16855649 Printronix P5000 Line Matrix Printers Maintenance Manual

Maintenance Manual

Printronix P5000 PSA3 Line Matrix Printers

176475-001C

Maintenance ManualP5000 PSA3 Line Matrix Printers

Trademark AcknowledgementsTrademark AcknowledgementsANSI is a registered trademark of American National Standards Institute, Inc.Centronics is a registered trademark of Genicom Corporation.Code V is a trademark of Quality Micro Systems.Chatillon is a trademark of John Chatillon & Sons, Inc.Dataproducts is a registered trademark of Dataproducts Corporation.EIA is a registered service mark of Electronic Industries Association.ENERGY STAR is a registered trademark of the United StatesEnvironmental Protection Agency. As an ENERGY STAR Partner,Printronix has determined that this product meets the ENERGY STARguidelines for energy efficiency.IBM is a registered trademark of International Business MachinesCorporation.IEEE is a registered trademark of the Institute of Electrical and ElectronicsEngineers.IGP is a registered trademark of Printronix, Inc.Intelligent Printer Data Stream and IPDS are trademarks of InternationalBusiness Machines Corporation.LinePrinter Plus is a registered trademark of Printronix, Inc.MS-DOS and Microsoft Windows (3.1x, 95, 98, Me, NT, 2000, and XP) aretrademarks of Microsoft Corporation.PC-DOS is a trademark of International Business Machines Corporation.PGL is a registered trademark of Printronix, Inc.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.RibbonMinder is a trademark of Printronix, Inc.SureStak is a trademark of Printronix, Inc.Torx is a registered trademark of Camcar/Textron Inc.Utica is a registered trademark of Cooper Power Tools.

Warranty And Copyright InformationWarranty And Copyright InformationPrintronix, Inc. makes no representations or warranties of any kind regardingthis material, including, but not limited to, implied warranties ofmerchantability and fitness for a particular purpose. Printronix, Inc. shall notbe held responsible for errors contained herein or any omissions from thismaterial or for any damages, whether direct, indirect, incidental orconsequential, in connection with the furnishing, distribution, performance oruse of this material. The information in this manual is subject to changewithout notice.This document contains proprietary information protected by copyright. Nopart of this document may be reproduced, copied, translated or incorporatedin any other material in any form or by any means, whether manual, graphic,electronic, mechanical or otherwise, without the prior written consent ofPrintronix, Inc.All rights reserved.

Copyright 2003, 2004 Printronix, Inc.

Communication NoticesFederal Communications Commission (FCC) Statement: This equipmenthas been tested and found to comply with the limits for a Class A digitaldevice, pursuant to Part 15 of the FCC Rules. These limits are designed toprovided reasonable protection against harmful interference when theequipment is operated in a commercial environment. This equipmentgenerates, uses, and can radiate radio frequency energy and, if not installedand used in accordance with the instruction manual, may cause harmfulinterference to radio communications. Operation of this equipment in aresidential area is likely to cause harmful interference, in which case the userwill be required to correct the interference at his own expense.Properly shielded and grounded cables and connectors must be used in orderto meet FCC emission limits. Printronix is not responsible for any radio ortelevision interference caused by using other than recommended cables andconnectors or by any unauthorized changes or modifications to thisequipment. Unauthorized changes or modifications could void the usersauthority to operate the equipment.This device complies with Part 15 of the FCC Rules. Operation is subject tothe following two conditions: (1) this device may not cause harmfulinterference, and (2) this device must accept any interference received,including interference that may cause undesired operation.Canadian Department of Communications Compliance Statement: ThisClass A digital apparatus complies with Canadian ICES-003.Avis de conformite aux normes du ministere des Communcations duCanada: Cet appareil numerique de la classe A est conform norme NMB-003 du Canada.European Community (EC) Conformity Statement:This product is in conformity with the protection requirements of EC CouncilDirective 89/336/EEC on the approximation of the laws of the Member States

Communication Noticesrelating to electromagnetic compatibility. Printronix cannot acceptresponsibility for any failure to satisfy the protection requirements resultingfrom a non-recommended modification of the product, including the fitting ofnon-Printronix option cards.German Conformity Statement:Zulassungsbescheinigung Gesetz ber die elektromagnetischeVertrglichkeit von Geraten (EMVG) vom 30. August 1995Dieses Gert ist berechtigt in bereinstimmung mit dem deutschen das EG-Konformittszelchen - CE - zu fhren.Der Auteller der Konformittserklrung ist die Printronix......(1)Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:

EN 55022 Klasse A Gerte bedrfen folgender Hinweise:Nach dem EMVG: Gerte drfen an Orten, fr die sie nicht asreichendentstrt sind, nur mit besonderer Genehmigung des Bundesminesters frPost und Telekommunikation oder des Bundesamtes fr Post undTelekommunikation betrieben werden. Die Genehmigung wird erteilt, wennkeine elektromagnetischen Strungen zu erwarten sind. (Auszug aus demEMVG, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nachParagraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung(Amtsblatt 14/93) kostenpflichtig.EN 55022: Dieses ist eine Kategorie A Vorrichtung. Betrieb in denWohnbereichen kann elektrische Strung verursachen. Es ist dieVerantwortlichkeit des Benutzers, passende Gegenmanahmen zu ergreifen.EN 55024: Begrenzung Werte fr Gebrauch in bevlkerten Bereiche,kommerziellen und Industriegebieten sind innen bereinstimmung mit denspezifizierten Anforderungen Hinsichtlich Strfreiheit.Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Gerte,wie in den Handbchern angegeben, zu installieren und zu betreiben.This product has been tested and found to comply with the limits for Class AInformation Technology Equipment according to European Standard EN55022. The limits for Class A equipment were derived for commercial andindustrial environments to provide reasonable protection against interferencewith licensed communication equipment.

Das Gert erfllt die Schutzanforderungen nach EN 55022 undEN 55024 Klasse A.

This is a Class A product. In a domestic environment this product maycause radio interference in which case the user may be required to takeadequate measures.

Warning

Communication Notices

Table Of Contents

1 Maintenance Overview ....................................... 15About The Printer................................................................................. 15The P5000 PSA3 Printer Family.......................................................... 15

H-Series Printers ........................................................................... 15How To Identify A PSA3 Printer .................................................... 16

Important Maintenance Notes.............................................................. 18About This Manual............................................................................... 18

How To Use This Manual .............................................................. 19Notices .......................................................................................... 20

Safety Notices...................................................................................... 21Hinweise zur Sicherheit ....................................................................... 21Controls And Indicators ....................................................................... 22

Electrical Controls, Cabinet Models .............................................. 22Electrical Controls, Pedestal Models............................................. 24Mechanical Controls, All Models ................................................... 26

Tools, Test Equipment, And Supplies.................................................. 28Plugging In The Printer ........................................................................ 29Printronix Customer Support Center.................................................... 29Maintenance Training Available For Printronix Products..................... 29

2 Preventive Maintenance ..................................... 31Cleaning The Printer............................................................................ 31Cleaning The Outside Surfaces........................................................... 31Cleaning The Shuttle Frame Assembly ............................................... 33Cleaning The Card Cage Fan Assembly ............................................. 34

3 Troubleshooting.................................................. 35Introduction .......................................................................................... 35Troubleshooting Aids ........................................................................... 359

Start Here... ......................................................................................... 36Troubleshooting Display Messages..................................................... 37

List Of Messages .......................................................................... 37Troubleshooting Other Symptoms ....................................................... 94

General Symptom List................................................................... 95Communications Failures .................................................................. 118Diagnostic Printer Tests..................................................................... 120

Table of ContentsSelecting And Running Diagnostic Printer Tests ........................ 121Boot Diagnostics Menu...................................................................... 124Hex Code Printout ............................................................................. 127

How To Print A Hex Dump .......................................................... 128ASCII Character Set .......................................................................... 129Soft vs. Hard Reset............................................................................ 130The Power On Sequence .................................................................. 131

Controller Board Handshake Sequences.................................... 131DC Software Initialization And Power Up.................................... 135

4 Adjustment and Test Procedures ..................... 137Introduction ........................................................................................ 137

