Printronix P7000 Series User manual

Maintenance Manual
Printronix P7000 Series of Line Matrix Printers

177705-001F
Maintenance Manual
P7000 Series of Line Matrix Printers

Trademark Acknowledgements
ANSI is a registered trademark of American National Standards Institute, Inc.
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ENERGY STAR® is a registered trademark of the United States
Environmental Protection Agency. As an ENERGY STAR® Partner,
Printronix has determined that this product meets the ENERGY STAR®
guidelines for energy efficiency.
IBM is a registered trademark of International Business Machines
Corporation.
IEEE is a registered trademark of the Institute of Electrical and Electronics
Engineers.
IGP is a registered trademark of Printronix, Inc.
Intelligent Printer Data Stream and IPDS are trademarks of International
Business Machines Corporation.
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LinePrinter Plus is a registered trademark of Printronix, Inc.
Linux is a registered trademark assigned to Linus Torvalds.
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trademarks of Microsoft Corporation.
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Primelogic is a trademark of PTC Group, 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.
SureStak is a trademark of Printronix, Inc.
Torx is a registered trademark of Camcar/Textron Inc.
UNIX is a registered trademark of The Open Group.
Utica is a registered trademark of Cooper Power Tools.

Warranty And Copyright Information
Printronix, Inc. 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, Inc. shall not
be held responsible for errors contained herein or any omissions from this
material or for any damages, whether direct, indirect, incidental or
consequential, in connection with the furnishing, distribution, performance or
use of this material. The information in this manual is subject to change
without notice.
This document contains proprietary information protected by copyright. No
part of this document may be reproduced, copied, translated or incorporated
in any other material in any form or by any means, whether manual, graphic,
electronic, mechanical or otherwise, without the prior written consent of
Printronix, Inc.
All rights reserved.
Copyright © 2005, 2011, Printronix, Inc.
E NERGY S TAR
The Environmental Protection Agency ENERGY STAR ® Computers program is
a partnership effort with manufacturers of data processing equipment to
promote the introduction of energy-efficient personal computers, monitors,
printers, fax machines, and copiers to help reduce air pollution and global
warming caused by electricity generation.
Printronix, Inc. participates in this program by introducing printers that reduce
power consumption when they are not being used. As an ENERGY STAR
®
Partner, Printronix has determined that this product meets the ENERGY STAR
®
guidelines for energy efficiency.
NOTE: The ENERGY STAR ® emblem does not represent EPA endorsement of
any product or service.

Communication Notices
Federal Communications Commission (FCC) Statement
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may cause harmful interference
to radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
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.
Unauthorized changes or modifications could void the user’s authority to
operate the equipment.
This device complies with Part 15 of the FCC Fules. Operation is subject to
the following two conditions: (1) this device may not cause harmful
interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
European Union (EU) Conformity Statement
Printronix cannot accept responsibility for any failure to satisfy the protection
requirements resulting from a non-recommended modification of the product,
including the fitting of option cards not authorized by Printronix.
This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to European standard EN
55022. The limits for Class A equipment were derived for commercial and
industrial environments to provide reasonable protection against interference
with licensed communication devices.
This is a Class A product. In a domestic environment this product may
cause radio interference in which case the user may be required to
take adequate measures.
WARNING

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. Such cables
and connectors are available from Printronix authorized dealers. Printronix
cannot accept responsibility for any interference caused by using other than
recommended cables and connectors.
Industry Canada Compliance Statement
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A conform á la norme NMB-003 du
Canada.
Statement of CISPR 22 Edition 2 Compliance
Attention: This is a Class A Product. In a domestic environment this product
may cause radio interference in which case the user may be required to take
adequate measures.
Japanese VCCI Class A
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.

Australia/New Zealand
Attention: This is a Class A Product. In a domestic enviroment this product
may cause radio interference in which case the user may be required to take
adequate measures.
Korea
China
Declaration: This is a Case A Product. In a domestic environment this
product may cause radio interference, in which case the user may be required
to take practical actions.
German Conformity Statement
Zulassungsbescheinigung Gesetz über die elektromagnetische
Verträglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EG-
Konformitätszelchen - CE - zu führen.
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und
EN 55024 Klasse A.

