ribbon is folded or torn.
5. The ribbon mask is bent or deformed.

These issues can affect print quality, causing missing, smeared, or light characters.

This answer is automatically generated

0

Related Manuals for Printronix P8000 SERIES

Summary of Contents for Printronix P8000 SERIES

  • Page 1: Maintenance Manual

    Maintenance Manual Printronix P8000 Cartridge Ribbon Printer Series of Line Matrix Printers...
  • Page 3 P8000 Series Cartridge Ribbon Printer Maintenance Manual...

  • Page 4: Trademark Acknowledgements

    Printronix makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct or indirect, incidental or consequential, in connection with the furnishing, distribution, performance, or use of this material.
  • Page 5 PostScript is a trademark of Adobe Systems Incorporated. PrintNet is a registered trademark of Printronix, Inc. Printronix is a registered trademark of Printronix, Inc. PSA and PSA3 are trademarks of Printronix, Inc. QMS is a registered trademark of Quality Micro Systems.

  • Page 7: Table Of Contents

    Table of Contents 1 Maintenance Overview ......... 15 Printronix P8000 Series Cartridge Ribbon Printer (CRP) .......15 Order the Correct Spares ..............18 Printer Serial Number............... 19 How to Identify a P8000 Cartridge Ribbon Printer ......19 H-Series Printers ................20 HD Printers..................20 Zero Tear Pedestal (ZTP) Printers ...........
  • Page 8 Table of Contents 3 Troubleshooting ............ 47 Introduction ..................... 47 Troubleshooting Aids ................47 Start Here....................48 Troubleshooting Display Messages............49 Diagnostics for EXX, BAD NVM, or ILL NVM Errors ......50 Fault Messages (ASCII in Alphabetical Order) ........51 P8000 CRP H-Series (Numerical Prefix Listing) ......
  • Page 9 Table of Contents Automatic Download (.exe)..............199 Manual Two-Key Download Sequence..........201 Manual Three-Key Download Sequence ..........202 Sending Firmware in Download Mode..........203 Sending Firmware via Ethernet (LPR)..........203 Sending Firmware via USB ............203 Installing a Microsoft Loopback Adapter ........204 Sending Firmware via Parallel............209 Sending Firmware via Serial ............210 Reprogramming the Security Key............211 How to Reprogram the Security Key ..........211...
  • Page 10 Table of Contents Platen Open Motor ................. 248 Platen Stop Assembly ..............250 Power Supply Board ..............251 Power Switch ................. 252 Ribbon Drive Motor ................ 253 Security Key ................... 254 Shaft, Splined ................. 256 Shaft, Support ................258 Shuttle Frame Assembly ..............259 Spring, Extension, Hammerbank ...........
  • Page 11 Table of Contents A Wire Data ............317 Cable Routing ..................320 Low Speed - Cabinet Model ............320 Low Speed - Pedestal Model ............321 High Speed - Cabinet Model ............322 High Speed - Pedestal Model ............323 Low Speed Controller Board..............324 High Speed Controller Board..............334 Power Supply..................343 Low Speed: 300, 500, and 1000 LPM Models .......343 High Speed: 600, 800, 1500, and 2000 LPM Models ....345...
  • Page 12 Table of Contents Control Panel Menus ................435 Performance Considerations ..............436 How to Set the ZTP Printer to Help Mitigate Paper Jams ....437 Removing the Paper Ironer ............438 Adjustments and Tests ................. 439 List of Adjustments and Tests Procedures........439 Preparing the ZTP Printer for Maintenance ........
  • Page 13 Table of Contents Form Design Checklist................482 Summary ....................485 Storage and Handling ..............485 G Customer Support..........487 Printronix Customer Support Center.............487 Printronix Supplies Department ............487 Corporate Offices..................488 H Communication Notices ........489 Notices....................489 Energy Star...................491 Communication Statements..............492 Software License Agreement..............496...
  • Page 14 Table of Contents...

  • Page 15: Maintenance Overview

    The Printronix P8000™ Line Matrix Printing Platform extends the series of technology innovations that cement Printronix’s leadership position. Line matrix printing is Printronix’s flagship technology, and it remains the...
  • Page 16 Chapter Printronix P8000 Series Cartridge Ribbon Printer (CRP) Table 1. P8000 Series Models and Configurations Print Speed Model Number Configuration (Lines per Minute) P8003H P8003HZT P8005 LMPPLS (Line Matrix Printer Pedestal Low Speed) P8005ZT P8010 1000 P8010ZT 1000 P8006H P8006HZT...
  • Page 17 Five printer configurations are available: Tabletop (P80XX or P80XXH) • The tabletop models are designed for space constrained environments, allowing for the printer to be placed on a desk or tabletop for quiet use. • Paper guides allow for paper input under the table or as a small stack on the table.

  • Page 18: Order The Correct Spares

    Chapter Printronix P8000 Series Cartridge Ribbon Printer (CRP) Enclosed Pedestal (P80XX or P80XXH) • The enclosed pedestal model has a lower enclosure that holds the input paper while providing for near silent operation. • The paper enclosure can accommodate a full paper box (12” maximum length forms).

  • Page 19: Printer Serial Number

    Housing Code: 0 = Tabletop, Open Pedestal, Enclosed Pedestal, Zero Tear Pedestal 2 = Cabinet P8003H Printronix Line H = H-Series printer Matrix Printer HD = High Definition printer P8000 CRP Printer ZT = Zero Tear Pedestal printer...

  • Page 20: H-Series Printers

    Chapter Printronix P8000 Series Cartridge Ribbon Printer (CRP) H-Series Printers H-Series models print the ideogrammic symbols used in China, Hong Kong, South Korea, and Taiwan. (See Table 2.) These Kanji/Hanzi/Hangul printers are indicated by the letter H in the model number suffix. (See Figure 1 and Table 2.) H-Series printers have unique shuttle assemblies which are only...

  • Page 21: Printer Configuration Code

    Printer Configuration Code Printer Configuration Code Every printer has a configuration code which specifies the printer’s cabinet type, controller board revision level, V8 ASIC revision level, and MECA ASIC revision level. The configuration code is included in the configuration printout. Figure 2 shows how to interpret the printer’s configuration code.

  • Page 22: Important Maintenance Notes

    Always handle hammersprings by the thick mounting base. • Use only the ribbon cartridges specified in the User’s Manual. Using ribbon cartridges not made by Printronix can lead to degraded print quality, expensive damage to the printer, and can void the owner’s warranty.

  • Page 23: Notices

    IGP/VGL Programmer’s Manual Describes the optional Code V™ Printronix emulation. The Code V Printronix emulation allows the user to create and store forms; generate logos, bar codes, and expanded characters; create other graphics, and merge graphics with alphanumeric data as a document is printed.

  • Page 24: How To Use This Manual

    Chapter About this Manual • LQ-1600K Emulation For The P8000 H-Series Of Line Matrix Printers Programmer’s Reference Manual Defines the host control codes for the LQ-1600K emulation. • KS Programmer’s Reference Manual Defines the host control codes for the KS emulation. •...

  • Page 25: Safety Notices

    How to Use this Manual Safety Notices WARNING Always disconnect the AC power cord from the printer or power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 26: Indicators And Controls

    Chapter Indicators and Controls Indicators and Controls Indicators Power Switch Turns printer on and off: 1 = on, 0 = off. Status Indicator On when the printer is online, off when the printer is offline. Flashes to indicate a fault or warning. Liquid Crystal Display.
  • Page 27 Control Panel Keys ADVANCE Performs advance to top-of-form, as defined by the current active form length. The key works both online and offline. • If online with data in the printer buffer, the data will print and then the paper will move to the next top-of-form. •...
  • Page 28 Chapter Indicators and Controls Sets the top-of-form on the printer. This key is active only when the printer is offline and will not operate if the printer is in a fault condition. The paper moves down to the print position and aligns to the top-of-form. Refer to the Quick Setup Guide for complete instructions on how to set the top-of-form.
  • Page 29 Control Panel Keys UP or DOWN ( Moves up or down between levels in the configuration menus and makes vertical forms adjustment. In Offline mode or after pressing VIEW, press to adjust the paper up or down in 1/72 inch increments for fine vertical forms alignment.
  • Page 30 Chapter Indicators and Controls See Detail B (Figure 4) and Detail C (Figure 5) on page 31. Rotated 180 Degrees (Off) (On) Power Switch Figure 3. Electrical Controls...

  • Page 31: Cabinet Model

    Control Panel Keys Cabinet Model From Figure 3 on page 30. Message Display Circular Pad Status Indicator CONFIG VIEW SELECT ONLINE ADVANCE CANCEL ENTER Figure 4. Cabinet Model Control Panel Pedestal Model From Figure 3 on page 30. Legend: TOF = Set TOF (Top of Form) VIEW = View/Eject ADVANCE = Paper Advance CONFIG = Print Config...

  • Page 32: Mechanical Controls

    Chapter Indicators and Controls Mechanical Controls Control or Indicator Function Paper Supports Help prevent paper jams by supporting inner sections of paper. They are positioned manually by sliding them along the tractor shafts. Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. This lever must be fully opened (raised) to load paper, unload paper, and move paper with the vertical position knob.
  • Page 33 Mechanical Controls Ribbon Ribbon Cartridge Tab (2) Ribbon Tension Knob Tractor (2) Blue Tractor Lock (2) Splined Shaft Hammerbank Cover and Paper Ribbon Mask Support (2) Slot (2) Vertical Position Knob Platen Lever Ribbon Cartridge Interface Platen Stop Shuttle Cover Assembly (Air Shroud) Figure 6.

  • Page 34: Tools And Test Equipment

    Hammer Tip Alignment Tool, Long P7/P8X20/HD/P8X08H (253651-901) Hex Bits for Torque Screwdriver — 3/16”, 3/32”, 5/32”, 5/64” Hex L-Keys — 1/16”, 3/32”, 5/32”, 5/64”, 7/64” Lubricant, Bearing (Printronix P/N 211191-001) Nut Drivers — 1/4”, 5/16” Nut Driver or Open End Wrench, 7/32”...

  • Page 35: Plugging In The Printer

    Mechanical Controls Plugging in the Printer Power Cord Requirements In compliance with international safety standards, a P8000 CRP is equipped with a three-pronged electrical plug on the power cord. When this power cord is plugged into a correctly wired AC power outlet, the ground conductor ensures that the printer chassis is at ground (earth) electrical potential.

  • Page 36: Printronix Customer Support Center

    Chapter Printronix Customer Support Center Printronix Customer Support Center The Printronix Customer Support Center offers technical support with: • Installation • Configuration and setup • Loading supplies and operating the printer • Specifications of the proper ribbons, forms, and paper •...

  • Page 37: Preventive Maintenance

    Preventive Maintenance Cleaning the Printer The printer is designed to require very little maintenance. Aside from normal replenishment of paper and ribbons, the only preventive maintenance necessary is periodic cleaning. Clean the printer every six months or after every 1000 hours of operation, whichever occurs first. If the printer is located in a dusty area or is used for heavy duty printing, clean it more often.

  • Page 38: Cleaning The Interior

    Chapter Cleaning the Printer Cleaning the Interior 1. Power off the printer and unplug the printer power cord. 2. Open the printer cover. 3. Fully raise the platen lever. 4. Unload the paper. 5. Remove the ribbon cartridge. 6. Lift the ribbon out of the ribbon path. 7.
  • Page 39 Cleaning the Interior Ribbon Ribbon Cartridge Tab (2) Ribbon Tension Knob Tractor (2) Blue Tractor Lock (2) Splined Shaft Hammerbank Cover and Paper Ribbon Mask Support (2) Slot (2) Vertical Position Knob Platen Lever Ribbon Cartridge Interface Platen Stop Shuttle Cover Assembly (Air Shroud) REV B...

  • Page 40: Cleaning The Shuttle Frame Assembly

    Chapter Cleaning the Shuttle Frame Assembly Cleaning the Shuttle Frame Assembly Low Speed (P8X05, P8X10, P8X03H) IMPORTANT For low speed hammerbanks, DO NOT remove the hammersprings, combs, or frets when cleaning the shuttle. CAUTION When instructed to use alcohol for cleaning, be sure to use 99.95% alcohol or higher otherwise damage to the hammerbanks will occur.
  • Page 41 Low Speed (P8X05, P8X10, P8X03H) 14. Using a clean soft cloth, wipe the hammerbank cover and ribbon mask to remove lint, ink, and paper residue. Clean the holes in the cover strips. Carefully wipe between the hammerbank cover and the ribbon mask. NOTE: Due to evaporation, do not open alcohol packets until they are required for cleaning.

  • Page 42: High Speed (P8215, P8X00Hd, P8X06H, P8X08H, P8220)

    Chapter Cleaning the Shuttle Frame Assembly High Speed (P8215, P8X00HD, P8X06H, P8X08H, P8220) IMPORTANT For high speed hammerbanks, remove the hammersprings when cleaning the shuttle. Use the hammer tip alignment tool when installing the hammersprings (see Table 4 on page 44). CAUTION When instructed to use alcohol for cleaning, be sure to use 99.95% alcohol or higher otherwise damage to the hammerbanks will occur.
  • Page 43 High Speed (P8215, P8X00HD, P8X06H, P8X08H, IMPORTANT Do not bend the ribbon mask when cleaning between the cover and mask. 14. Using a clean soft cloth, wipe the hammerbank cover and ribbon mask to remove lint, ink, and paper residue. Clean the holes in the cover strips. Carefully wipe between the hammerbank cover and the ribbon mask.
  • Page 44 Chapter Cleaning the Shuttle Frame Assembly 18. Use tape or a nonabrasive marker or pencil to mark the location of each fret in relation to the counter balance. 19. Remove the fret mounting hardware and set aside for later reassembly. 20.

  • Page 45: Cleaning The Card Cage Fan Assembly

    High Speed (P8215, P8X00HD, P8X06H, P8X08H, Cleaning the Card Cage Fan Assembly 1. Cabinet Models: Remove the paper path (page 243). Pedestal Models: Remove the electronics barrier panel (page 237). 2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint.
  • Page 46 Chapter Cleaning the Card Cage Fan Assembly...

  • Page 47: Troubleshooting

    Troubleshooting Introduction This chapter lists fault messages and general symptoms, and provides procedures for troubleshooting printer malfunctions. NOTE: Because you must operate the printer to check its performance and sometimes you may have to reconfigure it, always have the User’s Manual handy when you troubleshoot.

  • Page 48: Start Here

    Chapter Start Here... Start Here... Are you here because of an Go to Troubleshooting Display error message? Messages, page 49. Power on the printer and observe the control panel for the following sequence of events (retry as required): Did the status 1.

  • Page 49: Troubleshooting Display Messages

    Troubleshooting Display Messages WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to do so could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 50: Diagnostics For Exx, Bad Nvm, Or Ill Nvm Errors

    If the problem persists, then invoke a diagnostic option that will capture the failure dump in a flash file that can be later uploaded from PrintNet Enterprise Suite and sent to Printronix Customer Support Center for analysis (see Appendix H, page 487).

  • Page 51: Fault Messages (Ascii In Alphabetical Order)