Adjustments and Tests................................................................ 137Preparing The Printer For Maintenance ............................................ 138Returning The Printer To Normal Operation...................................... 139Belt, Paper Feed Timing, Adjustment ................................................ 140Belt, Platen Open, Adjustment........................................................... 142Paper Scale Alignment ...................................................................... 144Platen Gap Adjustment...................................................................... 146Ribbon Guide Alignment.................................................................... 148Paper Out Adjustment ....................................................................... 150Hammer Phasing Adjustment ............................................................ 154Loading Flash Memory ...................................................................... 156

Loading Through The Serial Or Parallel Port .............................. 156Loading Software When Flash Is Blank Or Defective ................. 160Loading Through the Network Interface Card (NIC) ................... 161

Coil Temperature Adjustment ............................................................ 164Dynamic Paper Tension Adjustment ................................................. 165Tractor Belt Tension Adjustment ....................................................... 167Shuttle Electrical Short Check ........................................................... 168Hammer Bank Power Cable Shorts Test........................................... 169Cable Shorts Test .............................................................................. 170Main Wire Harness Test Diagnostic .................................................. 17210

Table of Contents5 Replacement ProceduresAnd Illustrated Parts Lists...................................... 173

Organization Of This Chapter ............................................................ 173Section I: Replacement Procedures .................................................. 174

List Of Removal / Installation Procedures ................................... 174Belt, Paper Feed Timing ............................................................. 176Belt, Platen Open ........................................................................ 177Circuit Breaker ............................................................................ 178Connector Coupling Shrouds ...................................................... 179Control Panel Assembly, Cabinet Models ................................... 181Control Panel Assembly, Pedestal Models ................................. 182Controller Board .......................................................................... 183Cover Assembly, Hammer Bank / Ribbon Mask ......................... 185Cover Assembly, Shuttle ............................................................. 186Cover Assembly, Top, Pedestal Models ..................................... 187CT Board..................................................................................... 188Dashpot ....................................................................................... 189Fan Assembly, Cabinet Exhaust ................................................. 190Fan Assembly, Card Cage .......................................................... 191Fan Assembly, Hammer Bank..................................................... 192Hammer Spring Assembly........................................................... 193Magnetic Pickup (MPU) Assembly .............................................. 195Memory and Security Key ........................................................... 196NIC (Network Interface Card) Assembly ..................................... 199Paper Feed Motor ....................................................................... 200Paper Ironer ................................................................................ 202Paper Path .................................................................................. 203Platen .......................................................................................... 204Platen Open Motor ...................................................................... 208Power Supply Board ................................................................... 210Resistors, Terminating ................................................................ 211Ribbon Drive Motor ..................................................................... 213Ribbon Guide Assembly (L/R)..................................................... 214Ribbon Hub ................................................................................. 215Shaft, Splined.............................................................................. 216Shaft, Support ............................................................................. 218Shuttle Frame Assembly ............................................................. 219Spring, Extension, Hammer Bank ............................................... 221Switch Assembly, Paper Detector ............................................... 222Switch Assembly, Platen Interlock .............................................. 223Tractor (L/R) ................................................................................ 22411

Table of ContentsSection II: Illustrated Parts Lists ........................................................ 225Illustrations of Printer Components ............................................. 225

6 Principles Of Operation..................................... 263Line Matrix Printing ............................................................................ 263Printing Rates .................................................................................... 266Printing Mechanism ........................................................................... 266

Shuttle Frame Assembly ............................................................. 267Paper Transport System ............................................................. 269Ribbon Transport System ........................................................... 270

Logical Control Of The Printer ........................................................... 271Control Panel ..................................................................................... 272Controller Board................................................................................. 273

Data Controller ............................................................................ 275Engine Controller ........................................................................ 277

Power Supply Board .......................................................................... 279AC Power .................................................................................... 279DC Power.................................................................................... 279

Printer Interface ................................................................................. 280Graphics ............................................................................................ 280

A Wire Data ......................................................... 281

B Abbreviations And Signal Mnemonics.............. 327

C Metric Conversion Tables ................................ 335

D SureStak Power Stacker .............................. 337Contents ............................................................................................ 337Introduction ........................................................................................ 338Stacker Operation.............................................................................. 338Removing The Power Stacker ........................................................... 345Installing The Power Stacker ............................................................. 351Replacing The Constant Force Spring............................................... 362Replacing The Timing Belts............................................................... 364Replacing The Roller Drive Shaft ...................................................... 367Illustrated Parts Breakdown............................................................... 371

List of Illustrations ....................................................................... 37112

Table of ContentsE Paper Specifications And Forms Design.......... 383Introduction ........................................................................................ 383General Paper Specifications ............................................................ 384Paper Guidelines ............................................................................... 385

Terms And Definitions................................................................. 385Environmental Considerations .................................................... 387Form Types ................................................................................. 387Form Weight................................................................................ 387Form Thickness........................................................................... 387Form Evenness ........................................................................... 387Tractor Pin Engagement ............................................................. 387Methods Of Forms Attachment ................................................... 388Chaff Content .............................................................................. 389

Form Design Checklist....................................................................... 390Summary ........................................................................................... 393

Storage And Handling ................................................................. 393

F Maintenance Information About Other P5000Printers .................................................................. 39513

Table of Contents14

1 Maintenance Overview

About The PrinterPrintronix P5000 PSA3 line matrix printers introduce the third generationof Printronix System Architecture (PSA). This specialized architecture putsall data control and printer control electronics on one circuit board, the PSA3controller board. The use of flash memory on this board permits rapid accessto stored printer emulations and very fast processing of print data. A variable-speed shuttle and micro-step paper control enable these printers to print awide variety of high-volume jobs with minimum maintenance and maximumreliability.A P5000 PSA3 printer is an excellent graphics printer, with optional featuresthat simplify the creation of images. The IGP and Code V Printronixemulations, for example, are simple but versatile graphics programminglanguages that load into flash memory.The printer is also easy to use. The operator can select every printer functionat the printer control panel or by sending control codes in the data streamfrom the host computer to the printer. For greater security and to protectspecial printer configurations, the operator can program which keycombination locks and unlocks the ENTER key on the control panel.

The P5000 PSA3 Printer FamilyThe P5000 PSA3 printer family consists of machines that print at variousspeeds and are available in both floor cabinet and pedestal models. (SeeTable 1 on page 17.)

IMPORTANT The controller board and card cage in these printers have beenredesigned and are not compatible with earlier P5000 printers.This manual covers only P5000 single hammer bank printers that use thePSA3 controller board. Earlier P5000 printers that use the CMX or CFXcontroller board are covered in maintenance manuals 164253-001 and175455-001. P5000 printers with dual hammer banks are covered inmaintenance manual 173843-001. (See page 395.)

H-Series PrintersThe H-Series line of Kanji/Hanzi/Hangul printers has been expanded and allH-Series printers now use the PSA3 controller board. (See Table 1.) Inaddition, H-Series models have a specially designed platen and unique15

Chapter 1 The P5000 PSA3 Printer Familyshuttle frame assembly which are not interchangeable with earlier P5XKA(Asian) models or any other P5000 series printers.H-Series models print eight character sets used in China, Hong Kong, SouthKorea, and Taiwan, as shown below:

How To Identify A PSA3 PrinterA P5000 PSA3 printer is easily identified by the PSA3 trademark on the cover,but each printer also has a model number that provides important information.The model number is coded to indicate the printer type, family, maximumrated speed, housing, and certain options. Figure 1 shows how to interpret amodel number.Table 1 lists the models in the P5000 PSA3 family. Remember that thespeeds listed in Table 1 are the highest attainable under controlled testconditions. The speed of printing for real world print jobs is determined bythe interaction of many variables and varies from print job to print job. (Formore information, see Printing Rates on page 266.)