EN 55022 Klasse A Geräte bedürfen folgender Hinweise:
Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht asreichend
entstört sind, nur mit besonderer Genehmigung des Bundesminesters für
Post und Telekommunikation oder des Bundesamtes für Post und
Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn
keine elektromagnetischen Störungen zu erwarten sind.” (Auszug aus dem
EMVG, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nach
Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
EN 55022: Dieses ist eine Kategorie A Vorrichtung. Betrieb in den
Wohnbereichen kann elektrische Störung verursachen. Es ist die
Verantwortlichkeit des Benutzers, passende Gegenmaßnahmen zu ergreifen.
EN 55024: Begrenzung Werte für Gebrauch in bevölkerten Bereiche,
kommerziellen und Industriegebieten sind innen Übereinstimmung mit den
spezifizierten Anforderungen Hinsichtlich Störfreiheit.
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte,
wie in den Handbüchern angegeben, zu installieren und zu betreiben.
European Union (EC) Electromagnetic Compatibility
Directives
This product conforms to the protection requirements of EC Council Directive
89/336/EEC on the approximation of the laws of the Member States relating
to electromagnetic compatibility. Printronix cannot accept responsibility for
any failure to satisfy the protection requirements resulting from a non-
recommended modification of the product, including the fitting of option cards
not authorized by Printronix.
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen EMVG
vom 9.Nov.92 das EG-Konformitätszeichen zu furhren.
Properly shielded and grounded cables and connectors must be used to
reduce the potential for causing interference to radio and TV communication
and to other electrical or electronic equipment. Printronix cannot be
responsible for any interference caused by using other than recommended
cables and connectors.
This product has been tested and found to comply with limits for Class A
Information Technology Equipment according to CISPR 22/European
Standard EN 55022. The limits for Class A equipment were derived for
commercial and industrial environments to provide reasonable protection
against interference with licensed communication equipment.
Warning: This is a Class A product. In a domestic environment this product
may cause radio interference in which case the user may be required to take
adequate measures.
Dieses Gerät erfüllt die Bedingungen der EN 55022 Klasse A. Für diese
Klasse von Geräten gilt folgende Bestimmung nach dem EMVG:

Chapter
Geräte dürfen an Orten, für die sie nicht ausreichend entstört sind, nur mit
besonderer Genehmigung des Bundesminesters für Post und
Telekommunikation oder des Bundesamtes für Post und Telekommunikation
betrieben werden. Die Genehmigung wird erteilt, wenn keine
elektromagnetischen Störungen zu erwarten sind.
(Auszug aus dem EMVG vom 9.Nov.92, Para.3, Abs.4)
Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost
noch nicht veröffentlict worden.

Table of Contents
1 Maintenance Overview ......................................... 17
Printronix P7000 Printers........................................................................17
Order The Correct Spares................................................................18
How To Identify A P7000 Printer......................................................18
H-Series Printers..............................................................................20
HD Printers.......................................................................................20
Zero Tear Pedestal (ZTP) Printers...................................................20
Printer Configuration Code...............................................................21
Forms Handling................................................................................21
Important Maintenance Notes.................................................................22
Notices .............................................................................................22
About This Manual..................................................................................23
How To Use This Manual.................................................................24
Safety Notices.........................................................................................25
Hinweise zur Sicherheit ..........................................................................25
Controls And Indicators ..........................................................................26
Electrical Controls ............................................................................26
Mechanical Controls.........................................................................28
Tools And Test Equipment .....................................................................30
Plugging In The Printer ...........................................................................31
Printronix Customer Support Center.......................................................32
Printronix Supplies Department........................................................32
Maintenance Training For Printronix Products .......................................33
2 Preventive Maintenance....................................... 35
Cleaning The Printer...............................................................................35
Cleaning The Outside Surfaces..............................................................35
Cleaning The Shuttle Frame Assembly ..................................................37
Cleaning The Card Cage Fan Assembly ................................................38

Table of Contents
3 Troubleshooting .................................................... 39
Introduction.............................................................................................39
Troubleshooting Aids..............................................................................39
Start Here... ............................................................................................40
Troubleshooting Display Messages........................................................41
List Of Messages .............................................................................42
Troubleshooting Other Symptoms........................................................185
General Symptom List....................................................................186
Communications Failures .....................................................................209
Diagnostic Printer Tests........................................................................211
Selecting And Running Diagnostic Printer Tests ...........................212
Boot Diagnostics Menu.........................................................................217
Factory Menu........................................................................................220
Exception Menu....................................................................................222
Hex Code Printout ................................................................................223
How To Print A Hex Dump .............................................................224
ASCII Character Set .............................................................................226
Soft vs. Hard Reset...............................................................................227
4 Adjustments and Tests ....................................... 229
Introduction...........................................................................................229
Adjustments and Tests...................................................................229
Preparing The Printer For Maintenance ...............................................230
Returning The Printer To Normal Operation.........................................231
Belt, Paper Feed Timing, Adjustment...................................................232
Belt, Platen Open, Adjustment..............................................................234
Paper Scale Alignment .........................................................................236
Platen Gap Adjustment.........................................................................238
Ribbon Guide Alignment.......................................................................240
Paper Out Adjustment ..........................................................................242
Hammer Phasing Adjustment...............................................................245
Loading Flash Memory .........................................................................247
Loading Software With The Firmware Download Utility .................247
Loading Through Parallel Port Using DOS ....................................249
Loading Software If Flash Contains Only Boot Code.....................250
Loading Software Through The NIC ..............................................252
Reprogramming the Security Key.........................................................253
How To Reprogram The Security Key ...........................................253
Coil Temperature Adjustment ...............................................................255
Dynamic Paper Tension Adjustment ....................................................256
Tractor Belt Tension Adjustment ..........................................................258
Shuttle Electrical Short Check ..............................................................259