    Fault Messages (ASCII in Alphabetical Order) Find the message in the Message List below and follow the suggested procedure. After correcting an error, press the CANCEL key to clear the message and place the printer in the offline state. If an error is not cleared, the printer will try to print again but will display the error message until the error is cleared.
  • Page 52 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution B21 STATUS: Status message informing No action required. PRINTER RESET the operator that the printer is undergoing a system reset. B22 ERROR: Error can only occur during a 1.
  • Page 53 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution x/y BARCODES / Printer detects fewer Press the ONLINE key. Not Found barcodes than the set value for "Barcodes on Page" menu option. x represents the number of barcodes not found, and y represents the "Barcodes on Page"...
  • Page 54 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution CARTRIDGE The ribbon cartridge is 1. Make sure a ribbon cartridge is MISSING missing or installed installed in the printer. Install new cart improperly.
  • Page 55 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution CLEAR PAPER JAM Paper jam. 1. Inspect the paper path for jams. Clear jams. Load paper. 2. Press ADVANCE several times and check that forms feed without erratic motion, noise, or pin-hole damage.
  • Page 56 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution CLOSE PLATEN The forms thickness lever is 1. Load paper. Close the forms open. thickness lever. 2. Power off the printer. Remove the paper path (cabinet model) or electronics barrier panel (pedestal model).
  • Page 57 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution D51 STATUS Status message: The printer No action required. PROGRAMMING is loading firmware, where DONE %XX represents the percentage completed. DIAGNOSTIC Status message: the printer No action required. PASSED passed its memory and hardware initialization tests.
  • Page 58 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution E00 EXE @ ADDR0 An illegal or unsupported 1. Cycle Power. Run the print job E01A TYPE 0x40 instruction was attempted in again.
  • Page 59 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution E-Net Test Unavailable The ethernet did not initialize Cycle power. Wait for “E-Net Ready” correctly. to display, then retry operation. If it still fails, replace the controller board, and contact customer support (page 487) ERROR NOR FLASHED Problem programming Boot...
  • Page 60 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution ERROR: PROGRAM The printer does not see a There is no program in printer NOT VALID program in flash memory. memory. Download the emulation. ERROR: SECURITY The security key is not 1.
  • Page 61 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution EXHAUST FAN FLT Exhaust Fan Fault. Sensor 1. Cycle power. If the message (Cabinet models only) cannot detect current in the appears, press CANCEL. fan circuit. 2. Check that the exhaust fan is connected to exhaust fan cable connector J307.
  • Page 62 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution FIRMWARE ERROR Application software tried to 1. Cycle power. Run the print job. If perform an illegal printer the message appears, download function or damaged the emulation software again memory is detected on the...
  • Page 63 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution H00: PCI SLOT ? The controller board is not 1. Cycle power. If the message See User Manual communicating with a PCI appears, power down and reseat card. This could indicate a the PCI card.
  • Page 64 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution <Online, etc..> This is a status message, 1. Advise the user to move the Half Speed Mode not an operational state. The printer to cooler, cleaner location.
  • Page 65 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution HAMMER DRIVER Driver Circuit Bad: the 1. Cycle power. If the message CIRCUIT BAD* hammer coil count test appears, press CANCEL. failed. 2. Power off the printer. Remove the shuttle cover.
  • Page 66 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution HMR BANK FAN FLT Hammerbank Fan Fault. 1. Cycle power. If the message Sensor cannot detect appears, press CANCEL. If the current in the fan circuit. message does not clear, go to step 3.
  • Page 67 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution ILL INST ACCSS Illegal Instruction Accessed. 1. Cycle power. Run the print job See Manual Firmware error on the again. If the message appears, controller board. download the emulation software again (page 194).
  • Page 68 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution INTAKE FAN CHECK Sensor cannot detect 1. Cycle power. If the message current in the card cage fan appears, press CANCEL. If the circuit.
  • Page 69 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution INTERRUPT UNUSED This message is generated 1. Cycle power. If this message VECTOR 00 when the controller board occurred once and never again, gets an interrupt it does not you can ignore it.
  • Page 70 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution LOAD PAPER The printer is out of paper. 1. Load paper. Press CANCEL. If message does not clear, go to the next step. 2.
  • Page 71 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution LOADING PROGRAM The printer has deleted the No action required. INTO FLASH previous program from flash memory and is loading the new program into flash memory. MEMORY FAILURE Boot-up routines did not Power up the printer.
  • Page 72 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution ONLINE Printer state message: No action is required. printer is online and in communication with host. PANEL Panel Code has a bad Reload released firmware.
  • Page 73 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution PAP FIFO UNDRFL* Paper First In First Out 1. Cycle power. Run the print job Underflow. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 74 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution PAP INVLD CMD* Paper Invalid Command. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board.
  • Page 75 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution PLAT INV CMD* Platen Invalid Command. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again. 2.
  • Page 76 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution POWER SUPPLY HOT The printer has sensor 1. Inspect printer environment for circuits that sample the severity. Advise the user to move operating temperature of key the printer to cooler, cleaner components of the power...
  • Page 77 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution PRINTER HOT This message indicates 1. Controller board sensors report internal temperatures over high temperatures on the board. 80° Celsius (176° Inspect printer environment for Fahrenheit). Print jobs will severity.
  • Page 78 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution PROTECTED INSTR* Protected Instruction. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again.
  • Page 79 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution PS/PDF ERROR: Fault displayed when 1. Cleck the Postscript/PDF job for STACK ERROR Postscript/PDF failed to syntax (Postscript) errors. process a job. One or more 2. Clear the fault. Postscript/PDF of the following errors were will continue with the next job.
  • Page 80 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution RIBBON STALL The controller board does 1. Cycle power. If the message not detect ribbon movement. appears, power off the printer. 2. Check that the ribbon cartridge is properly set.
  • Page 81 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution SD CARD ERROR The printer has been Power down, reseat card, and power Remove SD Card powered up with a card in up again. If error persists, power the SD slot, but the card is down, remove card, and try another not functioning properly.
  • Page 82 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution SDSC CARD The printer has been Power down, remove SD card, and NOT SUPPORTED powered up with an SDSC insert an SDHC card in the printer. Remove SD Card card, and SDSC cards (<...
  • Page 83 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution SHUT DRVR CIR* The shuttle driver circuit on 1. Power down the printer. Remove See User Manual the controller board is the paper path or top cover to drawing too much current. gain access to the card cage.
  • Page 84 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution SHUTTLE JAM The shuttle is not moving or 1. Set the forms thickness lever to SHUTTLE STALL is moving at the wrong match the thickness of paper, but speed.
  • Page 85 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution SHUTTLE TYPE The shuttle type was not 1. Power down the printer. Remove NOT SUPPORTED* detected at power-up or the the paper path or top cover to shuttle installed in the printer gain access to the card cage.
  • Page 86 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution SPX NOT NEEDED The user has attempted to 1. Remove the SPX from the Debug OPTIONS ENABLED use the SPX to turn on Port.
  • Page 87 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution STACKER FAULT Two situations can trigger 1. Open the cabinet rear door and this message: check for obstructions preventing 1. The stacker elevator is elevator movement. Remove any obstructed while attempting obstructions.
  • Page 88 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution STACKER FULL Status message: the power 1. Unload the stacker. paper stacker is full. 2. Check the stacker limit switches. (See page 141.) If the limit switches are OK, go to the next step.
  • Page 89 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution STACKER JAM This message is triggered if 1. Open the cabinet rear door and there is paper inside the check for obstructions preventing throat of the stacker elevator movement. Remove any elevator, but the elevator is obstructions.
  • Page 90 Chapter Fault Messages (ASCII in Alphabetical Order) Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution TCB CORRUPTED* Task Control Block 1. Cycle power. Run the print job Corrupted. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 91 Table 5. P8000 ASCII Error Messages List Displayed Message Explanation Solution UP DRV. SHORT* Upper Driver Short. Hammer 1. Cycle power. If the message driver circuits on the appears, press CANCEL. If the controller board are shorted message does not clear, replace to ground.

  • Page 92: P8000 Crp H-Series (Numerical Prefix Listing)

    Chapter Fault Messages (ASCII in Alphabetical Order) P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 000:SHUTTLE TYPE The shuttle type was not 1. Power down the printer. Remove NOT SUPPORTED* detected at power-up or the the paper path or top cover to shuttle installed in the printer gain access to the card cage.
  • Page 93 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 104:POWER SUPPLY The printer has sensor 1. Inspect printer environment for circuits that sample the severity. Advise the user to move operating temperature of key the printer to cooler, cleaner components of the power location.
  • Page 94 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 105:PRINTER HOT This message indicates 1. Controller board sensors report internal temperatures over high temperatures on the board. 80° Celsius (176° Inspect printer environment for Fahrenheit).
  • Page 95 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 402:CLEAR PAPER Paper jam. 1. Inspect the paper path for jams. Clear jams. Load paper. 2. Press ADVANCE several times and check that forms feed without erratic motion, noise, or pin-hole damage.
  • Page 96 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 403:CLOSE PLATEN The forms thickness lever is 1. Load paper. Close the forms open. thickness lever. 2. Power off the printer. Remove the paper path (cabinet model) or electronics barrier panel (pedestal model).
  • Page 97 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 410:LOAD PAPER The printer is out of paper. 1. Load paper. Press CLEAR. If message does not clear, go to the next step. 2.
  • Page 98 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 411:PARITY ERROR The printed output may Verify that the printer matches contain random ? (question host serial configuration settings mark) characters. Make a for Data Protocol, Baud Rate, configuration printout.
  • Page 99 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 414:RIBBON STALL The controller board does 1. Cycle power. If the message not detect ribbon movement. appears, power off the printer. 2. Check that the ribbon cartridge is properly set.
  • Page 100 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 415:SHUTTLE JAM The shuttle is not moving or 1. Set the forms thickness lever to is moving at the wrong match the thickness of paper, but speed.
  • Page 101 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 416:STACKER FULL Status message: the power 1. Unload the stacker. paper stacker is full. 2. Check the stacker limit switches. (See page 141.) If the limit switches are OK, go to the next step.
  • Page 102 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 417:STACKER JAM This message is triggered if 1. Open the cabinet rear door and there is paper inside the check for obstructions preventing throat of the stacker elevator movement.
  • Page 103 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 419:RBN END PNT* Integrated Print Install a new ribbon cartridge. Install New RBN Management System software has determined that the ribbon is out of ink. 420:EXC RBN WEAR Status message that Install a new ribbon cartridge.
  • Page 104 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 433:WELD SNSR The incorrect cartridge type 1. Make sure the correct ribbon See User Manual is being used for the printer. cartridge type is installed and is properly seated.
  • Page 105 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 448:SD WRT. FAIL A write operation to the SD has Ensure that the write protect tab on the WRITE PROTECTED failed because the the SD card SD card is not active.
  • Page 106 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 609:EXHAUST FAN Exhaust Fan Fault. Sensor 1. Cycle power. If the message CHECK cannot detect current in the appears, press CANCEL. (Cabinet model only) fan circuit.
  • Page 107 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 614:HAMMER BANK* Hammerbank Not Installed. 1. Install the shuttle frame NOT INSTALLED Self-test routines do not assembly. detect hammer coils at 2. Remove the paper path (cabinet printer start-up.
  • Page 108 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 615:HAMMER FAN Hammerbank Fan Check. 1. Cycle power. If the message CHECK Sensor cannot detect appears, press CANCEL. If the current in the fan circuit. message does not clear, go to step 3.
  • Page 109 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 616: INTAKE FAN Sensors S/B Sensor cannot 1. Cycle power. If the message CHECK detect current in the card appears, press CANCEL. If the cage fan circuit.
  • Page 110 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 619:PAPER FEED Paper Feed Driver Circuit. 1. Cycle power. If the message DRIVER CIRCUIT* The paper feed driver circuit appears, replace the controller See Manual on the controller board is board.
  • Page 111 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 623:STACKER FAULT Two situations can trigger 1. Open the cabinet rear door and this message: check for obstructions preventing 1. The stacker elevator is elevator movement.
  • Page 112 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 624:UPPER DRIVER Upper Driver Short. Hammer 1. Cycle power. If the message SHORT* driver circuits on the appears, press CANCEL. If the controller board are shorted message does not clear, replace to ground.
  • Page 113 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 703:ILLEGAL Illegal External Bus Access. 1. Cycle power. Run the print job EXTERNAL BUS Firmware error on the again. If the message appears, ACC* controller board.
  • Page 114 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 708:PAPER FIFO Paper First In First Out 1. Cycle power. Run the print job OVERFLOW* Overflow. Firmware error on again. If the message appears, the controller board.
  • Page 115 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 710:PAP ILLGL ST* Paper Illegal State. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again.
  • Page 116 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 718:PLAT INV PARM* Platen Invalid Parameter. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board.
  • Page 117 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 723:SHUTL INV CMD* Shuttle Invalid Command. 1. Cycle power. Run the print job Firmware error on the again. If the message appears, controller board. download the emulation software again.
  • Page 118 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution 730:TCB Task Control Block 1. Cycle power. Run the print job CORRUPTED* Corrupted. Firmware error again. If the message appears, on the controller board. download the emulation software again.
  • Page 119 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution B22 ERROR: Error can only occur during a 1. Download again. DECOMPRESS SIZE* program download (data 2. Check communications cable was corrupt). being used (Parallel, USB, Network).
  • Page 120 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution D50 STATUS Status message: The printer No action required. UPGRADING PANEL is upgrading the panel, where %XX represents the percentage completed. D51 Status %XX Status message: The printer No action required.
  • Page 121 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution E00 EXE @ ADDR0 An illegal or unsupported 1. Cycle Power. Run the print job E01A TYPE 0x40 instruction was attempted in again. If the message appears, E01B TYPE 0x60 the application program.
  • Page 122 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution E-Net Test Unavailable The ethernet PCBA did not Cycle power. Wait for “E-Net Ready” initialize correctly. to display, then retry operation. If it still fails, replace the controller board, and contact customer support (page 487).
  • Page 123 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution ERROR: PROGRAM The printer does not see a There is no program in printer NOT VALID program in flash memory. memory. Download the emulation. ERROR: SECURITY The security key is not 1.
  • Page 124 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution FLASH: WAS NOT Printer encountered an error Contact customer support CLEARED while trying to program Flash (page 487). memory. FLASH: WRITE ERROR Printer encountered an error Contact customer support while trying to program Flash...
  • Page 125 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution <Online, etc...> This is a status message, 1. Advise the user to move the Half Speed Mode not an operational state. The printer to cooler, cleaner location. controller samples the 2.
  • Page 126 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution ILL NVM VALUE 5 Illegal value was stored into the Cycle power. Run the print job again. ILL NVM VALUE 6 Novram module. If the message appears, load the ILL NVM VALUE 7 latest emulation software.
  • Page 127 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution NEW SPX DETECTED The printer detects an SPX Press the ENTER key. The following PRESS ENTER in its debug port and the actions occur: SPX is valid for this printer.
  • Page 128 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution REMOVE USED SPX Status message: An SPX is 1. Remove the SPX from the Debug THEN PRESS ENTER depleted because it has Port.
  • Page 129 P8000 CRP H-Series (Numerical Prefix Listing) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution SF ERROR Structured Field Error. Not a printer problem. Have the Application software has system administrator correct violated structured data field applications data or configuration. parameters.
  • Page 130 Chapter Fault Messages (ASCII in Alphabetical Order) Table 6. P8000 H-Series Error Messages List Displayed Message Explanation Solution TCP PORT BUSY Error message reported by 1. Power on the printer. the Printer Manager when 2. If the printer is online, press the ethernet interface option is ONLINE key to place the printer installed.

  • Page 131: Troubleshooting Other Symptoms

    P8000 CRP H-Series (Numerical Prefix Listing) Troubleshooting Other Symptoms WARNING Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to do so could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 132: General Symptom List

    Chapter Troubleshooting Other Symptoms General Symptom List Table 7 is a list of possible printer problems that are not indicated by messages on the LCD. Troubleshooting procedures are included for each symptom. If you encounter a problem that is not listed in Table 7, troubleshoot using the Half-Split Method described on page 131.
  • Page 133 General Symptom List Table 7. General Symptom List Symptom Solution Jams CLEAR PAPER JAM 1. Power off the printer. Remove the paper path (cabinet message instead of LOAD model) or electronics barrier panel (pedestal model). PAPER when printer is out of Remove the barrier shield (cabinet model) or the barrier paper shield and electronics barrier panel (pedestal model).
  • Page 134 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution CLEAR PAPER JAM 1. Power off the printer. Remove the paper path. Check that message will not clear but connector P107 is fully seated in connector J107 on the paper moves controller board.
  • Page 135 General Symptom List Table 7. General Symptom List Symptom Solution Control Panel Initializing...on control panel 1. With the printer powered on, simultaneously press <ONLINE> <TOF><DOWN>. If th edisplay changes to “PANEL CHECK COMPLETE” the panel is good. 2. Power off the printer. Remove the paper path. Disconnect the control panel cable from the panel and from J110 on the controller board.
  • Page 136 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Control panel display shows 1. Remove the paper path (cabinet model) or electronics garbled, broken characters barrier panel (pedestal model). Check cable connections into the controller board. Make sure the control panel cable is seated in connector J110 on the controller board.
  • Page 137 General Symptom List Table 7. General Symptom List Symptom Solution Power Failures No power, and control panel 1. Check that the AC power outlet has power. Restore AC blank, and card cage fan not power if necessary. running 2. Unplug the printer AC power cord from the printer (leave it plugged into the power outlet) and check for AC power at the printer end of the cord.

  • Page 138: Power Stacker

    Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Power Stacker Printer does not detect 1. Check that the power stacker is enabled under the Printer presence of power stacker Control menu. (Refer to the User’s Manual.) If the power stacker enable/disable option does not appear in the menu, go to the next step.
  • Page 139 General Symptom List Table 7. General Symptom List Symptom Solution Stacker “chatters” at upper or 1. Power off the printer. Unload paper. Open the rear cabinet lower limit door and check that stacker motion is not obstructed by the control panel cable or other obstruction. Remove obstruction or reroute the stacker control panel cable as necessary.
  • Page 140 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Stacker does not stack 1. Check for and remove obstructions preventing elevator properly movement. 2. Check for misaligned stacker rails. Adjust the stacker rails if they are not vertical and parallel. 3.
  • Page 141 General Symptom List Table 7. General Symptom List Symptom Solution Stacker limit switch check NOTE: This procedure tests the upper and lower limit switches on the right vertical rail. These magnetic switches are normally closed. You can quickly check their functionality with a small, powerful magnet. Right Vertical Rail You will usually be referred to this procedure from Upper Limit...
  • Page 142 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Stacker motor check NOTE: This procedure tests the four stacker motors and their cables. You will usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.

  • Page 143: Print Quality

    General Symptom List Table 7. General Symptom List Symptom Solution Print Quality Characters or dots are 1. Check the forms thickness lever: if it is set too loose or too missing, smeared, too light, tightly print quality can be affected. Set the forms or too dark.
  • Page 144 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Horizontal misalignment of 1. Take the printer offline and print a test pattern of All H’s. If characters (Dots or characters shift left or right from line to line, there might be characters move left or right a proportional spacing problem.
  • Page 145 General Symptom List Table 7. General Symptom List Symptom Solution Vertical misalignment of 1. Load paper. Press ADVANCE and check that paper feeds characters: smoothly. Press VIEW to verify that paper moves in both 1. Dots or characters move directions. Check the forms thickness lever: if it is set too up or down from dot row to loose or too tightly print quality can be affected.

  • Page 146: Printer Operation

    Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Printer Operation Downloads consistently fail NOTE: Most download problems are detected by software during the procedure and communicated by LCD messages. If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure.
  • Page 147 General Symptom List Table 7. General Symptom List Symptom Solution Paper feeds poorly 1. Check the forms thickness lever: if it is set too tightly paper feeding can be affected. Set the forms thickness lever to match the thickness of the paper being used. 2.
  • Page 148 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Paper feeds poorly 11. Load paper. Power on the printer. Press ADVANCE and (continued) VIEW several times and check that paper moves in both directions. Replace the paper feed motor if paper does not move in both directions.
  • Page 149 General Symptom List Table 7. General Symptom List Symptom Solution Printer does not print self 1. Power off the printer. Remove the paper path (cabinet tests model) or electronics barrier panel (pedestal model). Disconnect the control panel cable from connector J110 on the controller board.
  • Page 150 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution TOF is lost repeatedly 1. Check that the customer is setting the forms length to match the size paper used. Set the forms length to match the length of paper being used. 2.
  • Page 151 General Symptom List Table 7. General Symptom List Symptom Solution Shuttle Shuttle does not move 1. Power down the printer. Remove the shuttle cover. Check the MPU gap. Adjust the gap between the MPU assembly and the flywheel to 0.010 ± 0.001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU clamp screw to 18 inch-pounds (2.03 N•m).
  • Page 152 Chapter Troubleshooting Other Symptoms Table 7. General Symptom List Symptom Solution Shuttle is noisy 1. Check the bolts securing the mechanism base to the base pan. Tighten the mechanism base mounting bolts if they are loose enough to permit movement of the mechanism base.