Figure 1. How to Interpret Model Numbers

Character Set Where Used

GB China

BIG-5, with an additional 3000 Cantonese characters Hong Kong

BIG-5TCADCI (1st and 2nd segments)DCI (3rd segment)CNS

Taiwan

KSC 5601 South Korea

Printronix LineMatrix Printer

P5000 Printer

P5220S-SS

Housing Code:0 = Pedestal1 = Table Top2 = Floor Cabinet

Speed Rating:03 = 340 lines per minute (lpm)05 = 500 lpm06 = 600 lpm08 = 750 lpm10 = 1000 lpm15 = 1500 lpm20 = 2000 lpm

QA = Pedestal model with optionalQuick-Access coverSS = Cabinet model with optionalSureStak power paper stacker

D = Dual hammer bankH = H-Series printerS = Single hammer bank16

How To Identify A PSA3 PrinterTable 1. P5000 PSA3 Printers

Model Maximum PrintSpeedPrinter

Enclosure Hammer BankController

Board1

P5003H 340 lpm Pedestal 60 Hammers PSA3

P5005 500 lpm Pedestal 28 Hammers PSA3

P5005-QA 500 lpmPedestal w/

Quick-AccessCover

28 Hammers PSA3

P5005-12 500 lpm Pedestal 28 Hammers,12 MIL tips

PSA3

P5005-12-QA 500 lpmPedestal w/

Quick-AccessCover

28 Hammers,12 MIL tips PSA3





Quick-AccessCover

60 Hammers PSA3



Quick-AccessCover

102 Hammers PSA3

P5203H 340 lpm Cabinet 60 Hammers PSA3

P5205 500 lpm Cabinet 28 Hammers PSA3

P5205-12 500 lpm Cabinet 49 Hammers,12 MIL tips

PSA3





P5215-SS 1500 lpmCabinet

w/SureStakPaper Stacker

102 Hammers PSA3

P5220S 2000 lpm Cabinet 126 Hammers PSA317

Chapter 1 Important Maintenance NotesImportant Maintenance NotesTo ensure the best performance of the printer, remember these maintenanceprinciples when you service it. Failure to observe these guidelines can resultin damage to the equipment: Do not adjust the platen gap unless

1) the original shuttle frame assembly or platen has been replaced with anew or rebuilt unit, or2) you are instructed to do so in a troubleshooting procedure.

Never bend or tweak hammer springs. The hammer springs andhammer tips are delicate and precisely aligned, so always handlehammer springs by the thick mounting base.

Use only the ribbons specified in the Users Manual. Using incorrectribbons can lead to ink migration problems, degraded print quality, andexpensive damage to the printer.

Do not close the forms thickness lever (platen lever) too tightly.Closing the forms thickness lever too tightly can lead to smearing,degraded print quality, paper jams, and damage to the platen and shuttleassembly.

About This ManualThis is a field service maintenance manual. It is designed so that you canlocate maintenance information quickly.This manual does not explain how to install, operate, or configure the printer.For that information, refer to the Quick Setup Guide and the Users Manual.This manual does not explain how to program application software foroperation with the printer. Programming information for the protocols used bythe printer is in the appropriate programmers reference manual: LinePrinter Plus Programmers Reference Manual

Defines host control codes for the LinePrinter Plus emulations. Character Sets Reference Manual

Information about and examples of the character sets available inPrintronix line matrix printers.

P5220S-SS 2000 lpmCabinet

w/SureStakPaper Stacker

126 Hammers PSA3

1 The PSA3 controller board is installed in a redesigned card cage with new I/O connections.Printers that use the PSA3 board cannot use the earlier CMX and CFX controller boards.

Table 1. P5000 PSA3 Printers

Model Maximum PrintSpeedPrinter

Enclosure Hammer BankController

Board118

How To Use This Manual Network Users ManualInformation about network protocols, configuration, and networkoperation.

Coax/Twinax Programmers Reference ManualDefines host control codes and character sets for the optional coax/twinaxemulations.

ANSI Programmers Reference ManualDefines host control codes and character sets for the ANSI emulation.

IPDS Twinax Emulation Programmers Reference ManualAn overview of Intelligent Printer Data Stream (IPDS) features,commands, and diagnostics.

IGP/PGL Programmers Reference ManualDescribes the optional IGP Printronix emulation. The IGP Printronixemulation allows the user to create and store forms; generate logos, barcodes, and expanded characters; create other graphics, and mergegraphics with alphanumeric data as a document is printed.

IGP/VGL Programmers ManualDescribes the optional Code V Printronix emulation. The Code VPrintronix emulation allows the user to create and store forms; generatelogos, bar codes, and expanded characters; create other graphics, andmerge graphics with alphanumeric data as a document is printed.

How To Use This ManualTaking a systematic approach to maintenance tasks will help you restore theprinter to operation as quickly as possible:1. Locate the procedure or information you need in the Table of Contents or

Index.2. Read the entire procedure before you do it.3. Gather the parts and tools you will need.4. Make sure you understand all notices before you start a task. Notices are

defined below.19

Chapter 1 About This ManualNoticesFor your safety and to protect valuable equipment, you must read and complywith all information highlighted under notices.The heading of a notice indicates the kind of information it contains:

WARNING Describes a condition that could hurt you.CAUTION Describes a condition that could damage equipment.

IMPORTANT Information vital to proper operation and maintenance of the printer.NOTE: Tip(s) for efficient operation, maintenance, and troubleshooting.

Printing Conventions In This ManualControl panel keys and indicators are highlighted in UPPERCASE BOLDPRINT.Example: Press the CANCEL key, then press the ON LINE key.LCD (Liquid Crystal Display) messages are set off by quotation marks ( ).Example: Press the ON LINE key. OFF LINE appears on the LCD.Control panel key combinations are indicated by the + (plus) symbol.Example: Press = + >.means Press the =(UP) key and the >(DOWN) key at the same time.

IMPORTANT The Safety Notices on the next page apply at all times when you areworking on the printer. Please read them now.20

NoticesSafety NoticesWARNING Always disconnect the AC power cord from the printer or power source

before performing any maintenance procedure. Failure to remove powercould result in injury to persons or damage to equipment. If you mustapply power during maintenance, you will be instructed to do so in themaintenance procedure.

WARNING Always disconnect the AC power cord before cleaning the printer.WARNING To prevent injury from electric shock, wait at least one minute after

shutting off power before removing the power supply circuit board.Wear a properly grounded static wrist strap when handling the powersupply board. Handle the board by the sides. Do not touch componentsor flex the board during removal/installation.

WARNING Over time, the upper edge of the paper ironer can become sharp. Toavoid cutting yourself, handle the paper ironer on the sides.

WARNING Hold the printer cover securely while disengaging the dashpot.

Hinweise zur SicherheitVORSICHT Bevor Sie anfllige Wartungsarbeiten durchfhren, mssen Sie zuerst

immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabelnicht herausgezogen, knnen Verletzungen oder Gerteschdenentstehen. Falls die Wartungsarbeit Stromzufuhr erfordert, wird imWartungsablauf darauf hingewiesen.

VORSICHT Ziehen Sie das Netzkabel aus der Steckdose, bevor Sie den Druckerreinigen.

VORSICHT Um Verletzungen durch Elektroschocks zu vermeiden, warten Siemindestens eine Minute nach Stromausschaltung, bevor Sie dieelektrische Schaltkarte entfernen. Bitte immer einen geerdeten,statischen Handgelenkriemen tragen, wenn Sie die elektrischeSchaltkarte handhaben. Halten Sie die Karte nur an den seitlichenAuswurfshebeln. Whrend des Herausnehmens/Installierens drfen dieKomponenten der Karte nicht berhrt oder gebogen werden.

VORSICHT Die obere Kante der Papierschiene wird mit der Zeit scharf. Halten Siedie Schiene deshalb an den Seiten, damit Sie sich nicht schneiden.

VORSICHT Behalten Sie die Druckerabdeckung sicher im Griff, wenn Sie dasGasfederpaket entfernen.21

Chapter 1 Controls And Indicators

SwiInd

tive-line

Powe

Status

L

ON LIN

PAADV

VIEW

CA

=

> (D

< ( ; ( SE

PRT

JOB SPRIN

EN

= + O

(IPDSo

Controls And IndicatorsElectrical Controls, Cabinet Models

tch oricator Function

ActiveOn-line

AcOff

r Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.

Indicator On when the printer is on-line, off when the printer is off-line. Flashes to indicate a fault orwarning.

CD Liquid Crystal Display. Displays printer status messages, fault messages, and menus whichpermit user to set various configurations.

E/CLEAR Toggles the printer on-line and off-line. Clears the printer after a fault is corrected and returnsthe printer to off-line state.

PERANCE

Prints any data in the buffer then moves paper up one line at the currently active line spacing.If pressed longer than 1/2 second, moves paper to the next Top Of Form as defined by thecurrently active form length.

/ EJECT Moves the current print position to the tractor area for viewing. When paper is in VIEWposition, Printer in View displays and microstep adjustment feature is active. (See UP andDOWN keys.) Holding the key down for more than 1/2 second invokes EJECT and paper isadvanced two pages. (EJECT can be disabled via the menus.) Pressing the key a secondtime moves paper back to the print position from either VIEW or EJECT position.

NCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).(UP) Displays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72

inch.(See VIEW / EJECT key.)

OWN) Displays next lower level of a configuration menu. In VIEW mode, moves paper down1/72 inch. (See VIEW / EJECT key.)

NEXT) Displays the next option in a configuration menu.PREV) Displays the previous option in a configuration menu.T TOF Moves paper downward from TOF (Top Of Form) alignment mark to the print station and sets

this as the first line of print on a page, independent of forms length. If there are data in thebuffers, the printer slews to the page position where printing left off and prints the data.

CONFIG Prints the current printer configuration.

ELECT/T MODE

Allows selection of the active configuration or print mode (typeface) of the printer. Thefunctionality depends on the current setting of the Job Select/Print Mode under the MAINT/MISC menu. (Refer to the Users Manual.)

TER Enters an option displayed on the LCD into printer non-volatile memory. Starts and stopsprinter tests, sets a value, or prints the configuration. This key is locked and unlocked by auser-selectable key combination. (Refer to the Users Manual.)

N LINE

emulationnly)

When pressed in off-line mode, if there are data in the printer buffer, the printer goes on-line,prints one page, then returns to the off-line mode. This can be repeated until the end of aprint job. Only one page prints each time you press = + ON LINE. If there are no data in theprinter buffer, the printer is placed in on-line mode.This key combination does not work if the printer is in the fault state.

;+< Resets the printer by reloading the power-up configuration and resetting the internal state.22

Electrical Controls, Cabinet ModelsFigure 2. Electrical Controls, Cabinet Models

SET TOFPRT CONFIG

JOB SELECT/PRINT MODE

ENTER ON LINE/CLEARPAPER ADVANCE

VIEW/EJECT CANCEL

LCD Status Indicator

Power Switch

(Off) (On)

ArrowKeys

A

B

A B23

Chapter 1 Controls And Indicators

SI

ee

P

Sta

PR

=

emElectrical Controls, Pedestal Models

witch orndicator Function

ActiveOn-line

ActivOff-lin

ower Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.

tus Indicator On when the printer is on-line, off when the printer is off-line. Flashes to indicate a faultor warning.

LCD Liquid Crystal Display. Displays printer status messages, fault messages, and menuswhich permit user to set various configurations.

ON-LINECLEAR

Toggles the printer on-line and off-line. Clears the printer after a fault is corrected andreturns the printer to off-line state.

PAPERADVANCE

Prints any data in the buffer then moves paper up one line at the currently active linespacing. If pressed longer than 1/2 second, moves paper to the next Top Of Form asdefined by the currently active form length.

VIEWEJECT

Moves the current print position to the tractor area for viewing. When paper is in VIEWposition, Printer in View displays and microstep adjustment feature is active. (See UPand DOWN keys.) Holding key down for more than 1/2 second invokes EJECT andpaper is advanced two pages. (EJECT can be disabled via the menus.) Pressing key asecond time moves paper back to the print position from either VIEW or EJECT position.

CANCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).

UPDisplays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72inch. (See VIEW / EJECT key.)

DOWN

Displays next lower level of a configuration menu. In VIEW mode, moves paper down 1/72 inch. (See VIEW / EJECT key.)

NEXT

Displays the next option in a configuration menu.

PREV

Displays the previous option in a configuration menu.

SETTOF

Moves paper downward from TOF (Top Of Form) alignment mark to the print station andsets this as the first line of print on a page, independent of forms length. If there are datain the buffers, the printer slews to the page position where printing left off and prints thedata.

PRTCONFIG

Prints the current printer configuration.

JOBSELECT/INT MODE

Allows selection of the active configuration or print mode (typeface) of the printer. Thefunctionality depends on the current setting of the Job Select/Print Mode under theMAINT/MISC menu. (Refer to the Users Manual.)

ENTER Enters an option displayed on the LCD into printer non-volatile memory. Starts and stopsprinter tests, sets a value, or prints the configuration. This key is locked and unlocked bya user-selectable key combination. (Refer to the Users Manual.)

+ ON LINE

(IPDSulation only)

When pressed in off-line mode, if there are data in the printer buffer, the printer goes on-line, prints one page, then returns to the off-line mode. This can be repeated until theend of a print job. Only one page prints each time you press = + ON LINE. If there are nodata in the printer buffer, the printer is placed in on-line mode.This key combination does not work if the printer is in the fault state.

+ Resets the printer by reloading the power-up configuration and resetting the internalstate.24

Electrical Controls, Pedestal ModelsFigure 3. Electrical Controls and Indicators, Pedestal Models

PREV NEXTSET PRT ENTER

ON-LINE PAPER VIEW CANCEL

JOB

UP DOWNLCD SELECT

CLEAR ADVANCE EJECT

TOF CONFIG

Status Indicator ON-LINECLEAR PAPERADVANCE

VIEWEJECT

CANCEL

Power Switch

(Off) (On)

SETTOF

DOWNUP

NEXTPREV PRT

CONFIG

JOB SELECT/PRINT MODE

ENTER

(Rotated 180Degrees)

A

B

A

B

C

C

SETTOF

PRTCONFIG

JOBSEL/

PRINTMODE25

Chapter 1 Controls And IndicatorsMechanical Controls, All Models

Control or Indicator Function

Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. Levermust be fully opened (raised) to load or unload paper.

Paper Supports Help prevent paper jams by supporting inner sections of paper. Theyare positioned manually by sliding them along the shafts.

Forms ThicknessPointer and Scale

Indicates the relative thickness of forms and paper. Set this lever at Afor thin (single-part) forms, B for thicker forms, and so on.

Tractors (2) Hold and feed paper. Used to set side margin and position paperhorizontally.

Tractor Locks (2) Lock tractors in position.Vertical Position Knob Used to set top of form or the first line to be printed. Rotate this knob

to move the paper vertically. Works when the forms thickness lever isopen.

Ribbon Loading PathDiagrams

Instructions showing how to load the ribbon correctly. One diagram iscast in relief on the shuttle cover, and another is printed on the paperscale.

Paper Scale A horizontal scale graduated in tenths of an inch, useful for settingpaper margins and counting text columns. (See below.)

1 10 20

1 inch

0.1 inch ColumnNumber26

Mechanical Controls, All ModelsFigure 4. Mechanical Controls, All Models

Tractor Lock

Left Tractor

Right Tractor

VerticalPositionKnob

Forms ThicknessLever and Scale

FormsThicknessPointer

Tractor Lock

PaperSupports

Ribbon LoadingPath Diagrams27

Chapter 1 Tools, Test Equipment, And SuppliesTools, Test Equipment, And SuppliesFor field level maintenance of the printer, you will need these tools:

Adapter, 1/4 in. hex to 1/4 in. square, Utica HW-18Alcohol, anhydrousAllen Wrench, 1/16 inchAllen Wrench, 3/32 inchAllen Wrench, 5/32 inchAllen Wrench, 7/64 inchAllen Wrench, 5/64 inchESD Wrist StrapFeeler Gauge, 0.010 inchFeeler Gauge, 0.011 inchFeeler Gauge, 0.040 inchForce Gauge, (Chatillon NY, Gauge-r, 0-20 lb., CAT 719-20)Force Gauge, Fish Scale type, 0-16 oz.Hex bit, 3/16 in., torque screwdriverHex bit, 3/32 in., torque screwdriverHex bit, 5/32 in., torque screwdriverHex bit, 5/64 in., torque screwdriverLubricant, Bearing (Printronix P/N 101805-001)Nut Driver, 1/4 inchNut Driver, 5/16 inchNut Driver or Open End Wrench, 7/32 inchOpen End Wrench, 5/16 inchPliers, Grip Ring, ExternalScrewdriver, flat tipScrewdriver, Phillips, #1Screwdriver, Phillips, #2Screwdriver, Torque, Utica TS-35Tie Wraps, 4 inchTorx T-10, T-15 Driver28

Mechanical Controls, All ModelsPlugging In The PrinterIn compliance with international safety standards, this printer is equipped witha three-pronged electrical plug on the power cord. When this power cord isplugged into a correctly wired power outlet, the ground conductor ensures thatthe printer chassis is at ground (earth) electrical potential.