  • Page 153: Communications Failures

    General Symptom List Communications Failures Many host-printer communications problems are complex. With the exception of a defective interface cable, most communications problems are not a result of a hardware failure. They usually result from an incompatible configuration of the host computer system, network (LAN, print server, controller, multiplexer, etc.), or the printer.
  • Page 154 Chapter Communications Failures Table 8. Communications Problems Ethernet responds to “ping” Ethernet 1. Open a telnet session using the IP address of and “telnet” utilities, and the ethernet. can print from “ftp”, but 2. Enter these commands: card cannot be accessed config http on by a browser.

  • Page 155: Diagnostic Printer Tests

    General Symptom List Diagnostic Printer Tests A set of printer tests is included in the DIAGNOSTICS configuration menu for use as diagnostic tools. Use these tests to check the print quality and basic operation of the printer. You will also use some of the tests in some adjustment procedures.

  • Page 156: Selecting And Running Diagnostic Printer Tests

    Chapter Diagnostic Printer Tests • Acoustics — A test used by the manufacturer to measure acoustic properties of the printer. This test has no value as a maintenance tool. • Demo — Prints representative lines of the various CPI available and some sample bar codes.
  • Page 157 Selecting and Running Diagnostic Printer Tests Step Press LCD Result Notes UNTIL ENTER Cycle through choices. X = Full Width or X = 80 columns. Wait for printer to ENTER stop.
  • Page 158 Chapter Diagnostic Printer Tests Step Press LCD Result Notes Cycle through the choices. Starts test. ENTER Stops test. ENTER Locks the ENTER key and control panel. Press ENTER to go back into the menus or press ONLINE ONLINE again to go ONLINE. Configuration changes were detected and you...
  • Page 159 Selecting and Running Diagnostic Printer Tests Step Press LCD Result Notes 19a. Saves the ENTER Configuration as Config 1 then returns the printer ONLINE. 19b. Places the printer online after permanently saving the configuration changes as Config 1. Examine print quality. Characters should be fully formed and of uniform density.
  • Page 160 Chapter Diagnostic Printer Tests Printing the Ethernet Test NOTE: You must set TOF after printing the Ethernet Test. Step Press LCD Result Notes Make sure the printer is on. Raise the printer cover. Load paper. Set TOF. (Refer to the User’s Manual.) The printer must be offline to run a print test.
  • Page 161 Selecting and Running Diagnostic Printer Tests Step Press LCD Result Notes Starts printing. ENTER Wait for printing to PLEASE WAIT stop. Locks the ENTER key and control panel. Press ENTER to go back into the menus or press ONLINE ONLINE again to go ONLINE.
  • Page 162 Chapter Diagnostic Printer Tests Step Press LCD Result Notes 15b. Places the printer online after permanently saving the configuration changes as Config 1. Set TOF. (Refer to the User’s Manual.)

  • Page 163: Boot Diagnostics Menu

    Selecting and Running Diagnostic Printer Tests Boot Diagnostics Menu Printer boot-up software contains a “Boot Diagnostics” menu that you can access by holding down two keys while powering on the printer. This menu is not intended for the end user, but provides useful information for manufacturing and maintenance personnel.
  • Page 164 Chapter Boot Diagnostics Menu > = Down Arrow Key BOOT DIAGNOSTICS < = Next Arrow Key PRESS ENTER ENTER DIAGNOSTICS MENU DIAGNOSTICS MENU DIAGNOSTICS MENU < < MISC. TOOLS EXIT DIAGNOSTICS EXCEPTION VIEWER > ENTER > B30: STATUS INITIALIZING... MISC. TOOLS MENU MISC.

  • Page 165: Factory Menu

    Factory Menu Printer software contains a Factory menu that you can access by holding down the four arrow keys when the printer is in the offline state. This menu is not intended for the end user, but is used by manufacturing and maintenance personnel to set or change certain operational perameters.
  • Page 166 Chapter Factory Menu > = Down Arrow Key < = Next Arrow Key ↵ Press (ENTER) to select or activate. Factory Factory Factory Factory Factory > > > > > Set Coil Temp Serial Number PNE Access Demo Count Program Tracing ↵...
  • Page 167 From previous ↵ > < = Down Arrow Key, = Next Arrow Key, Press (ENTER) to select or activate. page. Factory Buffer Size Clear Trace Flags Trace Flags < < < ↵ 4 KB* Program Tracing ↵ ↵ < to Run 0 KB (Use to view options.)

  • Page 168: Exception Menu

    Chapter Exception Menu Exception Menu The exception menu is only accessible when certain faults occur. It provides additional troubleshooting information for some fault mesages. You will only use this menu when directed to by a troubleshooting procedure. When you come to this procedure, the printer will be powered on, with a specific fault message displayed which prevents further operation.

  • Page 169: Firmware Diagnostic Port

    The firmware diagnostic port enables you to help with firmware troubleshooting when necessary. Diagnostic routines built into the software are used by Printronix engineers to determine the cause of a fault or failure. In some cases the engineers will ask for specific information to be captured or provide a diagnostics test build.
  • Page 170 6. Type the command dump and capture the output to a file. The dump command will take a couple of minutes to complete. 7. Send the file to the Printronix Customer Support Center along with other diagnostic information (see page 36).

  • Page 171: Hex Code Printout

    Capturing Information Hex Code Printout A hex code printout (or “hex dump”) prints every ASCII data character received from the host computer, and lists its corresponding two-character hexadecimal code. (See Figure 13 below.) You can use hex dumps as an aid in troubleshooting data reception problems.

  • Page 172: How To Print A Hex Dump

    Chapter Hex Code Printout How to Print a Hex Dump Step Press LCD Result Notes Make sure the printer is on. Raise the printer cover. ONLINE ENTER Unlocks the ENTER key and control panel. UNTIL ENTER...
  • Page 173 How to Print a Hex Dump Step Press LCD Result Notes Cycle through choices. Asterisk (*) indicates ENTER choice is active. Locks the ENTER key and control panel. Press ENTER to go back into the menus or press ONLINE ONLINE again to go ONLINE.
  • Page 174 Chapter Hex Code Printout Step Press LCD Result Notes 12a. Saves the ENTER Configuration as Config 1 then returns the printer ONLINE. 12b. Places the printer online after permanently saving the configuration changes as Config 1. Send a file from the host computer. the printer outputs a hex dump. Refer to the ASCII chart on page 175.

  • Page 175: Ascii Character Set

    How to Print a Hex Dump ASCII Character Set BITS OCTAL equivalent DECIMAL equivalent HEX equivalent ASCII Character Name BITS COLUMN (XON) 0 0 1 0 " 0 0 1 1 (XOFF) 0 1 0 0 0 1 0 1 &...

  • Page 176: Soft Vs. Hard Reset

    Chapter Soft vs. Hard Reset Soft vs. Hard Reset Soft Reset A soft(ware) reset clears printer memory then loads the power-up configuration set by the user. (If no power-up configuration has been set by the user, the factory default configuration is loaded.) It is called a soft reset because no hardware is tested.

  • Page 177: Adjustments And Tests

    Adjustments and Tests Introduction The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment and may need to be tested as part of a troubleshooting procedure. You usually will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.

  • Page 178: Preparing The Printer For Maintenance

    Chapter Preparing the Printer for Maintenance Preparing the Printer for Maintenance WARNING Unplug the printer power cord from the printer or power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 179: Returning The Printer To Normal Operation

    Adjustments and Tests Returning the Printer to Normal Operation When you have finished servicing the printer, return it to service by doing the following steps: 1. Load paper. 2. Connect the data (signal) cable(s) to the printer interface. 3. Plug the AC power cord into the printer and the power source. 4.

  • Page 180: Belt, Paper Feed Timing, Adjustment

    Chapter Belt, Paper Feed Timing, Adjustment Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237) 3. Remove the timing belt cover (1) by squeezing the front and back to release the plastic tabs from the slots in the side plate.
  • Page 181 Adjustments and Tests 1/8 inch Direction of Force Legend: Timing Belt Cover Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaft Figure 14. Paper Feed Timing Belt Adjustment...

  • Page 182: Belt, Platen Open, Adjustment

    Chapter Belt, Platen Open, Adjustment Belt, Platen Open, Adjustment 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237) 3. Remove the platen open belt cover (1) by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.
  • Page 183 Adjustments and Tests 3/16 inch Legend: Belt Cover Motor Mount Screw (2) Platen Open Motor Shaft Figure 15. Platen Open Belt Adjustment...

  • Page 184: Paper Scale Alignment

    Chapter Paper Scale Alignment Paper Scale Alignment 1. Open the printer cover. 2. Load paper. 3. Connect the power cord to the AC power source. 4. Set the printer power switch to 1 (on). 5. Verify that the shuttle cover (1) is properly installed (page 235). 6.
  • Page 185 Adjustments and Tests Legend: Shuttle Cover Screw, Button-Head, 5/64 inch hex (3) Paper Scale Figure 16. Paper Scale Alignment...

  • Page 186: Platen Gap Adjustment

    Chapter Platen Gap Adjustment Platen Gap Adjustment IMPORTANT Only do this procedure if the original equipment shuttle frame assembly or platen was replaced by a new or refurbished unit, or if you were instructed to in a troubleshooting procedure. Table 10 shows recommended platen gap settings for hammerspring assemblies versions 1, 2, and 3.
  • Page 187 Adjustments and Tests CAUTION Do not force the platen against the feeler gauge and do not move the feeler gauge laterally across the hammerbank. Damage to the hammer tips will result. 7. Insert the flat feeler gauge straight down between the hammerbank cover plate and ribbon mask, within four hammer positions of the left end of the hammerbank.

  • Page 188: Hammerspring Assembly, Version 3

    Chapter Platen Gap Adjustment Hammerspring Assembly, Version 3 1. Prepare the printer for maintenance (page 178). 2. Remove the ribbon cartridge and paper. (Refer to the User’s Manual.) 3. Remove the shuttle cover assembly (page 235). 4. Loosen the platen open belt (page 182, steps 2, 3, and 4). 5.

  • Page 189: Paper Out Adjustment

    Adjustments and Tests Paper Out Adjustment This procedure tests and sets the distance from the page perforation at which a LOAD PAPER fault message is triggered. This adjustment prevents printing on the platen when the printer runs out of paper. The measurement units are dot rows.
  • Page 190 Chapter Paper Out Adjustment 7. If the printer is online, press the ONLINE key to place the printer offline. “OFFLINE” displays. 8. Press (↵ ) ENTER to place the printer in Menu mode. Quick Setup displays. 9. On the control panel, press the keys to unlock the (↵...
  • Page 191 Adjustments and Tests 19. Press (↵ ) ENTER to place the printer in Menu mode. Quick Setup displays. 20. Press the key until “DIAGNOSTICS” displays. 21. Press (↵ ) ENTER. “DIAGNOSTICS / Printer Tests” displays. 22. Press until “Paper Out Dots” displays. 23.

  • Page 192: Hammer Phasing Adjustment

    Chapter Hammer Phasing Adjustment Hammer Phasing Adjustment You must check and adjust hammer phasing if the controller board is replaced, the shuttle frame assembly is removed, or if the MPU is replaced. The hammer phase value is a timing parameter that permits you to adjust the vertical alignment of dots in character printing.
  • Page 193 Adjustments and Tests Needs Needs Correct Adjustment Adjustment 11. Press until Phase Value displays. Press again: An asterisk (*) appears next to the phase value. 12. Press to decrease or to increase the phasing index value, then press ENTER to activate the value as it prints. Continue to increase or decrease the phasing index until the pattern of H’s is acceptable.

  • Page 194: Downloading Firmware

    Chapter Downloading Firmware Downloading Firmware There is 256 MB of FLASH memory on the controller board. The printer firmware which includes printer control languages (the “emulations”), the engine control, and printer operating system software are loaded into FLASH memory at the factory, but there are occasions when you may have to load this software: •...

  • Page 195: Firmware File Types (.Prg) And (.Exe)

    Adjustments and Tests Table 11. Firmware Download Methods User FLASH Firmware Download Method File Type(s) Files Web Page (Ethernet only). User needs the network option FILENAME.prg Preserved installed, a browser, and know the IP address. Windows Driver (any host IO). When the Windows Driver FILENAME.prg Preserved is installed, downloading firmware can be done easily...

  • Page 196: Web Page Download

    Chapter Web Page Download Web Page Download NOTE: This download method requires firmware with the .prg extension FILENAME.prg. 1. Make sure the printer is powered up, in ONLINE mode, and that the Ethernet cable is connected. 2. Get the IP address from the front panel (under Network Setup in the menus).
  • Page 197 Adjustments and Tests 7. Browse to the directory or enter FILENAME.prg in the “File to upload” field and click “Upgrade”. A Warning message opens. Figure 20. Uploading Firmware File for Upgrade 8. Click “Ok” to continue. After a few minutes, you are prompted to reboot. 9.

  • Page 198: Windows Driver Download

    2. Install the Windows Driver 2000/XP/Server 2003/Server 2008/Vista/ Windows 7/Windows 8 on the Starter Kit CD before continuing. Alternatively, drivers can be found on the http://www.printronix.com/products/drivers.aspx website. 3. Once the Windows Driver is installed on the PC, right-click the printer driver and select Properties.

  • Page 199: Automatic Download (.Exe)

    3. Install the Windows Driver 2000/XP/Server 2003/Server 2008/Vista/ Windows 7/Windows 8 on the Starter Kit CD before continuing. Alternatively, drivers can be found on the http://www.printronix.com/ products/drivers.aspx website. During the installation, make sure to share the printer when prompted and record the “Share name”.
  • Page 200 Chapter Automatic Download (.exe) IMPORTANT For USB connections, the printer must have a “Share name” established. 4. The “Share name” will be needed when executing the FILENAME.exe command. This should be accomplished during installation, but can be verified at any time. Select the driver, right-click the mouse button and select “Printer Properties”.

  • Page 201: Manual Two-Key Download Sequence

    Adjustments and Tests 7. Execute FILENAME.exe as follows: Connection Type Enter Command Parallel FILENAME –a -pb <Enter> Serial mode COM1:9600,N,8,1 <Enter> mode LPT1=COM1 <Enter> FILENAME –a -pb <Enter> FILENAME –a –pbSharedName <Enter> where SharedName of the printer is the ‘Share name’...

  • Page 202: Manual Three-Key Download Sequence

    Chapter Manual Three-Key Download Sequence 8. Send the firmware to the printer as described for various host IO options: • “Sending Firmware via Ethernet (LPR)” on page 203 • “Sending Firmware via USB” on page 203 • “Sending Firmware via Parallel” on page 209 •...

  • Page 203: Sending Firmware In Download Mode

    NOTE: The three-key download sequence only allows download through USB or Parallel. Although the program file FILENAME.prg is used in the examples, any file with a Printronix header can be substituted in this process to download flash files. Sending Firmware via Ethernet (LPR) NOTE: You will need the IP Address of the printer.

  • Page 204: Installing A Microsoft Loopback Adapter

    Chapter Sending Firmware in Download Mode 4. Copy the file to the printer by entering these commands at the command prompt: copy /b FILENAME.prg lpt1: <Enter> where FILENAME.prg is the target firmware FILENAME –pb <Enter> where FILENAME.exe is the target firmware. IMPORTANT DO NOT interrupt the downloading process once it has started.
  • Page 205 Adjustments and Tests d. Start the “Add legacy hardware” process from the “Action” menu as shown Figure 26.   Figure 26. Adding Legacy Hardware 2. Click “Next” in the initial “Welcome to the Add Hardware Wizard” screen. The second screen will ask if you have already connected the hardware to your computer.
  • Page 206 Chapter Sending Firmware in Download Mode 4. Select “Add a new hardware device” (typically at the bottom of the installed hardware list) and then click “Next”.   Figure 28. Adding a New Hardware Device 5. When asked how you would like to have the hardware installed, select the “Advanced”...
  • Page 207 Adjustments and Tests 6. Select “Network adaptor”, then click “Next”.   Figure 30. Selecting Network Adapter Hardware 7. Select “Microsoft Loopback Adapter”, then click “Next”.   Figure 31. Selecting Microsoft Loopback Adapter as the Network Adapter Type...
  • Page 208 Chapter Sending Firmware in Download Mode 8. Click “Next” to start installation.   Figure 32. Starting the Installation 9. After installation is complete, click “Finish” to close the wizard.   Figure 33. Complete Hardware Installation...

  • Page 209: Sending Firmware Via Parallel

    Adjustments and Tests 10. To verify installation, go back to the Control Panel and select “System” for WinXP. Under the “Hardware” tab, select “Device Manager”. For Windows 7, select “Device Manager” directly from Control Panel. 11. Select the “Network Adaptors” and expand the selection if necessary. You should see “Microsoft Loopback Adaptor”...

  • Page 210: Sending Firmware Via Serial

    Chapter Sending Firmware in Download Mode Sending Firmware via Serial Downloading firmware using serial RS-232 is not recommended due to the size of the firmware and significant wait time required to complete the process. Downloading through serial requires firmware in the form FILENAME.prg only.

  • Page 211: Reprogramming The Security Key

    Adjustments and Tests Reprogramming the Security Key The security key on the PSA4 controller board can be reprogrammed with a Software Program Exchange (SPX) module. This allows the user or a service technician to enable features such as new emulations without having to remove covers and install a new security key on the controller board.
  • Page 212 Chapter Reprogramming the Security Key 4. Power on the printer. The printer will begin its boot-up sequence. 5. When the printer detects a valid SPX, the control panel displays: “NEW SPX DETECTED PRESS ENTER” NOTE: If an error message displays, find the message in the Message List in Chapter 3 and follow the troubleshooting instructions.

  • Page 213: Coil Temperature Adjustment

    Adjustments and Tests Coil Temperature Adjustment Do this procedure only when the original controller board or shuttle frame assembly have been replaced or you are instructed to do so in a maintenance or troubleshooting procedure. DO NOT do this procedure if the original controller board or shuttle frame assembly were removed and reinstalled as part of other maintenance tasks.

  • Page 214: Dynamic Paper Tension Adjustment

    Chapter Dynamic Paper Tension Adjustment Dynamic Paper Tension Adjustment This procedure helps you identify and eliminate conditions that contribute to paper jams, excessive tension on the paper feed motor, and vertical dot compression or expansion. 1. Open the printer cover. 2.
  • Page 215 Adjustments and Tests 8. Use the scale to pull the paper slowly straight up through the print station for about six inches and note the maximum force exerted on the scale. Do not pull any page perforations through the print station. (Figure 37.) Scale Figure 37.

  • Page 216: Tractor Belt Tension Adjustment

    Chapter Tractor Belt Tension Adjustment Tractor Belt Tension Adjustment First line print compression can be reduced by adjusting the tension of the tractor belts. The procedure below removes the slack that can occur in some tractors. IMPORTANT Only do this procedure when the user reports that the first print line of forms is compressed and only after adjusting the dynamic paper tension (page 214).

  • Page 217: Shuttle Electrical Short Check

    Adjustments and Tests Shuttle Electrical Short Check This procedure checks for metallic debris and checks for hammer coils shorting to the shuttle frame. The hammer driver circuit board attached to the shuttle frame assembly can attract metal objects because of the magnets in the hammerbank. Such stray metal pieces can cause electrical shorting and damage to the shuttle assembly.

  • Page 218: Hammerbank Power Cable Shorts Test

    Chapter Hammerbank Power Cable Shorts Test 13. Install the ribbon cartridge. (Refer to the User’s Manual.) 14. Return the printer to normal operation (page 179). Hammerbank Power Cable Shorts Test This test determines if the hammerbank power cable is shorted. 1.

  • Page 219: Cable Shorts Test

    Adjustments and Tests Cable Shorts Test This test determines if a cable has a short to ground or a pin-to-pin short (also called a wire-to-wire short). Such shorts can be caused by cables resting on or moving across sharp edges. The edges over time can wear away the non- conductive shielding of the cable, exposing the conductor.
  • Page 220 Chapter Cable Shorts Test 9. If you find a short to ground, replace the cable. If no short is detected, repeat steps 7 and 8 for the rest of the pins on the same end of the cable. If no shorts to ground are detected for any of the pins, proceed to the next section, which checks for pin-to-pin shorts.

  • Page 221: Main Wire Harness Test Diagnostic

    Adjustments and Tests Main Wire Harness Test Diagnostic This is a procedure for extended testing of various printer components. 1. Prepare the printer for maintenance (page 178). 2. Remove the paper path (page 243). 3. For Tabletop and Pedestal models, remove the electronics barrier panel (page 237).

  • Page 222: Set Printer Serial Number

    Chapter Set Printer Serial Number Set Printer Serial Number The printer’s serial number is on the identification label next to the input/ output ports at the rear of the printer. It is also stored in the non volatile memory on the controller board. It is important that the serial number stored in the non volatile memory on the controller board matches the serial printed on the identification label.
  • Page 223 Adjustments and Tests 6. Type the new serial number in the Printer Serial Number box. 7. Click the “Submit” button at the bottom of the page. 8. Click on the “System” tab at the top of the page. 9. Click on the “Reboot” button. 10.
  • Page 224 Chapter Set Printer Serial Number...

  • Page 225: Replacement Procedures

    Replacement Procedures Organization of this Chapter This chapter contains written procedures for removing and installing components that are replaceable at the field service level of maintenance. The replacement procedures refer you to the illustrations in Chapter 6 on page 265. Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before...
  • Page 226 Chapter Replacement Procedures Cover Assembly, Top, Pedestal Models ......... page 236 Dashpot................... page 236 Electronics Barrier Panel..............page 237 Fan Assembly, Cabinet Exhaust ............. page 238 Fan Assembly, Card Cage .............. page 239 Fan Assembly, Hammerbank............page 239 Magnetic Pickup (MPU) Assembly..........page 240 Paper Feed Motor ................

  • Page 227: Belt, Paper Feed Timing

    Belt, Paper Feed Timing Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate.

  • Page 228: Belt, Platen Open

    Chapter Replacement Procedures Belt, Platen Open Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Remove the platen open belt cover by squeezing the top and bottom to release the plastic tabs from the slots in the side plate.

  • Page 229: Cartridge Interface Board (Cib)

    Cartridge Interface Board (CIB) Cartridge Interface Board (CIB) Removal 1. Prepare the printer for maintenance (page 178). 2. Unplug P20 from J20 on the CIB. 3. Remove the three 6-32 x 1/4 inch button head fasteners securing the cartridge interface board to the motor mounting flange. 4.

  • Page 230: Control Panel Assembly - Cabinet Model

    Chapter Replacement Procedures Control Panel Assembly - Cabinet Model Removal 1. Prepare the printer for maintenance (page 178). 2. Open the printer cover. 3. Disconnect the ribbon cable connector P310 from the J310 on the back of the control panel assembly. (See page 272, item 2.) 4.

  • Page 231: Control Panel Assembly - Pedestal Model

    Control Panel Assembly - Pedestal Model Control Panel Assembly - Pedestal Model Removal 1. Prepare the printer for maintenance (page 178). 2. Open the printer cover. 3. Remove the four screws securing the panel bracket to the printer cover. (See page 274, items 1, 2, and 3). 4.

  • Page 232: Controller Board

    Chapter Replacement Procedures Controller Board Removal IMPORTANT To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. Make a configuration printout of all saved configurations. (Refer to the User’s Manual.) NOTE: The MAC address for the onboard ethernet interface on the controller board will be printed on the printer’s configuration printout after completing this replacement procedure.
  • Page 233 Controller Board Installation CAUTION To prevent electrostatic damage to electronic components, always wear a properly grounded static wrist strap when you handle circuit boards. 1. If this is a replacement controller board, install the security key on the new controller (page 254). 2.

  • Page 234: Cover Assembly, Hammerbank / Ribbon Mask

    Chapter Replacement Procedures Cover Assembly, Hammerbank / Ribbon Mask Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the shuttle frame assembly (page 259). 3. Remove the three button-head fasteners on the hammerbank cover assembly. 4. Lift the thick plate of the hammerbank cover assembly at one end, and peel the cover away from hammerbank magnets.

  • Page 235: Cover Assembly, Shuttle

    Cover Assembly, Shuttle Cover Assembly, Shuttle Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Loosen the shuttle cover screws (page 278, item 2). 4. Unplug the weld sensor cable (page 320). 5.

  • Page 236: Dashpot

    Chapter Replacement Procedures Dashpot CAUTION Two persons may be required to do this procedure. Prop or hold the printer cover securely while disengaging the dashpot. Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet model: open the cabinet rear door. Pedestal model: open the printer lid.

  • Page 237: Electronics Barrier Panel

    Electronics Barrier Panel Electronics Barrier Panel NOTE: This procedure applies to the pedestal models only. CAUTION Do not drop screws into the card cage. Removal 1. Prepare the printer for maintenance (page 178). 2. Use a #2 Phillips screw driver to loosen the captive screws on both sides of the lower paper path assembly.

  • Page 238: Fan Assembly, Cabinet Exhaust

    Chapter Replacement Procedures Fan Assembly, Cabinet Exhaust NOTE: This procedure applies only to cabinet models. Removal 1. Prepare the printer for maintenance (page 178). 2. Open the front and rear cabinet doors and the printer cover. 3. Remove the paper fence/paper tray assembly. (See page 270.) 4.

  • Page 239: Fan Assembly, Card Cage

    Fan Assembly, Card Cage Fan Assembly, Card Cage Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Disconnect the card cage fan cable connector P306. (See page 296.) 4.

  • Page 240: Magnetic Pickup (Mpu) Assembly

    Chapter Replacement Procedures Magnetic Pickup (MPU) Assembly Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the ribbon. (Refer to the User’s Manual.) 3. Remove the shuttle cover (page 235). 4. Disconnect the magnetic pickup (MPU) cable connector P03 (page 288, item 5).

  • Page 241: Paper Feed Motor

    Paper Feed Motor Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Remove the timing belt cover by squeezing the front and back to release the plastic tabs from the slots in the side plate (page 278, item 7).

  • Page 242: Paper Ironer

    Chapter Replacement Procedures Paper Ironer WARNING Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides. IMPORTANT DO NOT remove the paper ironer on the Zero Tear Pedestal printers unless you are solving paper jam problems.

  • Page 243: Paper Guide Assembly

    Paper Guide Assembly Paper Guide Assembly Removal 1. Prepare the printer for maintenance (page 178). 2. Loosen—do not remove—the screws that secure the paper path to the card cage. (See Figure 2.) Cabinet model: Three screws Pedestal model: Four screws 3.

  • Page 244: Platen

    Chapter Replacement Procedures Platen Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the shuttle frame assembly (page 259). 3. Remove the paper ironer (page 242). 4. Remove the three 1/4 inch screws securing the paper ironer bracket assembly and remove the assembly.
  • Page 245 Platen Installation IMPORTANT Install the platen with the longer shaft on the right hand side of the printer. The dowel pins protruding from the ends of the platen are the platen shafts. The platen shafts are not of equal length. 1.
  • Page 246 Chapter Replacement Procedures Platen Adjust Bracket Platen Washers Wear Saddle Mechanism Base Platen Seat Figure 4. Positioning the Platen Adjust Brackets 9. Install the interlock switch bracket: a. Slide the bracket, with the interlock switch assembly attached, onto the platen shaft and up against the right side plate. b.
  • Page 247 Platen 13. Install the paper ironer bracket. (See Figure 3.) a. With the flat part of the bracket facing the front of the printer, place the two hooks of the upper part of the paper ironer over the platen shafts. The left hook of the paper ironer bracket goes between the left platen adjustment bracket and the platen.

  • Page 248: Platen Open Motor

    Chapter Replacement Procedures Platen Open Motor Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Cabinet Models: Remove the card cage fan (page 239). 4.
  • Page 249 Platen Open Motor Installation 1. Position the platen open motor assembly with the wires toward the rear (page 296, item 5). 2. Install the 5/16 inch lower motor mount screw and torque it to 30 inch-pounds (3.39 N•m). 3. Install the 5/32 inch upper motor mount screw, platen spring post, and platen belt spring such that the screw is just loose enough to permit movement of the motor in the slotted side plate.

  • Page 250: Platen Stop Assembly

    Chapter Replacement Procedures Platen Stop Assembly NOTE: The forms thickness lever is part of the platen stop assembly. Removal 1. Prepare the printer for maintenance (page 178). 2. Loosen—do not remove—the 7/64 inch clamp screw and pull the platen stop assembly off the platen shaft. (See page 292, items 12 through 15.) Installation 1.

  • Page 251: Power Supply Board

    Power Supply Board Power Supply Board WARNING To prevent injury from electric shock, wait at least one minute after shutting off power before removing the power supply board. Do not touch components on the board during removal or installation. Lift and handle the board only by the loops provided for this purpose.

  • Page 252: Power Switch

    Chapter Replacement Procedures Power Switch Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the card cage fan (page 239). 3. Disconnect the power switch electrical leads. Cabinet Models: See page 298. Tabletop and Pedestal Models: See page 282. 4.

  • Page 253: Ribbon Drive Motor

    Ribbon Drive Motor Ribbon Drive Motor Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Remove the shuttle cover (page 235). 4. Disconnect the ribbon drive motor cable connector at J06B (page 296, item 12, cable portion).

  • Page 254: Security Key

    The printer will not operate correctly without a security key. If you need to replace the security key, contact Printronix for a replacement. Installation 1. Put on a static wrist strap and ground the lead to an unpainted part of the printer frame.
  • Page 255 Security Key Low Speed Controller Board J9: Security Key High Speed Controller Board J9: Security Key Figure 5. Security Key...

  • Page 256: Shaft, Splined

    Chapter Replacement Procedures Testing NIC Operation You can test the NIC by running the Ethernet Test under the DIAGNOSTICS menu -> Printer Test. Verify that the NIC is configured and working correctly by examining the test printout. Shaft, Splined IMPORTANT In order to preserve correct alignment of the side plates, the barrier panel must remain installed and fastened during this procedure.
  • Page 257 Shaft, Splined 8. Install the paper supports on the splined and support shafts. (See page 290, item 4.) 9. Return the printer to normal operation (page 179). Tractor NOTE: Align the marks on both tractors before inserting the splined shaft. Tolerance Alignment Marks Ring...

  • Page 258: Shaft, Support

    Chapter Replacement Procedures Shaft, Support IMPORTANT In order to preserve correct alignment of the side plates, make sure the barrier panel remains installed and fastened during this procedure. Removal 1. Prepare the printer for maintenance (page 178). 2. Unlock the tractors and slide them to the far right. 3.

  • Page 259: Shuttle Frame Assembly

    Shuttle Frame Assembly Shuttle Frame Assembly Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Remove the shuttle cover assembly (page 235). 4. Disconnect the MPU cable connector P03 and shuttle motor cable connector P02 (page 288, items 5 and 6).
  • Page 260 Chapter Replacement Procedures Installation 1. Install the hammerbank / ribbon mask cover assembly if it was removed (page 234). CAUTION To prevent electrostatic damage to electronic components, wear a properly grounded static wrist strap when you handle the shuttle frame assembly.

  • Page 261: Spring, Extension, Hammerbank

    Spring, Extension, Hammerbank Spring, Extension, Hammerbank CAUTION Do not let the hammerbank rotate toward the platen during spring replacement. Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the ribbon cartridge. (Refer to the User’s Manual.) 3. Remove the shuttle cover assembly (page 235). 4.

  • Page 262: Switch Assembly, Paper Detector

    Chapter Replacement Procedures Switch Assembly, Paper Detector Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Remove the two 1/4 inch screws securing the paper detector switch assembly.

  • Page 263: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock Switch Assembly, Platen Interlock Removal 1. Prepare the printer for maintenance (page 178). 2. Cabinet Models: Remove the paper path (page 243). Tabletop and Pedestal Models: Remove the electronics barrier panel (page 237). 3. Fully close the forms thickness lever (position ‘A’). 4.

  • Page 264: Tractor (L/R)

    Chapter Replacement Procedures Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 178). 2. Remove the support shaft (page 258). 3. Remove the splined shaft (page 256). Installation 1. Using the replacement tractors, install the support shaft (page 258). 2.