WARNING Failure to properly ground the printer can result in electrical shock tothe operator.Do NOT use adapter plugs that have no grounding prong and never removethe grounding prong from the power cable plug. If an extension cord isrequired, make sure it is a three-wire cable with a properly grounded plug.

Printronix Customer Support CenterThe Printronix Customer Support Center offers technical support with: Installation Configuration and setup Loading supplies and operating the printer Specifications of which papers and ribbons give the best results Answers to post-sale service support questionsCall the Printronix Customer Support Center at:Americas (714) 368-2686Europe, Middle East, and Africa (31) 24 6489 410Asia Pacific (65) 6548 4114or visit the Printronix web page at www.printronix.com.http://www.printronix.com/public/servicessupport/default.aspx

Maintenance Training Available For Printronix ProductsPrintronix offers Product Maintenance Training Classes designed to enhancethe knowledge of your service personnel. Taught by a staff of experiencedprofessional instructors, these structured classes include: Theory of operation Hands-on work with the products Diagnosis of equipment failures Preventive and corrective maintenance requirements and proceduresCustomized classes designed to meet your specific needs are also availableupon request. Call Customer Training at (714) 368-2332 or visit the Printronixweb page at www.printronix.com.29

Chapter 1 Maintenance Training Available For Printronix Products30

2 Preventive Maintenance

Cleaning The PrinterThe printer is designed to require very little maintenance. Aside from normalreplenishment of paper and ribbons, the only preventive maintenancenecessary is periodic cleaning.Operating conditions vary widely, so the user must determine how often toclean the printer. But since there is no guarantee that the user will clean theprinter regularly, you should clean the printer whenever you are called toservice it.A cabinet model is illustrated in this chapter, but the cleaning procedures inthis chapter pertain to all models.

WARNING Always disconnect the AC power cord before cleaning the printer.CAUTION Do not use abrasive cleaners, particularly on the window.

Do not drip water into the printer. Damage to the equipment will result.Do not spray directly onto the printer when using spray solutions. Spraythe cloth, then apply the dampened cloth to the printer.Do not vacuum circuit boards.

Cleaning The Outside Surfaces1. Set the printer power switch to O (Off).2. Disconnect the AC power cord from the printer or the power source.3. Remove the paper.4. Remove the ribbon.5. Dampen a clean, lint-free cloth with water and a mild detergent or window

cleaning solution. Make the cloth damp, not wet. Wipe down the outsidesurfaces of the printer.

6. Dry the outside surfaces with a clean, lint-free cloth.7. Open the printer cover.8. Using a soft-bristled, non-metallic brush (such as a toothbrush), brush

paper dust and ribbon lint off the tractors, shuttle cover assembly (alsocalled the air shroud), base casting, and ribbon guides. Vacuum up theresidue. (Figure 5.)

9. Wipe the splined shaft with a soft cloth.31

Chapter 2 Cleaning The Outside SurfacesCAUTION To avoid corrosion damage, use only alcohol when cleaning printermechanical elements and make sure the cleaning solution contains nowater.

10. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides.11. Vacuum up dust and residue from the lower cabinet.12. Wipe the interior of the lower cabinet with a clean, lint-free cloth

dampened with water and a mild detergent or window cleaning solution.13. Dry the cabinet interior with a clean, lint-free cloth.14. Clean the shuttle frame assembly, as described in the next section.

Figure 5. Where to clean inside the cabinet or top cover.

NOTE: A cabinet model isshown here, but theprocedure is the same forpedestal models.

Base Casting

Shuttle CoverAssembly(Air Shroud)

Splined Shaft

Tractors

Forms ThicknessLever

Ribbon Guide32

Cleaning The Shuttle Frame Assembly1. Remove the shuttle cover assembly (page 186).2. Remove the shuttle frame assembly (page 219).3. Remove the paper ironer (page 202).

WARNING Over time, the upper edge of the paper ironer can become sharp. Toavoid cutting yourself, handle the paper ironer on the sides.4. Moisten a clean, soft cloth with alcohol. Wipe the paper ironer to remove

lint, ink, and paper residue.5. Install the paper ironer (page 202).6. Remove the hammer bank / ribbon mask cover assembly (page 185).

CAUTION The ribbon mask is thin and easily bent. When handling and cleaningthe ribbon mask be careful not to crease or kink it.7. Moisten a clean, soft cloth with alcohol. Wipe the hammer bank cover and

ribbon mask to remove lint, ink, and paper residue. Clean the holes in thecover strips.

CAUTION Do not use solvents or liquids to clean the hammer tips. Clean thehammer tips gentlytoo much pressure can chip them.8. Using a stiff, non-metallic brush (such as a toothbrush), gently brush the

hammer tips to remove lint and ink accumulations. (Figure 6.) Vacuum upany residue.

Figure 6. Cleaning the Hammer Tips

CAUTION The hammer bank contains a strong magnet. To prevent damage to thehammer tips, do not let the hammer bank cover assembly snap intoplace as the hammer bank magnet attracts it. Any impact of the coveragainst the hammer bank can break hammer tips.9. Install the hammer bank / ribbon mask cover assembly (page 185).10. Install the shuttle frame assembly (page 219).11. Install the shuttle cover assembly (page 186).12. Clean the card cage fan assembly, as described in the next section.

Hammer Tip33

Chapter 2 Cleaning The Card Cage Fan AssemblyCleaning The Card Cage Fan Assembly1. Cabinet Models: Remove the paper path (page 203).

Pedestal Models: Remove the top cover assembly (page 187).2. Vacuum the card cage fan assembly and surrounding areas to remove

paper particles, dust, and lint. (Figure 7.)3. Cabinet Models: Install the paper path (page 203)

Pedestal Models: Install the top cover assembly (page 187).4. Return the printer to normal operation (page 139).

Figure 7. Cleaning the Card Cage Fan Assembly

Card Cage Fan

NOTE: A cabinet model isshown here, but theprocedure is the same forpedestal models.34

3 Troubleshooting

IntroductionThis chapter lists fault messages and general symptoms, and providesprocedures for troubleshooting printer malfunctions.You must operate the printer to check its performance and sometimes youmay have to reconfigure it. Always have the Users Manual handy when youtroubleshoot because this manual does not cover printer operation orconfiguration.

Troubleshooting AidsTroubleshooting is faster and more effective if you understand the equipmentand make use of all available tools.This manual has a number of troubleshooting aids to help you isolate printermalfunctions: Start Here Logic Tree ............................................................... page 36 Troubleshooting Display Messages............................................ page 37 Message List............................................................................... page 37 Troubleshooting Other Symptoms .............................................. page 94 General Symptom List ................................................................ page 95 Communications Failures ......................................................... page 118 Diagnostic Printer Tests............................................................ page 120 Hex Code Printout .................................................................... page 127 ASCII Character Set ................................................................. page 129 The Power On Sequence ......................................................... page 131 Appendix A: Wire Data ............................................................. page 28135

Chapter 3 Start Here...Start Here...

Are you here because of anerror message? YES

NO

Go to Troubleshooting DisplayMessages, page 37.

Power on the printer andobserve the control panelfor the following sequenceof events (retry asrequired):1. All black squaresappear on the display.2. Display goes blank.3. TESTING HARDWAREPLEASE WAIT appearson display.Power on the printer.Did steps 1, 2, and 3occur?

NO

Did the fans come on after10 seconds?

YESAfter about 10seconds didthe fans comeon?

YES

YES

NO

Did the statusindicator lampcome on andONLINE appearon the display? (Ifdefault isOFFLINE, statusindicator will notcome on.)

NO

YESPrinter initializedsuccessfully.Other symptomsare listed inTable 3 page 95.

Go to Printerdoes notinitialize, page100.

Did ANY of steps 1 thru 3occur?

NO

Press ON LINE.Press PRT CONFIG.Press ENTER.Does machineconfigurationprint?

YES

NO

Go to the ControlPanel section ofTable 3 page 95.

The Control Panelis not functioning(Table 3 page 95)ORPrinter does notinitialize, page 100.

Go to No power, andcontrol panel is blank,and card cage fan is notrunning, page 99.

YES

NO

Are there blacksquares on thecontrol panel?

NO

Go to Printer does notinitialize, page 100.