  • Page 265: Illustrated Parts Breakdown

    Illustrated Parts Breakdown This chapter contains drawings of all electrical and mechanical assemblies in the printer. The table following each illustration lists the illustrated parts and their part numbers. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly. NOTE: Part numbers listed in the column labeled Europe, Mideast, and Africa (EMEA) are RoHS compliant.
  • Page 266 Chapter Illustrations of Printer Components Figure 1. Tabletop Details...
  • Page 267 Part No. Item (RoHS Description Notes Compliant) 257655-001 Control Panel/Cable/Overlay Pedestal Field Kit Includes control panel, cable, and overlay. 257552-001 Top Cover Assy,Tabletop, P8 257662-001 Field Kit, Lid,Hinge/Springs Includes two hinges and dashpot. Screw (4) Base Assembly, Tabletop, P8 Packaged Ped Kit, Stealth Black Stand assembly 256964-001 not 256964-001 Stand Assembly, Tabletop...
  • Page 268 Chapter Illustrations of Printer Components Figure 2. Cabinet Model Top Cover, Doors, and Casters...
  • Page 269 Part No. Item (RoHS Description Notes Compliant) 177505-901 Top Cover Assembly, Stealth Black Includes items 2 and 3. Window, Cabinet Part of item 1. 175680-001 Wireform Paper Path, Standard 177541-901 Rear Door Assembly, Stealth Black For printers without power stacker; includes items 9, 10, 11, and 12.
  • Page 270 Chapter Illustrations of Printer Components Figure 3. Cabinet Model Paper Fence, Paper Chains, and Front Access Stacker...
  • Page 271 Part No. Item (RoHS Description Notes Compliant) 158179-901 Passive Stacker Assembly Not used on printers with the power stacker; includes items 6, 7, and 8. 153503-001 Grommet Kit, Cabinet 153778-001 Chain Assembly Kit Includes one each, outer chain and inner chain. AC Power Cord Grommet, Power Cord (2) Included in item 2.
  • Page 272 Chapter Illustrations of Printer Components Figure 4. Control Panel and Cabinet Details...
  • Page 273 Part No. Item (RoHS Description Notes Compliant) 257654-001 Control Panel/Cable/Overlay Cabinet Field Kit Includes control panel, cable, and overlay. Cable Assembly, Control Panel Part of item 1. 107961-905 Dashpot Kit Includes ball studs, spring clips, and mounting hardware. Screw, w/Lock Washer (3) 6-32x.375 Screw, w/Lock Washer (3) 6-32x2.00...
  • Page 274 Chapter Illustrations of Printer Components Figure 5. Open Pedestal Details...
  • Page 275 Part No. Item (RoHS Description Notes Compliant) 257655-001 Control Panel/Cable/Overlay, Pedestal Field Kit Includes control panel, cable, and overlay. Screw (4) 256956-001 Top Cover Assy, Pedestal 257662-001 Field Kit, Lid,Hinge/Springs Includes two hinges and dashpot. Screw (4) Cable Assembly, Control Panel Part of item 1.
  • Page 276 Chapter Illustrations of Printer Components Figure 6. Enclosed Pedestal Details...
  • Page 277 Part No. Item (RoHS Description Notes Compliant) 257655-001 Control Panel/Cable/Overlay, Pedestal Field Kit Includes control panel, cable, and overlay. 256956-001 Top Cover Assembly, Ped, Blk 257662-001 Field Kit, Lid,Hinge/Springs Includes two hinges and dashpot. Screw (4) Base Assy,Pedestal 256935-001 Tray, Wire Form Stand Assembly, Enclosed Pedestal, P8 179162-001 Field Kit, Caster Kit, Ped...
  • Page 278 Chapter Illustrations of Printer Components Underside of the shuttle cover assembly. Ribbon Weld Processor PCBA located on the underside (see Detail B). Figure 7. Inside Covers, Cabinet Models...
  • Page 279 Part No. Item (RoHS Description Notes Compliant) 256424-901 Shuttle Cover Assembly or Shroud Assembly Air Shroud Assembly. Includes items 11, 13, and 14. Screw, Captive (5) 6-32x.38 with O-ring, .125x.250x.06 Part of item 1. Screw, Thread-forming (2) 6-32x.25 and #6 flat washer. Barrier Shield 175188-901 Paper Path, V3...
  • Page 280 Chapter Illustrations of Printer Components Underside of the shuttle cover assembly. Ribbon Weld Processor PCBA located on the underside (see Detail B). See Figure 9, page 282. Figure 8. Inside Covers and Card Cage, Pedestal Models...
  • Page 281 Part No. Item (RoHS Description Notes Compliant) 256424-901 Shuttle Cover Assembly or Shroud Assembly Air Shroud Assembly. Includes items 8, 9, and 10. Screw, Captive (5) 6-32x.38 with O-ring, .125x.250x.06 Part of item 1. Screw, Captive (2) 6-32x.38 and #6 flat washer with o-ring .094x.281x.094.
  • Page 282 Chapter Illustrations of Printer Components To IEC 320 AC Power Input (Connector J301, To Connector P1 Black Wire) (White Wire) From Figure 8, page 280. To IEC 320 AC Power Input Rotated 180 degrees. (Connector J301, White Wire) To Connector P1 (Black Wire) Figure 9.
  • Page 283 Part No. Item (RoHS Description Notes Compliant) 257656-001 Fan Assembly, Spares Kit, HB, CC, EXH Air flow is into card cage. Screw, w/Lock Washer (4) 6-32x1.75 Part of item 2. Card Cage, Pedestal 205501-001 Switch, Rocker,10A,125/250V...
  • Page 284 Chapter Illustrations of Printer Components Two places: Exploded to show assembly. Do not remove the clamps and screws. To J03 To J02 (MPU) (Shuttle Motor) Figure 10. Print Mechanism and Circuit Boards...
  • Page 285 Part No. Item (RoHS Description Notes Compliant) 256590-901 HB Cover Assy, 05 P8X05 256587-901 HB Cover Assy, 10 P8X10, P8X03H 254356-901 HB Cover Assy, 15 P8X15, P8X06H 254138-901 HB Cover Assy, 20 P8X20, P8X08H 256799-901 Shuttle Assembly, 05 P8X05 256835-901 Shuttle Assembly, 10 P8X10 256921-901...
  • Page 286 Chapter Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) 257764-001 Motor, Paper Feed, Field Kit, 20 P8X20 257763-001 Motor, Paper Feed, Field Kit, 5/10/15 P8X05, P8X10, P8X15 PCBA, Ribbon Motion Sensor (RMS) Part of 257663-001, Field Kit, Ribbon Motion/Weld Sensor.
  • Page 287 (Parts list continue on the next page.)
  • Page 288 Chapter Illustrations of Printer Components Spring Lug (Do not remove grease) Spring Lug (Do not remove grease) 0.010 ± .001 inch (0.254 ± .025 mm) CAUTION: Make sure the MPU cable does not touch the extension spring after cable connection. Figure 11.
  • Page 289 Part No. Item (RoHS Description Notes Compliant) 150281-001 Magnetic Pickup (MPU) Assembly Bracket, MPU Part of item 1. Screw, Socket Cap Part of item 1. 153537-001 Spring, Hammerbank MPU Cable Connector (P03) Part of item 1. 176507-001 Anti-Rotation Spring Constraint P8220 only.
  • Page 290 Chapter Illustrations of Printer Components IMPORTANT: To preserve correct alignment of the side plates, the barrier panel must remain installed and fastened if the splined or support shafts are removed or replaced. The barrier panel is shown in Figure 7 and Figure 8. Figure 12.
  • Page 291 Part No. Item (RoHS Description Notes Compliant) Screw, Socket Cap, 6-32x.312 Trilob (Self- Tapping) (2) 173130-001 Plate, Tractor Shaft, Left 151944-001 Bearing, Ball, Sealed 178990-901 Paper Support (2) Includes two pieces. Tolerance Ring,.37X.25,.006 THK,SS 257667-001, Spline/Support, Shafts with Tolerance Ring. Includes items 5, 6, and 9.
  • Page 292 Chapter Illustrations of Printer Components NOTE: Black tape faces paper NOTE: motion detector. On P8000HD, P8X06H, P8X08H, P8X15, and P8X20 models, install item 27 in front of item 3; that is, on the shuttle side. All others do not use item 27. NOTE: Item 25: Platen Hardware Kit...
  • Page 293 Part No. Item (RoHS Description Notes Compliant) Setscrew (2) Part of item 25. Bracket, Platen (2) Part of item 25. Ironer Assembly, Reverse Paper Feed 257665-001, Field Kit, Ironers, PPR Feed, AUX, includes items 3 and 27. Screw, Thread-forming (3) 6-32x.25 Not Used Plate, Ironer...
  • Page 294 Chapter Illustrations of Printer Components Part No. Item (RoHS Description Notes Compliant) Bushing, Platen Adjust, V2 Part of item 25.
  • Page 295 (Parts list continue on the next page.)
  • Page 296 Chapter Illustrations of Printer Components Note: Air flow is into card cage. Ribbon Drive Motor Cable Connector Figure 14. Motors, Fans, and Paper Detector Switch...
  • Page 297 Part No. Item (RoHS Description Notes Compliant) Card Cage Fan Assembly Screw, w/Lock Washer (3) Two 6-32x1.75 on bottom, One 6-32x0.50 on top left. Switch Assembly, Paper Detector 257653-001, Field Kit, Switch Assy, Platen Open/Paper Detect. 170172-001 Field Kit, Slotted Black Back Form Switch Optional switch used with black back forms.
  • Page 298 Chapter Illustrations of Printer Components See inside detail below. To IEC 320 AC Power Input (Connector J301, White Wire) To IEC 320 AC Power Input (Connector J301, Black Wire) To Connector P1 (Black Wire) To Connector P1 (White Wire) (Card cage fan and Black Wire power supply board removed for clarity.)
  • Page 299 Part No. Item (RoHS Description Notes Compliant) 205501-001 Rocker Switch, DPST,10A,125/250V IEC 320 AC Power Connector Connector J301 Part of Field Kit, AC Power. Chassis Ground Stud Connector P1 To power supply board connector J1 Part of Field Kit, AC Power. Cable Assembly, AC-In, Power Supply Part of Field Kit, AC Power.
  • Page 300 Chapter Illustrations of Printer Components Figure 16. I/O Panel on the Controller Board...
  • Page 301 Part No. Item (RoHS Description Notes Compliant) USB Port SD Memory Card Debug Port Screw Controller Board Ethernet Port Ethernet hard wired on Controller Board. To replace port, you must replace the entire controller board. Be sure to transfer the security key. The new board has a new MAC address which is found on the configuration printout.
  • Page 302 Chapter Illustrations of Printer Components...

  • Page 303: Principles Of Operation

    Principles Of Operation Line Matrix Printing A line matrix printer creates characters and graphics by printing patterns of ink dots an entire line at a time. Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix.
  • Page 304 Chapter Line Matrix Printing When the shuttle reaches the end of a horizontal sweep, it reverses direction, the paper advances upward one dot row, and the hammersprings print the next row of dots as the shuttle moves in the opposite direction. When a line of text characters is completed, hammer action stops and the paper advances to the first dot row of the next print line.
  • Page 305 Succesive Hammer Strokes Per Scan Shuttle 1 3 5 1 3 5 7 1 3 5 7 9 Scan Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram. NOTE: = Hammer Released and Dot Printed = Hammer Not Released;...

  • Page 306: Printing Rates

    Chapter Printing Rates Printing Rates A line matrix printer prints entire lines sequentially, and measures the printing speed of text in lines per minute (lpm). This is faster than a moving-printhead printer, which prints single characters sequentially and measures its speed in characters per minute (cpm).

  • Page 307: Shuttle Frame Assembly

    Shuttle Drive Motor Shuttle Frame Assembly The central element of the printing mechanism is the shuttle frame assembly, which houses the hammerbank assembly and the shuttle drive motor. (Figure 4.) Hammerbank Assembly Counterweight Connecting Rod Shuttle Frame Assembly Guide Shaft Shuttle Drive Motor Figure 4.

  • Page 308: Hammerbank Assembly

    Chapter Shuttle Frame Assembly Hammerbank Assembly A number of comb-like hammerspring assemblies are bolted to a solid hammerbank, forming the hammerbank assembly. The number of individual hammers on a hammerspring assembly and the number of hammerspring assemblies attached to the hammerbank vary by printer model: •...

  • Page 309: Paper Transport System

    Hammerbank Assembly While the hammer is in flight the coils are de-energized and their magnetic field collapses, restoring the magnetic attraction of the permanent magnet in the hammerbank. After striking the ribbon and paper, the hammer rebounds and is recaptured by the permanent magnet. When the shuttle reaches the end of a sweep, it reverses direction, the paper is micro-stepped upwards one dot row, and the hammersprings print the next row of dots as the shuttle sweeps in the opposite direction.

  • Page 310: Ribbon Transport System

    Chapter Ribbon Transport System prevents paper jams when paper direction is reversed after viewing the print area, setting top of form, or allowing applications to overprint forms. Paper is positioned horizontally using the tractors. Each tractor is locked in position with a friction lock and engages the paper perforations with six sprocket pins.

  • Page 311: Integrated Print Management System

    The default settings for the Integrated Print Management System are enabled at the factory, and the system functions without intervention as long as genuine Printronix ribbon cartridges are used and the Integrated Print Management options have been set. The user can change settings, as discussed later in this section.

  • Page 312: Ribbon End Point

    Chapter Integrated Print Management System Ribbon End Point Factory default is Normal. This value corresponds to the life expectancy of an authorized ribbon. The Integrated Print Management System tracks ribbon life to the recommended end point before declaring RIBBON INK LOW or RIBBON INK OUT.

  • Page 313: Logical Control Of The Printer

    Operation Ribbon Installation and Detection Previously used ribbons can be installed and used again to print, as long as they were not fully depleted and declared RIBBON INK OUT. Logical Control of the Printer The printer consists of four subsystems: the control panel, the controller board, the power supply board, and the print mechanism, as illustrated in Figure 8.

  • Page 314: Control Panel

    Chapter Control Panel Control Panel The user communicates with the printer by pressing keys on the control panel. The keys are momentary contact switches. The control panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user.

  • Page 315: Controller Board

    AC Power Controller Board The heart of a P8000 printer is the controller board (low speed for low speed printers and high speed for high speed printers), which controls all printer functions and supports all P8000 models. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammersprings.

  • Page 316: Printer Interface

    The VGL Advanced Graphics programming language (a QMS graphics emulation) and the PGL Advanced Graphics programming language (a Printronix IGP emulation) are options that install in flash memory on the controller board. These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics.

  • Page 317: A Wire Data

    Wire Data NOTE: Abbreviations, acronyms, and signal mnemonics are defined in Appendix B (page 369). Interconnection Diagram ..............page 319 Cable Routing Low Speed - Cabinet Model ............page 320 Low Speed - Pedestal Model ............page 321 High Speed - Cabinet Model ............page 322 High Speed - Pedestal Model ............
  • Page 318 Appendix A Power Stacker Cables Frame Cable, Power Stacker ..........page 358 Logic Cable, Power Stacker ..........page 359 Power Cable, Power Stacker ..........page 360 Rail Cable, Power Stacker ..........page 361 Elevator I/O Cable, Power Stacker ........page 362 Fan Assembly, Hammerbank............

  • Page 319: Interconnection Diagram

    Interconnection Diagram...

  • Page 320: Cable Routing

    Appendix A Cable Routing Low Speed - Cabinet Model Weld Sensor PCBA Exhaust Fan...

  • Page 321: Low Speed - Pedestal Model

    Low Speed - Pedestal Model Card Cage Fan Weld Sensor PCBA...

  • Page 322: High Speed - Cabinet Model

    Appendix A High Speed - Cabinet Model Weld Sensor PCBA Exhaust Fan...

  • Page 323: High Speed - Pedestal Model

    High Speed - Pedestal Model Card Cage Fan (air intake) Weld Sensor PCBA...

  • Page 324: Low Speed Controller Board

    Appendix A Low Speed Controller Board Sensor Interface Cartridge & Platen Interface J106 J107 CMD_OUTR1 CMD_OUTR2 PMD_C CMD_OUTR4 PMD_E 184566 REV A CMD_OUTR3 POD_A PAPER OUT & MOTION PLAT_1 DETECT PMD_A PLAT_2 POD_C PLAT_3 POD_E PLAT_4 PMD_K CON8J100 POD_K WS_ANODE WS_COLLECTOR WS_EMITTER WELD SKIP SENSOR...
  • Page 325 Low Speed Controller Board (continued) High Voltage Power Supply +45V +12V6 J101B C407 470PF C164 C145 100PF .1UF 10UF 10UF 2 25V 2 25V 100V 9P-PWR-CONN-TH Low Voltage Power Supply 8,16 N_STBY POWER SUPPLY C221 .062W .01UF J101A 100V C423 C424 C389 100PF...
  • Page 326 Appendix A Low Speed Controller Board (continued) Hammerbank Power J105 24,26 24,26 25,26 25,26 LDFB C392 C391 C390 C388 3300PF 3300PF 3300PF 3300PF 100V 100V 100V 100V 10P-1R-FLHDR +12V6 Hammerbank Logic 0.5W J108 50MHZ 0.5W HMR_DAT C191 HMR_DAT_RET 184566 REV A HMR_CLK HMR_CLK_RET CMD_DAT...
  • Page 327 Low Speed Controller Board (continued) 2P-HDR 2P-HDR 2P-HDR 184566 REV A 2P-HDR 2P-HDR 2P-HDR 2P-HDR...
  • Page 328 Appendix A Low Speed Controller Board (continued) USB_VBUS CR62 USB Port TVS-5V .062W J209 VBUS R116 USB_DN 11 CHASSIS CHASSIS R117 USB_DEVICE USB_DP 11 1 CR60 CR61 TVS-5V TVS-5V TVS-5V TVS-5V CR60 CR61 Diagnostic Port DB_TXD DB_RXD RJ25-JACK...
  • Page 329 Low Speed Controller Board (continued) J220 RJ-45 LAN (Ethernet) PHY_TD+ R134 R203 R202 49.9 .062W .062W .062W J220 R135 GRN_C GRN_A 11 YEL_C 49.9 YEL_A .062W CT_T PHY_TD- PHY_RD+ CT_R R129 SHL1 49.9 SHL2 7 NC 1 C297 .062W 1500PF RJ45_LAN_LED R130 49.9...
  • Page 330 Appendix A Low Speed Controller Board (continued) Host RS232 J201 Shuttle Drive J116 SHUT_A SHUT_B 9P-DSUB-RA SHUT_C CHASSIS_GND 3P-FLHDR 184566 REV A...
  • Page 331 Low Speed Controller Board (continued) 4.7K 4.7K Control Panel 4.7K 4.7K J110 184566 REV A SPI_CLK_DSP SPI_DSP_NCS SPI_MOSI_DSP SPI_MISO_DSP KB_NIRQ SPI_DRDY DSP_NRST 1 C219 .01UF 20P-BXHDR-EJT...
  • Page 332 Appendix A Low Speed Controller Board (continued) Software Security Key Device Paper Feed Interface J103 R136 PF_4 2.2K .062W PF_3 16,18 PF_2 SOFT_ID 184566 REV A PF_1 4P-FLHDR 3P-FLHDR...
  • Page 333 Low Speed Controller Board (continued) PCI Connection PCI_CON3V3 184566 REV A NINTA A6 PCI_NIRQ NINTB B7 NINTB NINTC A7 NINTC NINTD NINTD NPRSNT1 4,16 NPRSNT1 3.3V NPRSNT2 3.3VAUX NRST PCI_NRST PCI_CLK0 3.3V NGNT A17 NGNT0 NREQ0 NREQ 3.3V NPME PCI_AD31 AD31 AD30 PCI_AD30...

  • Page 334: High Speed Controller Board

    Appendix A High Speed Controller Board Sensor Interface J107 Cartridge & Platen Interface PMD_C J106 PMD_E CMD_OUTR1 POD_A PAPER OUT & MOTION CMD_OUTR2 DETECT PMD_A CMD_OUTR4 POD_C CMD_OUTR3 POD_E 184588 REV A PLAT_1 PMD_K PLAT_2 POD_K PLAT_3 WS_ANODE PLAT_4 WS_COLLECTOR CON8J100 WS_EMITTER WELD SKIP SENSOR...
  • Page 335 High Speed Controller Board (continued) High Voltage Power Supply +48V +12V6 J101B C407 470PF C164 C145 10UF 10UF 100PF .1UF 100V 9P-PWR-CONN-TH Low Voltage Power Supply 8,16 N_STBY .062W J101A 184588 REV A C221 .01UF C389 C423 C424 10UF 2.2K 100PF 100V .1UF...
  • Page 336 Appendix A High Speed Controller Board (continued) J105B 5,24,26 Hammerbank Power 5,24,26 5,25,26 5,25,26 5,26 LDFB C455 C456 C457 C458 3300PF 3300PF 3300PF 3300PF 100V 100V 100V 100V CONN_20PIN Hammerbank Power J105A 5,24,26 5,24,26 5,25,26 5,25,26 5,26 LDFB +12V6 Hammerbank Logic 0.5W 184588 REV A J108...
  • Page 337 High Speed Controller Board (continued) 2P-HDR 2P-HDR 2P-HDR 184588 REV A 2P-HDR 2P-HDR 2P-HDR 2P-HDR...
  • Page 338 Appendix A High Speed Controller Board (continued) USB_VBUS CR62 USB Port TVS-5V .062W J209 VBUS R116 USB_DN CHASSIS CHASSIS R117 USB_DEVICE USB_DP CR60 CR61 TVS-5V TVS-5V Diagnostic Port TVS-5V TVS-5V CR60 CR61 DB_TXD DB_RXD RJ25-JACK...
  • Page 339 High Speed Controller Board (continued) J220 RJ-45 LAN (Ethernet) PHY_TD+ R134 R203 R202 49.9 .062W .062W .062W J220 R135 GRN_C GRN_A 11 YEL_C 49.9 YEL_A .062W CT_T PHY_TD- PHY_RD+ CT_R R129 SHL1 49.9 SHL2 7 NC 1 C297 .062W 1500PF RJ45_LAN_LED R130 49.9...
  • Page 340 Appendix A High Speed Controller Board (continued) Host RS232 J201 Shuttle Drive J116 SHUT_A SHUT_B SHUT_C 9P-DSUB-RA 3P-FLHDR CHASSIS_GND Paper Stacker J117 STK_R_NW STK_DATA STK_LOAD STK_CLK 184588 REV A STK_INSTALLED C445 C442 C444 C281 470PF 470PF 470PF 470PF C441 C443 470PF 470PF 14P-BOX-HDR...
  • Page 341 High Speed Controller Board (continued) Paper Feed Interface J103 4.7K PF_1 4.7K PF_2 Control Panel PF_3 4.7K FRONT PANEL PF_4 4.7K J110 4P-FLHDR 184588 REV A SPI_CLK_DSP SPI_DSP_NCS Software Security Key Device R136 2.2K SPI_MOSI_DSP .062W SPI_MISO_DSP 16,18 SOFT_ID KB_NIRQ SPI_DRDY Device DSP_NRST...
  • Page 342 Appendix A High Speed Controller Board (continued) PCI Connection PCI_CON3V3 184588 REV A NINTA A6 PCI_NIRQ NINTB B7 NINTB NINTC A7 NINTC NINTD NINTD NPRSNT1 4,16 NPRSNT1 3.3V NPRSNT2 3.3VAUX NRST PCI_NRST PCI_CLK0 3.3V NGNT A17 NGNT0 NREQ0 NREQ 3.3V NPME PCI_AD31 AD31...

  • Page 343: Power Supply

    Power Supply Low Speed: 300, 500, and 1000 LPM Models P101A +3.3V RTN Orange NSTBY Black +3.3V White +3.3V White NTEMP Blue +3.3V RTN Orange Cable Assembly AC In Power Supply AC Common Chassis Ground LOAD P101B +45V White = FAST-ON TERMINAL +45V White +45V...
  • Page 344 Appendix A Table 1. P101A Pin Assignments Pin # Assignment +3.3 Volt Return/Logic Ground NSTBY (Not Standby) +3.3 Volts +3.3 Volts N-Temp-Hi (Temperature OK) +3.3 Volt Return/Logic Ground Table 2. P101B Pin Assignments Pin # Assignment +45 Volts +45 Volts +45 Volts +12.6 Volts +45/+12.6 Volt Return...

  • Page 345: High Speed: 600, 800, 1500, And 2000 Lpm Models

    High Speed: 600, 800, 1500, and 2000 LPM Models P101A NSTBY Black +3.3 RTN Orange +3.3V White +3.3V White NTEMP Blue +3.3V RTN Orange Cable Assembly AC In Power Supply AC Common Chassis Ground P101B LOAD +48V White +48V White +48V White = FAST-ON TERMINAL...
  • Page 346 Appendix A Table 3. P101A Pin Assignments Pin # Assignment NSTBY (Not Standby) +3.3 Volt Return/Logic Ground +3.3 Volts +3.3 Volts N-Temp-Hi (Temperature OK) +3.3 Volt Return/Logic Ground Table 4. P101B Pin Assignments Pin # Assignment +48 Volts +48 Volts +48 Volts +12.6 Volts +48/+12.6 Volt Return...

  • Page 347: Surestak Power Stacker Pcba

    SureStak Power Stacker PCBA...

  • Page 348: Cable Assemblies Centronics I/O

    Appendix A Cable Assembly, Centronics I/O (Part of Parallel Port Field Kit, 257338-901) IMPORTANT To comply with Electromagnetic Compatibility (EMC) regulatory requirements, all interface cables must be of a minimal quality level, be the correct length, and be properly installed. RS-232 port and parallel port cables must meet the following specifications: 1) The cable design must be double...

  • Page 349: Ac In, Power Supply

    Cable Assembly, AC In, Power Supply Pedestal Model Part of AC Power Cables, Ped, Field Kit, 257659-001 Pin 3 Pin 3 From Power Switch Pin 1 Pin 1 Cabinet Model Part of AC Power Cables, Cab, Field Kit, 257658-001 Pin 3 Pin 3 From Power Switch 184619b...

  • Page 350: Ac Power Input

    Appendix A Cable Assembly, AC Power Input Table 5. Pedestal Model - Part of AC Power Cables, Ped, Field Kit, 257659-001 Wire Color Line Black Neutral White Ground Green/Yellow To Power Switch Input Power Connector 184620b To Power Switch Input Power Connector Table 6.

  • Page 351: Control Panel

    Cable Assembly, Control Panel Part of: Control Panel/Cable/Overlay, Cab, Field Kit, 257654-001 Control Panel/Cable/Overlay, Ped, Field Kit, 257655-001 Pin 1 Pin 1 184972a...

  • Page 352: Hammerbank Logic

    Appendix A Cable Assembly, Hammerbank Logic Part of: Cables, Hammerbank Logic/Pwr, 5/10, Field Kit, 257660-001 Cables, Hammerbank Logic/Pwr, 15/20, Field Kit, 257661-001 To Shuttle To Controller Board Pin 1 184966a...

  • Page 353: Hammerbank Power

    Cable Assy, Hammerbank Power Part of Cables, Hammerbank Logic/Power, 5/10, Field Kit, 257660-001 IMPORTANT: Use this cable on any P8000 printer except the P8000HD, P8208H, P8200HD, P8220, and P8206H For P8000HD, P8208H, P8206H, P8200HD, and P8220 use P/N 256918-901, shown on the next page. To Controller Board To Shuttle Wire Table...

  • Page 354: Dual Hammerbank Power

    Appendix A Cable Assy, Dual Hammerbank Power Part of Cables, Hammerbank Logic/Pwr, 15/20 Field Kit, 257661-001 IMPORTANT: Use this cable on the P8000HD, P8208H, P8220HD, P8206H, and P8220 printer. The P8220 printer requires two cables. For any other P8000 printer use P/N 257660-001 (part of Cables, Hammerbank Logic/Pwr, 5/10 Field Kit), see previous page.

  • Page 355: Motor Harness

    Cable Assembly, Motor Harness (P/N 256757-001) P307 P306 P109 P308 P116 J06B P106 184990a J06A 184990 REV A...

  • Page 356: Sensor Harness

    Appendix A Cable Assembly, Sensor Harness (P/N 256758-001) P108 P107 184989a 184989 REV A...

  • Page 357: Shuttle Motor Drive

    Cable Assembly, Shuttle Motor Drive Part of Cable Assy, Motor Harness 256757-001...

  • Page 358: Frame Cable, Power Stacker

    Appendix A Frame Cable, Power Stacker - Part of Cable Kit, Power Stacker, 257670-001...

  • Page 359: Logic Cable, Power Stacker

    Logic Cable, Power Stacker Part of Cable Kit, Power Stacker, 257670-001...

  • Page 360: Power Cable, Power Stacker

    Appendix A Power Cable, Power Stacker Part of Cable Kit, Power Stacker, 257670-001 Pin 1 Pin 1 184968a P106 Pin 1 Pin 1 Pin 2 Pin 2 Pin 3 Pin 3 Pin 4 Pin 4...

  • Page 361: Rail Cable, Power Stacker

    Rail Cable, Power Stacker - Part of Cable Kit, Power Stacker, 257670-001...

  • Page 362: Elevator I/O Cable, Power Stacker

    Appendix A Elevator I/O Cable, Power Stacker Part of Cable Kit, Power Stacker, 257670-001...

  • Page 363: Fan Assembly, Hammerbank

    Fan Assembly, Hammerbank (Part of Fan Assy Spares Kit, HB/CC/EXH, 257656-001) Pin 3 Pin 3 J308 Polarity Wire Color Pin 1 — Pin 2 — — Pin 3 — Black...

  • Page 364: Card Cage (Intake) Fan And Exhaust Fan

    Appendix A Card Cage (Intake) Fan and Exhaust Fan (Part of Fan Assy Spares Kit, HB/CC/EXH, 257656-001) Pin 1 Pin 3 184998a Wire Table **F(P) Polarity Pin 1 184998 REV A Pin 2 Pin 3...

  • Page 365: Magnetic Pickup (Mpu) Assembly

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

  • Page 366: Switch Assembly, Paper Detector

    Appendix A Switch Assembly, Paper Detector (Part of Switch Assy, Platen Open/Paper Detect, Field Kit, 257653-001) Pin 1 Pin 5 Cable Pin 1 Pin E Black Pin 2 Pin C Gray Pin 3 Pin K White Pin 4 Pin A Pin 5 Pin A Black...

  • Page 367: Switch Assembly, Platen Interlock

    Switch Assembly, Platen Interlock (Part of Switch Assy, Platen Open/Paper Detect Field Kit, 257653-001) Pin 1 184971a Pin 3 Interlock Wire Color Switch Pin 1 Black Pin 2 — — Pin 3 Gray...
  • Page 368 Appendix A...

  • Page 369: B Abbreviations

    Abbreviations NOTE: Signal abbreviations with first letter “N” are negative true. Abbreviation Definition KΩ 1,000 Ohms MegΩ 1,000,000 Ohms μF microfarad (10 farad) μs microsecond (10 second) μsec microsecond (10 second) A0, A1, etc. Address 0, Address 1, etc. Alternating Current Access Acknowledge Amplitude;...
  • Page 370 Appendix B Cathode Card Cage Card Cage Fan CHNG Change Circuit Clock Cover Open COLL Collector COMM Communication CONTLR Controller Command Connector, Connection Characters Per Inch CPLD Complex Programmable Logic Device Carriage Return Control Cartridge Ribbon Printer Cartridge Ribbon System Clear to Send Control Unit Current...
  • Page 371 DRVR Driver Data Set Ready Data Terminal Ready Engine Controller (a functional unit of the controller board) EEPROM Electrically Erasable/Programmable Read-Only Memory Exhaust Fan Elevator motor (power stacker) EMEA Europe, Mideast, and Africa ElectroMagnetic Interference EMIT Emitter EPROM Electrically Programmable Read-Only Memory Error Electrostatic Discharge Exhaust, Extra...
  • Page 372 Appendix B Hammer Driver, High Definition HDIC Hammer Driver Integrated Circuit HDPH Hammer Driver Phase Hammerbank Logic, Signals, and Power Hardware Integrated Circuit Identification Intelligent Graphics Printing INST Instruction Interrupt Input/Output Illustrated Parts Breakdown Inches Per Minute Interrupt Request Jack connector JEDEC Joint Electron Device Engineering Council.
  • Page 373 Motor Magnetic Pick-Up (Unit) millisecond (10 second) Motor and Sensors, Left Motor and Sensors, Right Negative True; Newton (metric unit of force) Network Interface Card (ethernet interface) Not Connected Not Connected Near Letter Quality Number NOVRAM Nonvolatile Random Access Memory nanosecond (10 second) NVRAM...
  • Page 374 Pin or Plug Part Number Paper Out Paper Out Detector Switch Paper PROM Programmable Read-Only Memory Power Supply Power Supply + 5 Volt PSA3 Printronix System Architecture, Third Generation Pointer, Printer Pulse Width Modulation Power Right Ribbon Read Ready Return Ribbon...
  • Page 375 Request Ribbon and Shuttle Processor Reset Request to Send Receive Data SNA Character Stream Security (Key) Select Sense, Sensor Structured Field Signal Ground Shuttle Hall (Effect) Shuttle Motor SHUT Shuttle SHUTL Shuttle SIMM Single Inline Memory Module SLCT Select (Online) Slew Rapid vertical paper movement Shuttle Motor Drive...
  • Page 376 Appendix B Task Control Block TEMP Temperature; Temporary Top Of Form (first print line) Test Point Transistor-Transistor Logic Transmit Data UART Universal Asynchronous Receiver/Transmitter UDPH Upper Drive Phase UNDEF Undefined USART Universal Synchronous/Asynchronous Receiver/ Transmitter Volts Volts, Alternating Current Volts, Direct Current Voltage at Collector Voltage at Drain Code V™...

  • Page 377: C Metric Conversion Tables

    Metric Conversion Tables Length Multiply To Obtain foot 0.3048* meter (m) foot 30.48* centimeter (cm) foot 304.8* millimeter (mm) inch 0.0254* meter (m) inch 2.54* centimeter (cm) inch 25.4* millimeter (mm) meter 3.280840 foot centimeter 0.03280840 foot millimeter 0.003280840 foot meter 39.37008 inch...
  • Page 378 Appendix C Mass and Density Multiply To Obtain pound* 0.4535924 kilogram (kg) ounce* 28.34952 gram (g) kilogram 2.204622 pound* gram 0.03527393 ounce* * avoirdupois Temperature To Convert Use Formula temperature Celsius (t temperature Fahreheit (t = 1.8 t + 32 temperature Fahreheit (t temperature Celsius (t = (t...

  • Page 379: D Surestak™ Power Stacker

    SureStak Power Stacker ™ Contents Introduction ..................page 380 Stacker Operation ................page 380 Setting Up The Power Stacker ..........page 381 Loading And Starting The Power Stacker......... page 384 Stacker Problems ................page 385 Stacker First Inspection ............page 385 Stacker Confidence Check ............

  • Page 380: Introduction

    Appendix D Introduction The SureStak Power Stacker is both a factory-installed and field upgradable option that augments the paper feed system of cabinet model printers. It is designed to work with forms 5 to 12 inches long (12.7 to 30.5 cm) and up to 16 inches (41 cm) wide without the paper tent installed or up to 15.5 inches (39.5 cm) wide with the paper tent installed.

  • Page 381: Setting Up The Power Stacker

    Setting Up the Power Stacker IMPORTANT If using Ethernet and/or USB, route the cables to the left and attach the cable clips. After connecting and placing the cables, manually move the the stacker to its uppermost position to ensure the stacker does not touch the cables.
  • Page 382 Appendix D 4. If the paper you will use is not wider than 15.5 inches (39.5 cm) pull out the paper tray and install the wireform paper tent. (Figure 3.) If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer. Paper Tent Paper Tray Note the positions of...
  • Page 383 5. Push or pull the paddle shaft toward the front or the rear of the printer to set the desired paper length. Align the indicator notch on the bearing bracket with the paper length indicator. The power stacker can handle paper or forms from 5 to 12 inches (12.7 to 30.5 cm) long.

  • Page 384: Loading And Starting The Power Stacker

    Appendix D Loading and Starting the Power Stacker 1. Press the PAPER ADVANCE key and hand feed the paper down into the paper throat of the stacker. Continue to advance the paper until it reaches the paper tent (if installed) and feed three to five extra sheets into the stacker.

  • Page 385: Stacker Problems

    Stacker Problems The power stacker augments the paper feed system of the printer. The most frequently occurring problems in the paper feed system are paper jams. Other problems that can occur are worn or poor electrical connections and cabling, worn or defective feed motors, worn or damaged mechanical components, or incorrect installation of the stacker assembly.

  • Page 386: Stacker Confidence Check

    Appendix D c. With the elevator at its lowest position, run the Shuttle Slow test (page 155) from the front operator panel. While the test runs, interrupt both IR beams, one at a time, and verify that the elevator rises. d.

  • Page 387: Stacker Motor Check

    6. Using the rear operator panel, press the PAPER ADVANCE (down arrow) key until three or four pages feed through the stacker throat. a. Check the LCD on the front operator panel for faults. If there is a fault, the paper out detector is failing and needs to be checked and cleaned.
  • Page 388 Appendix D 8. Check all four stacker motors for 15.2 ± 1.5 Ohms resistance per phase. All four motors are the same: Measure pin 1 to pin 2 for Phase A Measure pin 3 to pin 4 for Phase B pin 1 = red pin 2 = yellow pin 3 = orange...
  • Page 389 Table 1. Power Stacker Problems Symptom Origin of Symptom Explanation Solution Stacker limit switch Other troubleshooting A procedure that tests the page 141 check procedures. motion limit switch at the top and bottom of the right vertical rail. You will usually be referred to this procedure from other troubleshooting procedures.

  • Page 390: Removing The Power Stacker

    Appendix D Removing the Power Stacker 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Unload paper from the stacker area. (Refer to the User’s Manual.) 4. Remove the paper tent (if present). (Figure 6.) Paper Tent Figure 6.
  • Page 391 6. Remove the two 10-32 x 5/32 inch buttonhead screws and washers securing the vertical rails to the upper frame cross-member at the rear of the cabinet. (Figure 8.) 7. Remove the two Torx T-10 screws securing the stacker base to the cabinet floor.
  • Page 392 Appendix D 10. Loosen one turn (do not remove) the M3x6 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (Figure 9.) M3x6 Buttonhead Screw (Two on each rail) Access Hole in Tray Rail Figure 9.
  • Page 393 11. Lower the elevator assembly to its lowest position. Tilt the vertical rails towards the front of the printer to make room for removing the control panel. 12. Remove the two 4-40 x 1/4 inch screws securing the elevator I/O cable to the elevator assembly and disconnect the stacker I/O cable.
  • Page 394 Appendix D 13. Remove two screws, washers, and the standoff from the stacker control panel. (Figure 11.) Standoff Washer Washer Long Screw Short Screw Figure 11. Removing the Stacker Control Panel 14. Remove four cables from the stacker control panel, and remove the stacker control panel.
  • Page 395 NOTE: It may be easier to wear gloves for the next step. 15. Slide the stacker assembly slightly to the right to clear the air exhaust duct. Tilt the vertical rails toward the front of the printer until they clear the upper frame cross-member.