YESGo to Black squareson control paneldisplay, page 97.36

List Of MessagesTroubleshooting Display MessagesWARNING Always disconnect the AC power cord from the printer before doing a

maintenance procedure. Failure to remove power could result in injuryto you or damage to equipment. If you must apply power duringmaintenance, you will be instructed to do so in the maintenanceprocedure.Three kinds of messages appear on the Liquid Crystal Display (LCD): Status messages Configuration menus with associated options Fault messagesMost fault messages are cleared from the LCD by correcting the faultcondition then pressing the CLEAR key.Some fault messages can only be cleared by shutting down and restarting theprinter. These fault messages are indicated by an asterisk (*) appended to themessage.If printer logic circuits detect a fault condition, three things happen: The status indicator on the control panel flashes on and off. The audible alarm beeps if it is enabled. (Press CLEAR to silence the

alarm.) The control panel LCD displays a fault message.

List Of MessagesFind the message in the Message List below and follow the suggestedprocedure. After correcting an error, press the CLEAR key to clear themessage and place the printer in the off-line state.If an error is not cleared, the printer will try to print again but will display theerror message until the error is cleared.

Table 2. Message List

Message Explanation Solution

06 HOST REQUEST Status message: in CTemulation, the hostcomputer or printercontroller requires attention.

Not a printer problem.

08 HOLD PRINTTIMEOUT

Status message: in CTemulation, the printer wasoff-line more than 10minutes and theIntervention Requiredparameter is set to Send toHost.

Press ON LINE.37

Chapter 3 Troubleshooting Display Messages8.5V POWER FAIL * 8.5 Volt Power Failed.Internal power failure.

1. Cycle power. If the messageappears, replace the powersupply board.

2. Power on the printer. If themessage appears, replace thecontroller board. Record themessage and return it with thedefective board.

3. Power on the printer. If themessage appears, replace theshuttle frame assembly.

15 COMM CHECK Communication Check: amessage that appears in theCT emulation meaning theline is not active on a twinaxinterface.

1. Power off the printer. Check/reseat the twinax host data cableconnection and twinax I/O cableconnection at the CT board.

2. Disconnect the twinax auto-termination cable from the printer.Test the cable for the resistancesshown in Appendix A. If theresistances are incorrect, replacethe twinax auto-termination cable.

3. Power on the printer. Send a printjob to the printer. Verify that allother devices on the twinax lineare working properly. (Refer toline problem determinationprocedures, as recommended bythe host system.)

4. If the message is gone, the hosthas reestablished communicationwith the printer. If all other twinaxdevices work properly and themessage still appears, replacethe CT board. Record themessage and return it with thedefective board.


Message Explanation Solution38

List Of Messages15V CTL FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print jobagain. If the message appears,remove the hammer bank logiccable, inspect it for damage, andtest it for continuity. (SeeAppendix A.) Replace thehammer bank logic cable if it isdamaged or fails continuity test.

2. Cycle Power. Run the print jobagain. If the message appears,download the emulation softwareagain.

3. Cycle power. Run the print jobagain. If the message appears,replace the flash memory.

4. Power on the printer. Run theprint job again. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.

5. Check the resistance ofconnectors P106/LRIB M andP107/RRIB M. (Refer to the MainWire Harness Test Tables inAppendix A.) If ribbon motorresistance is not correct, replacethe motor and/or the intermediatecable, if installed.

6. Power on the printer. Run theprint job again. If the messageappears, replace the powersupply board.


22 INVALID ADDR Invalid Address: poll time-out on the twinax interfaceindicating the unit address isnot recognized by printer.

Have the system administrator makesure the printer address is correct.



Chapter 3 Troubleshooting Display Messages23.5V CTL FAIL* 23.5 Volt Controller Failed: avoltage failure on thecontroller board.






31 PAPER OUTTIMEOUT

In the CT emulation with acoax interface, a time-outmessage is sent to the hostif paper is not loaded within10 minutes after CLEARwas pressed to clear a paperout fault.

1. Load paper. Run a print test. Ifthe message appears, replacethe paper detector switchassembly.

2. Run a print test. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.



List Of Messages32 PAPER JAMTIMEOUT

In the CT emulation with acoax interface, a time-outmessage is sent to the hostif paper motion has notoccurred for 10 minutes afterCLEAR was pressed toclear a paper jam fault.

1. Clear the paper jam. PressCLEAR.

2. Press PAPER ADVANCEseveral times and check thatforms feed without erratic motion,noise, or pin-hole damage. Ifforms do not feed, go to Paperfeeds poorly, page 111. If formsfeed, go to step 3.

3. Press VIEW once and check thatforms move up. Make sure theforms thickness lever is not settoo tightly.

4. Press VIEW again and check thatthe forms thickness lever rotatesand the paper moves down. If theforms thickness lever does notrotate and/or the paper does notmove down, refer to Reversepaper feed: platen does notopen, page 113.

5. Check the paper tension betweenthe tractors. Adjust the righttractor so that it does not pullpaper too tightly or leave it tooloose. The right tractor shouldhold the paper under slighttension.

6. Check the dynamic papertension.

7. Inspect the ribbon mask forbends or deformation that blockthe paper path or prevent paperfrom exiting the pedestal topcover. Replace a damagedhammer bank cover assembly.

8. Check the condition and tensionof the platen open belt. Adjust theplaten open belt. Replace the beltif it is damaged.



Chapter 3 Troubleshooting Display Messages32 PAPER JAMTIMEOUT (continued)

9. Inspect the tractors and tractordoor springs for damage,excessive wear, and equal doorclosing tension. If either tractor isworn, damaged, or exhibitsuneven door closing tension,replace both tractor assemblies.

10. Check the condition and tensionof the paper feed belt. Adjust thepaper feed belt. Replace the beltif it is damaged.

11. Check the platen gap. Adjust theplaten gap if necessary.

12. Clean the paper motion detectorwith a cotton swab and alcohol.At the control panel, set the papermotion detector (PMD) faultsetting to DISABLE. Load paper.Run a print test and observe howthe paper feeds. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.If the message does not appear,replace the paper detector switchassembly and set the papermotion detector (PMD) toENABLE.

33 PLATEN OPENTIMEOUT

In the CT emulation with acoax interface, the formsthickness lever has beenopen for at least one minute.

1. Load paper. Close the formsthickness lever. Press CLEAR.

2. Run a print test. If a platen openor close platen messageappears, power off the printer.Remove the paper path orpedestal top cover. Disconnectconnector P107 from thecontroller board. Check continuityof the platen interlock switchcable from P107 to the switch.Replace the platen interlockswitch assembly if it failscontinuity test.

3. Run a print test. If a platen openor close platen messageappears, replace the controllerboard. Record the message andreturn it with the defective board.



List Of Messages34 RIBBON STALLTIMEOUT

In the CT emulation with acoax interface, the ribbonhas not moved for 10minutes after CLEAR waspressed to clear the ribbondrive fault.

1. Set the forms thickness lever tomatch the thickness of the paperbeing used, but not too tightly.

2. Inspect the ribbon guides for inkbuildup, which can inhibit ribbonmovement. Clean the printer.

3. Inspect the hammer bank cover/ribbon mask for bending ordamage. Replace if bent ordamaged.

4. Check the platen gap: if toosmall, it can inhibit ribbonmovement. Adjust the platen gap.

5. Power off the printer. Remove thepaper path or pedestal top cover.Disconnect P106 and P107 fromthe controller board. Check theresistance of LRIB M in P106 andRRIB M in P107. (Refer to theMain Wire Harness Test Tablesin Appendix A.) If ribbon motorresistance is not correct, replacethe motor. If the resistance iscorrect, disconnect the ribbonmotor cables from the motors andcheck continuity. Replace a cableif it fails the continuity test.

6. Power on the printer. Run adiagnostic print test. If theRIBBON STALL messageappears, replace the controllerboard. Record the message andreturn it with the defective board.

48V CIRCUIT*See Manual

The power supply is notgenerating a proper 48 Volts,or the controller board is notdetecting a 48 Volt outputfrom the power supplyboard.

1. Make sure the power supplyboard is correctly connected tothe controller board.

2. Power on the printer. If themessage appears, replace thepower supply.




Chapter 3 Troubleshooting Display Messages48V PWR FAIL* 48 Volt Power Failed: aninternal power failure.

1. Power off the printer. Remove thepaper path or pedestal top cover.Check that power supplyconnector P101 is fully seated inconnector J101 on the controllerboard.