  • Page 396: Installing The Power Stacker

    Appendix D Installing the Power Stacker NOTE: This section shows installation of the power stacker assembly, the stacker cable assemblies, and the stacker control panel. 1. Set the printer power switch to O (off). 2. Unplug the power cord. 3. Remove paper. 4.
  • Page 397 5. Connect the power stacker logic cable P103 to connector J117 on the controller board. (Figure 15.) 6. Connect the stacker power cable P6 to J6 on the controller board. (Figure 15.) 7. Route the stacker logic cable in front of the controller board and down through the cutout under the card cage fan.
  • Page 398 Appendix D 9. Pull the paper tray out until the holes in the rails permit access to the M3 buttonhead screws. (Figure 16.) 10. Loosen one turn—do not remove—the M3 screws securing the vertical rails to the stacker base. Each rail is secured by two screws. (Figure 16.) M3x6 Buttonhead Screw (Two on each rail) Access Hole in...
  • Page 399 11. Position the elevator assembly at the bottom of the vertical rails. (Figure 17.) 12. Connect the elevator I/O cable to the elevator assembly and install the two 4-40 x 1/4 inch screws, as shown in Figure 17. Vertical Rail Elevator Assembly Stacker I/O Cable...
  • Page 400 Appendix D NOTE: It may be easier to wear gloves for the next step. 13. Position the stacker assembly slightly to the right in order to clear the air exhaust duct, insert the vertical rails inside and under the upper frame cross-member, then slowly swing the base of the stacker assembly into the cabinet.
  • Page 401 16. Align the holes in the stacker base with the holes in the cabinet floor. (Figure 18c and Figure 19) 17. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer securing the left vertical rail to the upper frame cross-member. (Do not install the right hand screw yet.) (Figure 19.) 18.
  • Page 402 Appendix D 20. Gather the stacker rail cable, elevator I/O cable, logic cable, and power cable. Route the cables outboard of the elevator assembly. (Figure 20.) Elevator Elevator I/O Assembly Cable Rail Cable (To Card Cage) Control Panel) Stacker Stacker Logic Cable Power Cable Figure 20.
  • Page 403 21. Connect the stacker cables to the rear of the stacker control panel assembly and make sure the ejector levers close over the connectors. (Figure 21.) 22. Press rail cable connector P107 into the control panel until the ejectors close, then tie wrap the ejectors to the connector. (Figure 21, detail A.) Ejection Lever Logic Cable (P104)
  • Page 404 Appendix D 23. Apply the double-sided tape to one end of the control panel standoff. Remove the paper backing and hold the standoff inside the cabinet while you insert the upper mounting screw and washer through the hole in the frame.
  • Page 405 26. Install finger tight the 10-32 x 5/32 inch buttonhead screw and washer securing the right vertical rail to the upper frame cross-member. (Figure 19.) 27. Move the elevator assembly up and down on the vertical rails until it travels smoothly with no binding. 28.
  • Page 406 Appendix D 32. Install the paper fence. (Figure 24.) Stacker Base Paper Fence Figure 24. Paper Fence...
  • Page 407 33. If the paper you will use is not wider than 15.5 inches (39.5 cm), pull out the paper tray and install the paper tent. (Figure 25.) If the paper is wider than 15.5 inches (39.5 cm) leave the paper tent out of the printer Paper Tent Paper Tray Note the positions of...

  • Page 408: Replacing The Constant Force Spring

    Appendix D Replacing the Constant Force Spring 1. Remove the stacker assembly from the printer. (See page 390.) 2. Raise the elevator assembly to within about 1/4 inch of its highest position and secure it to the vertical rails using tie wraps or string. Do not over- tighten the tie wraps or string;...
  • Page 409 WARNING The constant force spring is powerful and under high tension. Protect your hands with gloves. To avoid pinching or cutting your fingers, grip the spring and drum firmly in the next two steps. Coil the spring slowly and carefully. Do not let the spring twist or crimp. 3.

  • Page 410: Replacing The Timing Belts

    Appendix D Replacing the Timing Belts 1. Remove the stacker assembly from the printer (page 390). 2. Raise the elevator assembly to its highest position and secure it to the vertical rails using tie wraps or string. Do not over-tighten the tie wraps or string;...
  • Page 411 6. Remove the shoulder screw and large washer that secure the constant force spring to the vertical rail. (Figure 30.) NOTE: Left is shown. Right is the same. Constant Force Spring Large Washer Shoulder Screw Figure 30. Releasing the Constant Force Spring 7.
  • Page 412 Appendix D 8. Remove the timing belt by working it around the vertical rail and constant force spring. (Figure 32.) 9. To install a timing belt, reverse the steps of this procedure. NOTE: Left timing belt is shown. Right is the same.

  • Page 413: Replacing The Roller Drive Shaft

    Replacing the Roller Drive Shaft 1. Remove the stacker assembly from the printer (page 390). 2. Unhook the right bearing pivot plate’s extension spring from the tab on the elevator. (Figure 33.) 3. Using an M-2 Allen wrench, remove the screw securing the right bearing pivot plate to the elevator.
  • Page 414 Appendix D 4. Move the idler shaft enough to expose the lower mount screw of the power stacker stepper motor. (Figure 34.) 5. Cut and remove the upper tie wrap securing the stepper motor wires to the elevator. (Be careful not to cut a motor wire.) 6.
  • Page 415 9. Remove the roller drive shaft, taking care to retain the bearing at the left end of the shaft and the collar at the right end of the shaft. (Figure 35.) 10. Remove the bearing and collar from the old roller drive shaft and retain these items for installation on the new roller drive shaft.

  • Page 416: Illustrated Parts Breakdown

    Appendix D Illustrated Parts Breakdown The Illustrated Parts Breakdown (IPB) consists of exploded drawings of the power stacker assembly and subassemblies. Parts are listed next to each drawing. NOTE: Part numbers listed in the column labeled Europe, Mideast, and Africa (EMEA) are RoHS compliant. These parts conform to requirements specified in DIRECTIVE 2002/95/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27 January 2003 on the restriction of the use of certain hazardous substances in...

  • Page 417: Figure 36. Stacker Assembly

    See page 419. 3 4 5 Figure 36. Stacker Assembly...
  • Page 418 Appendix D Part No. Item (RoHS Description Notes Compliant) Stacker Assembly, Power, Black Part of 251228-001, Field Kit, Pwr Stkr, Blk. Washer, 5/16 X .200 X .030, Stainless Steel Screw, Hex Skt Btn Hd, Zinc M3X8mm Washer, Shim, .125 ID X .010 inch Thick Timing Belt Tensioner Assy, Pwr Stkr Part of item 1.

  • Page 419: Figure 37. Elevator Detail: Motors, Rollers, And Paddles

    From page 417. See page 421. See page 425. 45 46 See page 423. See page 423. Figure 37. Elevator Detail: Motors, Rollers, and Paddles...
  • Page 420 Appendix D Part No. Item (RoHS Description Notes Compliant) 158313-001 Anti-Static Brush Shear Grommet Cap Nut Drive Shaft Assy (Roller Drive Shaft) Part of 257668-001, Field Kit, Stkr Motor. Includes items 14, 70, and 75. Spacer, Drive Roller Part of item 47. 202789-901 Bearing, Flanged 202824-901...

  • Page 421: Figure 38. Stacker Detail: Motor Bracket

    From page 419. Flag Connector Figure 38. Stacker Detail: Motor Bracket...
  • Page 422 Appendix D Part No. Item (RoHS Description Notes Compliant) Clip-On Bearing Holder, LED, Round Part of item 1. LED, IR, T-1, 3/4 Part of item 52.

  • Page 423: Figure 39. Stacker Detail: Elevator Bracket

    From page 419. Flag Connector Figure 39. Stacker Detail: Elevator Bracket...
  • Page 424 Appendix D Part No. Item (RoHS Description Notes Compliant) Clip-On Bearing Holder, LED, Flat Part of item 1. Photodarlington, NPN, Rectifier Part of item 52.

  • Page 425: Figure 40. Stacker Detail: Paper Motion Detector

    From page 419. Rotated 180 Degrees Connector Figure 40. Stacker Detail: Paper Motion Detector...
  • Page 426 Appendix D Part No. Item (RoHS Description Notes Compliant) Holder, LED, Flat Part of item 1. Photodarlington, NPN, Rectifier Part of item 52. Retaining Ring, External, 0.093 inch Part of item 115. Screw, Panhead, Type B, 2 x 3/16 Shaft, Paper Detector Switch, Long Part of item 115.

  • Page 427: E Zero Tear Pedestal (Ztp) Printer

    Zero Tear Pedestal (ZTP) Printer Contents Overview ..................page 428 Operation ..................page 429 Load Paper and Set Up the Tractors ........page 429 Remove Paper................page 430 Adjust the Paper Guides............page 431 Position the Paper Out Sensor ..........page 432 Set the Tear Bar Distance ............

  • Page 428: Overview

    Appendix E Tractor Assembly Support Gate ..........page 456 Illustrated Parts Lists............... page 458 Figure 16. ZTP Details ..............page 460 Figure 17. ZTP Inside Covers, Barrier Shield, and Shuttle Assy ..page 462 Figure 18. ZTP Circuit Boards and Paper Feed Assembly ..... page 464 Figure 19.

  • Page 429: Operation

    Operation Load Paper and Set Up the Tractors Cover Paper Paper Label Paper Supply Box Figure 1. Aligning and Loading Paper onto the Printer 1. Remove the paper from the box and set it down on the lower shelf (See Figure 1.) 2.

  • Page 430: Remove Paper

    Appendix E Outer Paper Guide Leaf (2) Center Paper Front Paper Guide Leaf (3) Guide Leaf Paper Tractor (2) Tractor Lock (2) Paper Out Sensor Figure 2. Adjusting the Horizontal Paper Tension 3. Unlock and open the tractor doors and slide the paper from below, through the black paper out sensor slot on the left side, and up between all front and rear paper guide leaves.

  • Page 431: Adjust The Paper Guides

    Adjust the Paper Guides Center Paper Guide Leaf Note: Paper guides located underneath. Front Paper Outer Paper Guide Leaf (3) Guide Leaf (2) Paper Guide Knob (3) Figure 3. Adjusting The Paper Guides NOTE: Ensure that the paper guide leaves are not damaged. 1.

  • Page 432: Position The Paper Out Sensor

    Appendix E 5. Using the paper scale as reference, position the middle paper guides in the center. 6. Reload the paper without unlocking the tractors. (See page 429.) Position the Paper Out Sensor At least 2 inches Sensor Knob Paper Out Sensor Paper Figure 4.

  • Page 433: Set The Tear Bar Distance

    Set the Tear Bar Distance To set the tear bar distance, do the following steps: 1. Make sure the printer is offline. 2. Press ENTER key to enter Menu mode. 3. Press the right arrow until the PRINTER CONTROL icon is highlighted. 4.

  • Page 434: Set The Top Of Form

    Appendix E Set the Top Of Form Paper Tear Bar Form Advance Knob Figure 6. Setting The Tear Off Position The ZTP printer uses the tear bar as the reference point for setting the tear off position. To set the position of the forms perforation to the tear bar, use the TOF button as follows: 1.

  • Page 435: Control Panel Menus

    Control Panel Menus The ZTP SETTINGS menu includes the ability to enable and disable features unique to the Zero Tear Pedestal (ZTP) printer, set the tear bar distance, set the auto present data time, and set the auto present wait time. This section defines these options.

  • Page 436: Performance Considerations

    Appendix E Performance Considerations Forms Type The paper feed tractors on the ZTP printer push the paper up through the print station instead of pulling it through, as in the standard pedestal printer. This limits the variety of forms the ZTP printer can use. If the forms do not fall within the range specified in Table 1, dot compression, line separation, and jamming may occur.

  • Page 437: How To Set The Ztp Printer To Help Mitigate Paper Jams

    Paper Jams Printer jams can occur if you tear off the form incorrectly. If you experience two or more paper jams per box of forms, follow these guidelines to help reduce jams: • Position the lower paper guides properly • Align the paper web tightness properly •...

  • Page 438: Removing The Paper Ironer

    Appendix E Try setting one or more of the following parameters to help mitigate Forms Jams when using lightweight stock or multi-part forms with thin plies: • Under the Emulation menu -> Font Attributes, select Typeface NLQ. • Under the Emulation menu -> Font Attributes, set Bold Print to Enable. •...

  • Page 439: Adjustments And Tests

    Adjustments and Tests The printer is a durable, low-maintenance machine, but some components and systems require occasional adjustment and may need to be tested as part of a troubleshooting procedure. You usually will be referred to this chapter by a troubleshooting procedure, or as part of a removal/installation procedure.

  • Page 440: Preparing The Ztp Printer For Maintenance

    Appendix E Preparing the ZTP Printer for Maintenance WARNING Unplug the printer power cord from the printer or power outlet before you do any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

  • Page 441: Barrier Panel

    Barrier Panel 1. Prepare the printer for maintenance (page 440). 2. Loosen (do not remove) the two #2 Phillips hold-down screws on the rear of the printer. (See page 460, item 4.) 3. Loosen the screws in the top corners of the barrier panel. (See Figure 7.) Barrier Panel Screw (2)

  • Page 442: Belt, Paper Feed Timing, Adjustment

    Appendix E Belt, Paper Feed Timing, Adjustment 1. Prepare the printer for maintenance (page 440). 2. Remove the hex screws and right cover plate. (See page 443, items 1 and 2.) 3. Loosen (do not remove) the two 5/16 inch motor mount bolts (item 3). 4.
  • Page 443 Direction of Force 1/8 inch 184641 REV A Legend: Screw, Hex w/Lockwasher (4) Cover Plate, Right Extension Motor Mount Bolt (2) Paper Feed Drive Motor Splined Shaf Pulley Paper Feed Timing Belt Paper Feed Motor Pulley Figure 9. Paper Feed Timing Belt Adjustment...

  • Page 444: Paper Guide Leaf, Front, Center, Outer

    Appendix E Paper Guide Leaf, Front, Center, Outer 1. Prepare the printer for maintenance (page 440). 2. Adjust the paper guides. (See page 431.) Paper Out Sensor, Adjustment 1. Prepare the printer for maintenance (page 440). 2. Adjust the paper out sensor. (See page 432.) Paper Tension, Horizontal 1.

  • Page 445: Replacement Procedures

    Replacement Procedures WARNING Unplug the printer power cord from the printer or power outlet before doing any maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. Only apply power during maintenance if you are instructed to do so in a maintenance procedure. IMPORTANT The components specified in this chapter are field replaceable units (FRUs).

  • Page 446: Belt, Paper Feed Timing

    Appendix E Belt, Paper Feed Timing Removal 1. Prepare the printer for maintenance (page 440). 2. Remove the hex screws and right cover plate. (See page 443, items 1 and 2.) 3. Loosen (do not remove) the two 5/16 inch paper feed motor mount screws.

  • Page 447: Control Panel Assembly

    Control Panel Assembly Removal 1. Prepare the printer for maintenance (page 178). 2. Open the printer cover. 3. Remove the four screws securing the panel bracket to the printer cover. (See page 460, items 1, 2, and 3). 4. Remove the two screws securing the control panel to the panel bracket. 5.

  • Page 448: Paper Feed Motor

    Appendix E Paper Feed Motor Removal 1. Prepare the printer for maintenance (page 440). 2. Remove the electronics barrier panel. (See page 237.) 3. Remove the paper feed timing belt. (See page 446.) 4. Trace the paper feed motor cables back to the controller board, releasing it from tie wraps.

  • Page 449: Paper Guide Leaf, Center

    Paper Guide Leaf, Center Removal 1. Prepare the printer for maintenance (page 440). 2. Remove the center paper guide knob and center paper guide leaf. (See page 453, Figure 13.) 3. Remove the top button head screw, bottom flat head screw, and center guide leaf.

  • Page 450: Paper Out Sensor

    Appendix E Paper Out Sensor Screw (4) Paper Out Sensor Cable Adaptor Cable Assembly Left Cover Plate Harness Tie Wraps (5) Connector Wrap Paper Out Sensor Sensor Knob Figure 11. Replacing the Paper Out Sensor Assembly Removal 1. Prepare the printer for maintenance (page 440). 2.
  • Page 451 Installation 1. Install the sensor knob and paper out sensor. 2. Route the paper out sensor cable up along the left side of the printer. (See Figure 11 on page 450.) 3. Connect J11 to P11 and install tie-wraps to secure the sensor cable. 4.

  • Page 452: Shaft, Splined

    Appendix E Shaft, Splined Right Cover Plate Motor Mount Screw (2) Screw (4) Paper Feed Timing Belt 184643 REV Figure 12. Removing the Right Cover Plate...
  • Page 453 Removal 1. Prepare the printer for maintenance (page 440). 2. Remove the hex screws and right cover plate. (See Figure 12.) 3. Loosen (do not remove) the two 5/16 inch paper feed motor mount screws. 4. Remove the paper feed timing belt. Center Block Block Mount (2) Mount...
  • Page 454 Appendix E Installation 1. Position the splined shaft so the alignment marks are at the bottom on both tractors. (See Figure 14.) 2. Slide the splined shaft through the right side plate, tractors, and block mounts. Make sure the same spline passes the marked groove on each tractor.

  • Page 455: Shaft, Support

    Shaft, Support Removal 1. Prepare the printer for maintenance (page 440). 2. Remove the hex screws and right cover plate. (See page 464, items 24 and 25.) 3. Unlock the tractors and slide them to the far right. (See page 468, item 1.) 4.

  • Page 456: Tractor (L/R)

    Appendix E Tractor (L/R) Removal 1. Prepare the printer for maintenance (page 440). 2. Remove the support shaft (page 455). 3. Remove the splined shaft (page 452). Installation 1. Using the replacement tractors, install the support shaft (page 455). 2. Install the splined shaft (page 452). 3.
  • Page 457 9. Return the printer to normal operation (page 440). Support Shaft Splined Shaft Tractor Door (2) Tractor Lock (2) Left Side Plate Tractor Assembly Support Gate (2) Right Side Plate Figure 15. Removing and Installing the Tractor Assembly Support Gate...

  • Page 458: Illustrated Parts Lists

    Appendix E Illustrated Parts Lists Only replaceable parts are given part numbers in the illustrated parts lists. Part numbers are not listed for common fasteners and attachment hardware. Items marked “Ref” in the illustrations refer to parts that are not spared or are part of another assembly.
  • Page 459 (Parts list continue on the next page.)
  • Page 460 Appendix E 184644 REV A Figure 16. ZTP Details...
  • Page 461 Part No. Item (RoHS Description Notes Compliant) 257655-001 Control Panel/Cable/Overlay, Pedestal Field Kit Includes control panel, cable, and overlay. Screw, Captive (4) 257360-001 Top Cover Assembly, ZTP, P8 257662-001 Field Kit, Lid, Hinge/Springs Includes two hinges and dashpot. Screw, 6-32X1/4, HWHS, STM/ZNB, AE B18.6.3 Cable Assembly, Control Panel Part of item 1.
  • Page 462 Appendix E To J02 (Shuttle Motor) Two places: Exploded to show assembly. Do not remove the clamps and screws. To J03 (MPU) See Figure 54, page 280. Figure 17. ZTP Inside Covers, Barrier Shield, and Shuttle Assembly...
  • Page 463 Part No. Item (RoHS Description Notes Compliant) 256424-901 Shuttle Cover Assembly or Shroud Assembly Air Shroud Assembly. Includes item 9. Screw, Captive (2) 10-24x.62 with O-ring, .125x.250x.06 Screw, Thread-forming (2) 6-32x.25 and #6 flat washer. 257117-001 Panel, Cover, Electronics 257116-001 Power Supply Insulator Taped to card cage along upper edge.
  • Page 464 Appendix E To the Terminator Board on the Shuttle Frame Figure 18. ZTP Circuit Boards and Paper Feed Assembly...
  • Page 465 Part No. Item (RoHS Description Notes Compliant) PCBA, Ribbon Motion Sensor (RMS) Part of 257663-001, Field Kit, Ribbon Motion/Weld Sensor. Not Used 256227-901 Power Supply, LM, LS 500, 1000, 03H 256279-901 Power Supply, LM, HS 1500 P101A and P101B Cable Connectors Part of item 3 Cable Assembly, AC-In, Power Supply Part of the following field kits:...
  • Page 466 Appendix E Part No. Item (RoHS Description Notes Compliant) 257764-001 Motor, Paper Feed, Field Kit, 20 257763-001 Motor, Paper Feed, Field Kit, 5/10/15 Not Used Not Used Not Used Paper Feed Assembly, ZTP Screw w/Lociwasher and Flat Washer 202220-001 Screw, 6-32x1/4, HWHS, STM/ZNB,AE B18.6.3 257347-001 Cover, Tractor Knob, ZTP, P8...
  • Page 467 (Parts list continue on the next page.)
  • Page 468 Appendix E Figure 19. ZTP Tractor Shafts, Paper Guides, and Paper Feed Motor...
  • Page 469 Part No. Item (RoHS Description Notes Compliant) 179065-901 Tractor Set, Non-Roller, 05/10/15 (Blue) Shaft, Spacer, Tractor, ZTP Part of item 24. Pad, Nylon, Mount Block, ZTP Part of item 24. Screw, Button Head (3) 256323-901 Field Kit, Paper Feed Motor, V3 Screw, Hex w/Lock Washer, 10-24x.50 (2) Part of item 5.
  • Page 470 Appendix E NOTE: Item 24: Platen Hardware Kit Figure 20. ZTP Platen and Integrated Print Management Sensor Assembly...
  • Page 471 Part No. Item (RoHS Description Notes Compliant) Setscrew (2) Part of item 24. Bracket, Platen (2) Part of item 24. Screw, Thread-forming (3) 6-32x.25 Ironer Assembly, Reverse Paper Feed 257665-001, Field Kit, Ironers, PPR Feed, AUX, includes items 3. Plate, Ironer Part of item 4.
  • Page 472 Appendix E Figure 21. ZTP Hammerbank Fan and Motors...
  • Page 473 Part No. Item (RoHS Description Notes Compliant) Switch Assembly, Paper Detector 257653-001, Field Kit, Switch Assy, Platen Open/Paper Detect. 170172-001 Field Kit, Slotted Black Back Form Switch Optional switch used with black back forms. Screw, Thread-forming, 6-32x.375 (2) Motor Assembly, Platen 257652-001, Field Kit, Motor, Platen Open with Timing Belt.
  • Page 474 Appendix E...

  • Page 475: F Paper Specifications And Forms Design

    Paper Specifications And Forms Design Introduction This appendix is divided into two sections. The first section lists general specifications for continuous form paper used in this printer. (Specific brands of paper are not recommended.) The second section goes into more detail, providing definitions, guidelines, and a checklist you can use to design forms that will run smoothly through the printer.

  • Page 476: General Paper Specifications

    Celsius (68 to 78 Fahrenheit) and 45% to 55% relative humidity. Printronix printers perform well with forms that meet the specifications listed in Table 1 and Table 2 below. NOTE: Printronix conforms to ANSI® Standard X3.96-1983, “American National Forms Information Systems for Continuous Business Forms,”...

  • Page 477: Paper Guidelines

    Paper Guidelines The terms below are used to describe and discuss continuous form paper. Terms and Definitions Chaff Bits of paper not completely removed after the punch process that creates tractor pin holes, major and minor perforations, etc. Cut Point The area along a perforation where a cut has been made that extends through the entire form.
  • Page 478 Appendix F The figure below illustrates the terms used in this appendix. Side Perforation Margin Area Tractor Pin Hole Page Perforation Cut Point Tie Point Print Area Form Span Side View of Form Printed Side of Form Outward Perforation Inward Perforation Figure 1.

  • Page 479: Environmental Considerations

    Environmental Considerations Before they are used, forms should be stored for at least 24 hours — preferably 48 hours — in the environment in which they will be used. This stabilizes the moisture content of the paper, resulting in better feeding and stacking.

  • Page 480: Methods Of Forms Attachment

    Appendix F Specification Inches Millimeters Hole centerline (CL) to edge of form 0.236 ± 0.028 6.0 ± 0.10 Hole Diameter (Serrations or any 0.156 ± 0.004 4.0 ± 0.10 occlusion due to incorrect registration of multipart forms cannot exceed this dimension.) Distance between centers of two 0.500 ±...

  • Page 481: Chaff Content

    Preferred Unacceptable Cut Point Tie Point Direction of Forms Movement Cut Point Tie Point Figure 2. Preferred vs. Unacceptable Form Staples Cut-To-Tie Ratio A common cut-to-tie ratio for bond forms is 4:1 (that is, 80% cut to 20% ties). This value is dictated chiefly by the application program that the form runs under.

  • Page 482: Form Design Checklist

    Appendix F Form Design Checklist Use this checklist to help you remember key areas of consideration when designing and ordering forms and paper stocks. Environment ________ Before they are used, forms are given at least 24 hours of condensing time in the environment in which they will be used.
  • Page 483 Form Evenness The evenness of the form = ________ (Not to exceed 0.003 in. / 0.00762 cm) Tenting due to buildup of perforation thickness must be minimized. A perforation thickness measured at the major perforation that exceeds 1.25 times the forms thickness measured in the print area will result in an unreliable and unpredictable form.
  • Page 484 Appendix F ________ Staples should be placed in the margins so that they coincide with areas of the form where printing will not occur Cut-To-Tie Ratio ____:____ (Typical ratio is 4:1, or 80% cut to 20% tie) Thickness Buildup = ________ in. / cm NOTE: A cut-to-tie ratio that causes a thickness buildup greater than 0.025 in.

  • Page 485: Summary

    Summary Because it is impossible to test all possible forms available for use in the printer, Printronix recommends that paper conform to the specifications outlined in this appendix for the best printer performance. But the guidelines in this appendix are not a substitute for actual testing.
  • Page 486 Appendix F...

  • Page 487: Customer Support

    Asia Pacific (65) 6548 4114 China (86) 800-999-6836 http://www.printronix.com/support.aspx Printronix Supplies Department Contact the Printronix Supplies Department for genuine Printronix supplies. Americas (800) 733-1900 Europe, Middle East, and Africa (33) 1 46 25 19 07 Asia Pacific (65) 6548 4116...

  • Page 488: Corporate Offices

    Phone: (65) 6542 0110 Fax: (65) 6546 1588 Printronix Commercial (Shanghai) Co. Ltd 22F, Eton Building East No.555, Pudong Av. Shanghai City, 200120, P R China Phone: (86) 400 886 5598 Fax: (86-21) 5138 0564 Visit the Printronix web site at www.printronix.com...

  • Page 489: H Communication Notices

    Web sites. The materials at those Web sites are not part of the materials for this Printronix product and use of those Web sites is at your own risk.
  • Page 490 Printronix encourages owners of information technology (IT) equipment to responsibly recycle their equipment when it is no longer needed. Printronix offers a variety of programs and services to assist equipment owners in recycling their IT products.

  • Page 491: Energy Star

    Agency and the U.S. Department of Energy with the goal of protecting the environment by using energy efficient products. Printronix participates in the Energy Star program for Imaging Equipment by introducing printers that reduce power consumption when they are not being used.

  • Page 492: Communication Statements

    Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Printronix is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment.

  • Page 493: Industry Canada Compliance Statement

    Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference to radio and TV communications and to other electrical or electronic equipment. Printronix cannot accept responsibility for any interference caused by using other than recommended cables and connectors.
  • Page 494 Störquelle zu öergrvßern. Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte, wie in den Printronix Handbüchern angegeben, zu installieren und zu betreiben. China Declaration: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may need to perform practical actions.
  • Page 495 Taiwan Warning: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user will be required to take adequate measures. Korea CAUTION: This product is equipped with a 3-wire power cord and plug for the user’s safety.

  • Page 496: Software License Agreement

    Appendix H Software License Agreement Your printer contains, among other software, Printronix operating software including, but not limited to the Embedded Configurable Operating System (the “eCos Software”) as embedded software. The terms of this Agreement apply only to the eCos Software, and all other embedded software supplied with the printer.
  • Page 497 Preamble The licenses for most software are designed to take away your freedom to share and change it. By contrast, the GNU General Public License is intended to guarantee your freedom to share and change free software--to make sure the software is free for all its users. This General Public License applies to most of the Free Software Foundation's software and to any other program whose authors commit to using it.
  • Page 498 Appendix H The precise terms and conditions for copying, distribution, and modification follow. GNU GENERAL PUBLIC LICENSE TERMS AND CONDITIONS FOR COPYING, DISTRIBUTION, AND MODIFICATION This License applies to any program or other work which contains a notice placed by the copyright holder saying it may be distributed under the terms of this General Public License.
  • Page 499 These requirements apply to the modified work as a whole. If identifiable sections of that work are not derived from the Program, and can be reasonably considered independent and separate works in themselves, then this License, and its terms, do not apply to those sections when you distribute them as separate works.
  • Page 500 Appendix H If distribution of executable or object code is made by offering access to copy from a designated place, then offering equivalent access to copy the source code from the same place counts as distribution of the source code, even though third parties are not compelled to copy the source along with the object code.
  • Page 501 8. If the distribution and/or use of the Program is restricted in certain countries either by patents or by copyrighted interfaces, the original copyright holder who places the Program under this License may add an explicit geographical distribution limitation excluding those countries, so that distribution is permitted only in or among countries not thus excluded.

  • Page 502: Bsd License

    Appendix H REPAIR OR CORRECTION 12. IN NO EVENT UNLESS REQUIRED BY APPLICABLE LAW OR AGREED TO IN WRITING WILL ANY COPYRIGHT HOLDER, OR ANY OTHER PARTY WHO MAY MODIFY AND/OR REDISTRIBUTE THE PROGRAM AS PERMITTED ABOVE, BE LIABLE TO YOU FOR DAMAGES, INCLUDING ANY GENERAL, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE PROGRAM (INCLUDING BUT NOT LIMITED...
  • Page 503 THIS SOFTWARE IS PROVIDED BY THE REGENTS AND CONTRIBUTORS “AS IS” AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE REGENTS OR CONTRIBUTORS BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, PROCUREMENT OF...
  • Page 504 Appendix H...
  • Page 505 Index Numerics 448 SD WRT. FAIL WRITE PROTECTED message, 105 000 SHUTTLE TYPE NOT SUPPORTED* 449 SD FILE WRITE message, 105 message, 92 450 SD FILE FULL File Too Big message, 105 104 POWER SUPPLY HOT* message, 93 451 SD NOT FOUND message, 105 105 PRINTER HOT* message, 94 452 SD FILE FULL Delete Files message, 105 12 VOLT FAILED*, 51...
  • Page 506 718 PLAT INV PARM* message, 116 Autodump Printer Exception, 168 719 PLAT INV STATE* message, 116 Automatic Download, 199 720 PROTECTED INSTRUCTION* message, 116 721 RIB INVLD CMD* message, 116 B11 ERROR RAM TEST FAILED, 51 723 SHUTL INV CMD* message, 117 B11 ERROR RAM TEST FAILED* message, 118 724 SHUTL INV PARM* message, 117 B12 ERROR PROGRAM MISSING* message, 118...
  • Page 507 Boards CLOSE PLATEN, 56 controller, 232 Code, configuration, printer, 21 layouts, connections, and pinouts, 317 COIL HOT 1, 56 power supply, 251 COIL HOT 2, 56 Boot diagnostics menu, 163 COIL TEMP FAIL message, 56 BUFFER OVERRUN, 53 Coil temperature adjustment, 213 Bxx Error No Downloader Found, 119 Communications failures, 153 Bxx ERROR: NO DOWNLOADER FOUND, 52...
  • Page 508 Customer Support Center, 36, 487 E03G DSI ECXIWX message, 58, 121 Cycle power, 176 E03H DSI ECXOWX message, 58, 121 E04A ISI NO TRA message, 58, 121 E04B ISI DIRECT message, 58, 121 D50 STATUS UPGRADING PANEL, 56 E04C ISI PROTEC message, 58, 121 D50 STATUS UPGRADING PANEL message, 120 E06 NOT ALIGNED message, 58, 121 D50 STATUS%XX Programming, 120...
  • Page 509 ERROR NOR FLASHED WAS NOT CLEARED Fault messages, 49 message, 122 000 SHUTTLE TYPE NOT SUPPORTED*, 92 ERROR NVRAM FAILURE message, 122 104 POWERSUPPLY HOT*, 93 ERROR OCCURRED FLUSHING QUEUES 105 PRINTER HOT*, 94 message, 122 401 BUFFER OVERRUN, 94 ERROR OCCURRED FLUSHING QUEUES*, 59 402 CLEAR PAPER JAM, 95 ERROR PROGRAM NOT COMPATIBLE...
  • Page 510 620 POWER VOLT CHECK*, 110 CARTRIDGE CONNECTION ERROR, 53 622 SHUTTLE DRIVER CRCUIT*, 110 CARTRIDGE INCOMPATIBLE, 53 623 STACKER FAULT, 111 CLEARING PROGRAM FROM FLASH, 119 624 UPPER DRIVER SHORT*, 112 COIL TEMP FAIL, 56 701 ACCESS NULL POINTER*, 112 D50 STATUS UPGRADING PANEL, 120 702 FIRMWARE ERROR, 112 D51 STATUS%XX Programming, 120...
  • Page 511 E32B CND 1 BP, 58, 121 NEW SPX DETECTED, 127 E32C CND 2 BP, 58, 121 NON VOLATILE MEMORY FAILED, 127 E32D CND 3 BP, 58, 121 ONLINE, 127 E32E CND 4 BP, 58, 121 PANEL BAD CHECKSUM, 127 E32F CND 5 BP, 58, 121 PLAT DRVR CIR, 110 E32G CND 6 BP, 58, 121 PLEASE WAIT...RESET IN PROGRESS, 127...
  • Page 512 Installation, 23 INTAKE FAN CHECK, 68 H00: PCI SLOT ? - See User Manual, 63 Integrated Print Management System, 311 H00: PCI SLOT ? message, 124 control panel menus, 311 H01: PCI J12 - See User Manual, 63 operation, 311 H01: PCI J12 message, 124 ribbon action, 312 Half Speed Mode, 64...
  • Page 513 Manual Three-Key Download Sequence, 202 PAP INVLD CMD*, 74 Manual Two-Key Download Sequence, 201 PAP INVLD PARM*, 74 Mechanical controls and indicators, 32 Paper MEMORY FAILURE, 71 detector switch assembly, replacement, 262 Menus dynamic paper tension adjustment, 214 boot diagnostics menu, 163 feed drive motor, replacement, 241 diagnostic printer tests, 155 feed timing belt replacement, 226...
  • Page 514 Power supply board CHECK ERROR, 78 principles of operation, 315 DICTIONARY ERROR, 78 replacement, 251 I/O ERROR, 78 POWER SUPPLY HOT, 76 INVALID ACCESS, 78 Power, cycle how to, 176 JOB ABORTED, 78 PREV + NEXT key, 29 STACK ERROR, 79 PREV or NEXT key, 29 SYNTAX ERROR, 79 Principles of operation, 303...
  • Page 515 shuttle cover assembly, 235 SD WRITING, 81 shuttle frame assembly, 259 SDSC CARD NOT SUPPORTED, 82, 128 splined shaft, 256 Security key support shaft, 258 location and replacement, 254, 255 tractor (L/R), 264 reprogramming with the SPX module, 211 weld sensor, 264 SECURITY KEY NOT DETECTED message, 128 Replacements SECURITY PAL NOT DETECTED, 82...
  • Page 516 Signal mnemonics, 369 SYS R/T ERROR, 89 Soft reset, 176 SYS R/T ERROR message, 129 SOFTWARE ERROR* CYCLE POWER, 85 Software Program Exchange (SPX) module, 211 TCB CORRUPTED*, 90 Specifications, paper, 475 TCP PORT BUSY, 90 Splined shaft TCP PORT BUSY message, 130 replacement, 256 Technical support, 36 skew adjustment, 189...
  • Page 517 paper guides, adjust, 431 paper jams, 437 UP + DOWN key, 29 paper jams, clear, 437 UP DRV. SHORT*, 91 paper jams, reverse feed, 437 UP or DOWN key, 29 paper out sensor adjustments, 444 USB, Sending Firmware, 203 paper out sensor replacement, 450 paper out sensor, position, 432 paper, remove, 437 VIEW key, 27...
  • Page 520 *256389-001* 256389-001C...

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