2. If the printer has the CT board,make sure it is correctly seated inthe controller board.

3. Power on the printer. If themessage appears, replace thehammer bank logic cableassembly (P108) and the powercable assembly (P105). (Refer toAppendix A.)

4. Power on the printer. If themessage appears, replace thepower supply board.


6. Power on the printer. If themessage appears, replaceshuttle frame assembly.

733 DP FIFO Busy* There is a timing problem inthe Engine Controllerfirmware.






List Of MessagesACCESS NULL PTR* Access Null Pointer: Theprocessor tried to access apointer that contains nothing(null).

1. Cycle power. Run the print jobagain. If the message appears,download the emulation softwareagain.

2. Cycle power. Run the print jobagain. If the message appears,replace the controller board.Record the message and return itwith the defective board.

ACTIVATE LOST The printer detects a twinaxprotocol communicationerror and reports the error.

1. Power off the printer. Disconnectthe AC power cord from theprinter. Reseat the twinax hostdata cable connection and thetwinax I/O cable connection at theCT board.

2. Disconnect the twinax auto-termination cable from the printer.Test the cable for the resistancesshown in the Main Wire HarnessTest Tables in Appendix A. Ifresistances are not correct,replace the twinax auto-termination cable.

3. Connect the power cord to theprinter. Power on the printer.Send a print job to the printer. Ifthe message appears, replacethe twinax cable.

4. Send a print job to the printer. Ifthe message appears, go toCommunications Failures,page 118.

A TO D OVERRUN* Analog to Digital Overrun.The analog-to-digitalconverter overflowed.

Cycle power. Run the print job again.If the message appears, replace thecontroller board. Record the messageand return it with the defective board.



Chapter 3 Troubleshooting Display MessagesB10 ERROR:NO DRAM DETECTED*

Boot-up routines did notdetect the presence of theSDRAM DIMM.

1. Cycle power. If the messageappears again, power down andcheck that there is an SDRAMDIMM installed on the controllerboard. If not, install the SDRAM.If so, reseat the SDRAM DIMM.

2. Power up the printer. If themessage appears, replace theSDRAM DIMM.

3. Power up the printer. If themessage appears, replace thecontroller board. Record themessage and return it with thedefective board.

B11 ERROR:RAM TEST FAILED*

SDRAM failed the bootinitialization test.

1. Cycle power. If the messageappears again, reseat theSDRAM DIMM.

2. Power up the printer. If themessage appears, replace theSDRAM DIMM.


B12 ERROR:PROGRAM MISSING*

The printer does not see aprogram in flash memory.

There is no program in printermemory. Download an emulation.

B13 ERROR:NOT COMPATIBLE*

The printer is not compatiblewith the downloadedprogram.

Load the correct emulation softwareoption(s) for this printer.

B19 ERROR:DC RETURNED*

This message indicates anincorrectly assembled andtested machine.

Cycle power. If the message appearsagain contact the printermanufacturer and report thismessage.

B20 - STATUS: 00%DOWNLOAD MODE

Status message informingthe operator that software isbeing downloaded throughthe printers parallel portusing the three-keydownload activation (page160). The percentageindicates the approximateamount loaded into theprinter.

No action required.



List Of MessagesB21 STATUS:PRINTER RESET

Status message informingthe operator that the printeris undergoing a systemreset.

No action required.

B22 ERROR:DECOMPRESS SIZE*

Flash memory has notpassed boot initializationtests.

1. Cycle power. If the messageappears again, reseat the flashSIMM(s).

2. Power up the printer. If themessage appears, replace theflash SIMM(s).


B23 ERROR:DECOMPRESS CKSUM*





B30 - STATUS:INITIALIZING

Status message informingthe operator that software isbeing downloaded throughone of the printers I/O portsusing the two-key downloadactivation (page 156).

No action required.

B40 ERROR: SDRAMEEPROM CKSUM BAD*







Chapter 3 Troubleshooting Display MessagesB41 ERROR: DIMMMEMORY NOT SDRAM*

The DRAM DIMM installedon the controller board is notSynchronous DRAM(SDRAM).

1. Cycle power. If the messageappears again, reseat the DRAMDIMM.

2. Power on the printer. If themessage appears, install a newSDRAM DIMM of the correct typeand size.


B42 ERROR: SDRAMROWS NOT ALLOWED*

Printer boot initializationtests detect incorrectSDRAM.




B43 ERROR: SDRAMTOO MANY BANKS*







List Of MessagesB44 ERROR: SDRAMNOT 64 BITS WIDE*





B45 ERROR: SDRAMIS WRONG VOLTAGE*





B46 ERROR: SDRAMHAS MIXED SIZES*







Chapter 3 Troubleshooting Display MessagesB47 ERROR: SDRAMLARGER THAN 256M*





B49 ERROR: SDRAM# LOGICAL BANKS*





B50 ERROR: SDRAMLOGIC COMB BANKS*







List Of MessagesBUFFER OVERRUN The print buffer hasoverflowed on a serialinterface. The printed outputmay contain random *(asterisk) characters. Makea configuration printout.

1. Verify that the printer matchesthe host serial interfaceconfiguration settings for DataProtocol, Baud Rate, Data Bits,Stop Bits, Parity, Data TerminalReady, and Request to Send. Setprinter serial interface parametersto match those of the host.

2. Send a print job to the printer. Ifthe message appears, go toCommunications Failures,page 118.



Chapter 3 Troubleshooting Display MessagesCLEAR PAPER JAM Paper jam. 1. Inspect the paper path for jams.Clear jams. Load paper.

2. Press PAPER ADVANCEseveral times and check thatforms feed without erratic motion,noise, or pin-hole damage. Ifforms do not feed, go to Paperfeeds poorly, page 111.If forms feed, go to step 3.

3. Press VIEW once and check thatforms move up. Make sure theforms thickness lever is not settoo tightly.

4. Press VIEW again and check thatthe forms thickness lever rotatesand the paper moves down. If theforms thickness lever does notrotate and/or the paper does notmove down, refer to Reversepaper feed: platen does notopen, page 113.

5. Check the paper tension betweenthe tractors. Adjust the righttractor so that it does not pullpaper too tightly or leave it tooloose. The right tractor shouldhold the paper under slighttension.

6. Check the dynamic papertension.

7. Inspect the ribbon mask forbends or deformation. Replace ifdamaged.

8. Check and adjust the platen openbelt. Replace the belt if it isdamaged.

9. Inspect the tractors and tractordoor springs for damage,excessive wear, and equal doorclosing tension. If either tractor isworn, damaged, or exhibitsuneven door closing tension,replace both tractor assemblies



List Of MessagesCLEAR PAPER JAM(continued)

10. Check the condition and tensionof the paper feed belt. Adjust thepaper feed belt. Replace the beltif it is damaged.

11. Check and adjust the platen gap.12. Clean the paper motion detector

with a cotton swab and alcohol.At the control panel, set the papermotion detector (PMD) faultsetting to DISABLE. Load paper.Run a print test and observe howthe paper feeds. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.If the message does not appear,replace the paper detector switchassembly and set the papermotion detector (PMD) toENABLE.

CLEARING PROGRAMFROM FLASH

Status message: emulationsoftware successfully loadedinto printer RAM and thechecksum matched. The oldprogram is now beingdeleted from flash memory.

No action required.



Chapter 3 Troubleshooting Display MessagesCLOSE PLATEN The forms thickness lever isopen.

1. Load paper. Close the formsthickness lever.

2. Power off the printer. Remove thepaper path or pedestal top cover.Disconnect connector P107 fromthe controller board. Checkcontinuity of the platen interlockswitch from P107/PLO to theswitch. Replace the switchassembly if it fails the continuitytest. (Refer to Appendix A, SwitchAssembly, Platen Interlock.)

3. With the forms thickness leverclosed (position A), hold a 0.011inch (0.028 cm) feeler gaugebetween the switch and the bodyof the forms thickness lever,gently press down on the switch,and tighten the two screws.

4. Check and adjust the platen openbelt. Replace the belt if it isdamaged.

5. Disconnect connector P106 fromthe controller board. Check theresistance of connector P106/PLAT M. (See the Main WireHarness Test Tables in AppendixA.) Replace the platen openmotor if it fails the resistance test.

6. Run a print test. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.



List Of MessagesCOIL HOT One or more hammer coilsare overheating. Inspect theprinter environment forseverity. The printer hassensor circuits that samplethe operating temperature ofkey components of the printmechanism. When higherthan normal temperaturesare sensed, print speed isautomatically reduced by50% and a COIL HOTmessage is sent to the LCDto inform the operator. Whenthe coil(s) cool down, printspeed automatically returnsto 100% and the messageclears from the LCD. Thismessage is normal forextremely dense print jobs,such as All Black plot. If theprinter often prints at halfspeed, it may be operating ina severe environment. Asevere environment is onewith an ambient temperatureat or above 40 Celsius(104 Fahrenheit) or that isdirty enough to createblockage of the cabinet fanvents. The printer mustnever be run at ambienttemperatures greater than40 Celsius (104Fahrenheit). If the printer islocated in such anenvironment, relocate it to acooler, cleaner area.

1. Advise the user to move theprinter to cooler, cleaner location.

2. Check the kinds of print jobs theuser is running: look for verydense graphics and layouts.Advise the user to run jobs insmaller batches.

3. Power off the printer. Remove thepaper path or pedestal top cover.Check all fan cable connections.

4. Power on the printer. Verify thatall fans operate. Replace any fanthat does not operate.

5. Inspect vents and fan airways forobstructions. Look underneathcabinet models for items blockingthe cabinet exhaust vents.Remove any obstructions fromvents and airways.

6. Install the paper path or pedestaltop cover. Load paper. Run theAll Es print test for 5 to 10minutes. If the message appears,replace the shuttle frameassembly.

7. Run the All Es print test for 5 to10 minutes. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.

8. If the printer is a P5220S model,set the coil temperature (page164).



Chapter 3 Troubleshooting Display MessagesCTL VOLT FAIL* Controller Voltage Failure.15 V failure on the controllerboard.






DIAGNOSTICPASSED

Status message: the printerpassed its memory andhardware initialization tests.

No action required.

DP FIFO Busy* There is a timing problem inthe Engine Controllerfirmware.






List Of MessagesDRVR CIR BAD* Driver Circuit Bad: thehammer coil count testfailed.

1. Cycle power. If the messageappears, press CLEAR.

2. Power off the printer. Remove theshuttle cover. At the shuttle frameassembly, disconnect thehammer bank logic and powercables. Power on the printer. IfHB NOT INSTALLD appears onthe LCD, replace the shuttleframe assembly. If HB NOTINSTALLD does not appear onthe LCD, replace the controllerboard.

E Net Test Unavailable The ethernet PCBA did notinitialize correctly.

Cycle power. Wait for E Net Readyto display, then retry operation. If itstill fails, replace the ethernet PCBA.

ERROR: DC PROGRAMNOT VALID

The printer cannot find thedata controller program orthe validation checksum iscorrupt.

1. Download the program again.2. If the message appears, replace

all flash memory SIMMs.

ERROR: DRAM ATADDRESS XXXXXXXX

The printer found a defectivememory location.

1. Replace the DRAM DIMM.2. Power on the printer. If the

message appears, replace thecontroller board. Record themessage and return it with thedefective board.

ERROR: EC PROGRAMNOT VALID

The printer cannot find theengine controller program orthe validation checksum iscorrupt.

1. Download the program again(page 156). If the messageoccurs again, replace all flashmemory SIMMs.

2. Power on the printer. Downloadthe emulation. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.



Chapter 3 Troubleshooting Display MessagesERROR: EC STOPPEDAT STATE XXXX

Where XXXX is a numberfrom 0000 to 0010. TheEngine Controller hasstopped and is in the stateidentified by the numberdisplayed. If the EC stops atstate 0000 at power-up,replace the controller board.Record the message andreturn it with the defectiveboard.

1. Power off the printer. Remove allflash memory SIMMs and DRAMDIMM. Inspect the SIMM andDIMM sockets on the controllerboard. If any socket pins are bentor damaged, replace thecontroller board.

2. Install the flash SIMMs andDRAM DIMM, making sure theyare fully and correctly seated.Power on the printer. Downloadthe emulation (page 156). If themessage appears, replace theflash SIMM(s).

3. Power on the printer. Downloadthe emulation. If the messageappears, replace the DRAMDIMM.

4. Power on the printer. Downloadthe emulation. If the messageappears, replace the controllerboard. Record the message andreturn it with the defective board.

ERROR: FLASHDID NOT PROGRAM

The printer encountered anerror trying to program flashmemory.

Download the program again (page156). If the message occurs again,replace the flash memory.

ERROR: FLASHNOT DETECTED

The printer could not findflash memory.

Check flash memory on the controllerboard. If present, reseat the flashSIMMs; if missing, install flashSIMMs.

ERROR: NO DRAMDETECTED

The printer could not findany DRAM.

Check DRAM on the controller board.If present, reseat DRAM; if missing,install DRAM.

ERROR: NVRAMFAILURE

The non-volatile SRAM onthe controller board hasfailed.

Replace the controller board. (DoNOT attempt to replace NVRAM.)Record the message and return itwith the controller board.

ERROR: PROGRAMNEEDS MORE DRAM

The printer requires moreDRAM in order to run thedownloaded program.

Add DRAM or use a smalleremulation program.

ERROR: PROGRAMNEEDS MORE FLASH

The printer requires moreflash memory in order to runthe downloaded program.

Add flash memory or use a smalleremulation program.



List Of MessagesERROR: PROGRAMNOT COMPATIBLE

The printer is not compatiblewith the downloadedprogram.

Use the correct emulation softwareoption(s) for this model printer.

ERROR: PROGRAMNOT VALID

The printer does not see aprogram in flash memory.

There is no program in printermemory. Download the emulation.

ERROR: SECURITY PALNOT DETECTED

The security key is notpresent or has failed.

1. Check the security key atconnector J9 on the controllerboard. If the key is absent, installthe correct key. If a security key ispresent, replace it.


ERROR: SHORT ATADDRESS XXXX

Hardware failure in DRAM orcontroller circuitry.

1. Download the program again.2. If the message occurs again,

replace the DRAM DIMM.3. If message occurs with new

memory, replace the controllerboard. Record the message andreturn it with the defective board.

ERROR: WRITINGTO FLASH

Hardware or software fault inflash memory.

1. Replace flash memory.2. If message occurs with new

memory, replace the controllerboard. Record the message andreturn it with the defective board.

ERROR: WRONGCHECKSUM

The printer received thecomplete program but thechecksum did not match.The data may have beencorrupted during download.

1. Power off the printer. Downloadthe program again from thebeginning. If the messagesappears, replace the DRAM.

2. Download the program using anew software diskette. If themessages appears, replace theflash memory.

3. Download the program. If themessages appears, replace thecontroller board. Record themessage and return it with thedefective board.



Chapter 3 Troubleshooting Display MessagesERROR OCCURREDFLUSHING QUEUES *

An interim message thatdisplays while the printerdiscards host data it cannotuse because a faultcondition exists. While thismessage displays, theasterisk (*) rotates.

Wait. When the asterisk (*) stopsrotating, a different fault message willappear: troubleshoot the finalmessage.

ETHERNET ADAPTERBEING INITIALIZED

Status message indicatingthat the PrintNet ethernetinterface is processing theboot procedure. (May occurwith older versions ofmicrocode.)

No action required.

ETHERNET DETECTED Status message indicatingthat the PrintNet ethernetinterface has establishedcommunication.

No action required.



List Of MessagesEXHAUST FAN FLT Exhaust Fan Fault. Sensorscannot detect current in thefan circuit.

1. Cycle power. If the messageappears, press CLEAR.

2. Check that the exhaust fan isconnected to exhaust fan cableconnector J307. Connect the fancable connector.

3. Power off the printer. Remove thepaper path. Disconnect connectorP107 from the controller board.Test connector P107/EHF forshorts or opens. (See the MainWire Harness Test Tables inAppendix A.) Replacecomponents that fail test.

4. Make sure connector P107/EHFhas a good connection at J107 onthe controller board.

5. Inspect for obstructions ofairways and vents. Check foritems beneath the printerblocking cabinet vents. Removeobstructions. Make sure cabinetexhaust fan vents are notblocked.

6. Power on the printer. Check forfan operation. If the messageappears or the fan does not work,replace the exhaust fan.

7. Power on the printer. If them

16855649 Printronix P5000 Line Matrix Printers Maintenance Manual

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Transcript of 16855649 Printronix P5000 Line Matrix Printers Maintenance Manual