Table of Contents
Hammer Bank Power Cable Shorts Test..............................................260
Cable Shorts Test .................................................................................261
Main Wire Harness Test Diagnostic .....................................................263
Power Supply Operational Check.........................................................264
5 Replacement Procedures ................................... 269
Organization Of This Chapter ...............................................................269
Replacement Procedures .....................................................................269
List Of Removal / Installation Procedures ......................................269
Belt, Paper Feed Timing ................................................................271
Belt, Platen Open ...........................................................................272
Circuit Breaker ...............................................................................273
Connector Coupling Shrouds .........................................................274
Control Panel Assembly.................................................................276
Controller Board .............................................................................277
Cover Assembly, Hammer Bank / Ribbon Mask ............................279
Cover Assembly, Shuttle................................................................280
Cover Assembly, Top, Pedestal Models ........................................281
CT Board........................................................................................282
Dashpot..........................................................................................283
Fan Assembly, Cabinet Exhaust ....................................................284
Fan Assembly, Card Cage .............................................................285
Fan Assembly, Hammer Bank........................................................286
Hammer Spring Assembly, Version 1 ............................................287
Hammer Spring Assembly, Version 2 ............................................289
Integrated Print Management Sensor ............................................295
Magnetic Pickup (MPU) Assembly.................................................296
Memory and Security Key ..............................................................297
NIC (Network Interface Card) Assembly ........................................299
Paper Feed Motor ..........................................................................301
Paper Ironer ...................................................................................302
Paper Path .....................................................................................303
Platen .............................................................................................304
Platen Open Motor .........................................................................308
Platen Stop Assembly ....................................................................310
Power Supply Board ......................................................................311
Resistors, Terminating, V5 Controller Board..................................312
Resistors, Terminating, V6 Controller Board..................................314
Ribbon Drive Motor ........................................................................316
Ribbon Guide Assembly (L/R)........................................................317
Shaft, Splined.................................................................................318
Shaft, Support ................................................................................320

Table of Contents
Shuttle Frame Assembly ................................................................321
Spring, Extension, Hammer Bank ..................................................323
Switch Assembly, Paper Detector..................................................324
Switch Assembly, Platen Interlock .................................................325
Tractor (L/R)...................................................................................326
6 Illustrated Parts Breakdown................................ 327
Organization Of This Chapter...............................................................327
Illustrations of Printer Components ................................................327
7 Principles Of Operation....................................... 369
Line Matrix Printing ...............................................................................369
Printing Rates .......................................................................................372
Printing Mechanism ..............................................................................372
Shuttle Frame Assembly.......................................................................373
Hammer Bank Assembly................................................................373
Shuttle Drive Motor ........................................................................374
Paper Transport System.......................................................................375
Ribbon Transport System.....................................................................376
Integrated Print Management System ..................................................377
Operation .......................................................................................378
The Ribbon Log..............................................................................380
Logical Control Of The Printer ..............................................................381
Control Panel........................................................................................383
Controller Board....................................................................................384
Data Controller ...............................................................................386
Engine Controller ...........................................................................388
Power Supply Board.............................................................................390
AC Power .......................................................................................390
DC Power.......................................................................................390
Printer Interface ....................................................................................391
Graphics ...............................................................................................391
A Wire Data ........................................................... 393
B Abbreviations...................................................... 447
C Metric Conversion Tables .................................. 455

Table of Contents
D SureStak™ Power Stacker ................................ 457
Contents ...............................................................................................457
Introduction...........................................................................................458
Stacker Operation.................................................................................458
Stacker Problems .................................................................................463
Stacker First Inspection..................................................................463
Stacker Confidence Check.............................................................464
Stacker Motor Check......................................................................465
Removing The Power Stacker ..............................................................468
Installing The Power Stacker ................................................................474
Replacing The Constant Force Spring..................................................486
Replacing The Timing Belts..................................................................488
Replacing The Roller Drive Shaft .........................................................491
Illustrated Parts Breakdown..................................................................494
List of Illustrations ..........................................................................494
E Zero Tear Pedestal (ZTP) Printer....................... 507
Contents ...............................................................................................507
Overview...............................................................................................508
Operation ..............................................................................................509
Load Paper And Set Up The Tractors............................................509
Remove Paper ...............................................................................510
Adjust The Paper Guides ...............................................................511
Position The Paper Out Sensor .....................................................513
Set The Tear Bar Distance.............................................................514
Set The Top Of Form .....................................................................515
Control Panel Menus ............................................................................516
Performance Limitations .......................................................................517
Adjustments And Tests.........................................................................519
List of Adjustments and Tests Procedures.....................................519
Preparing The ZTP Printer for Maintenance ..................................520
Returning The Printer To Normal Operation ..................................520
Barrier Panel ..................................................................................521
Belt, Paper Feed Timing, Adjustment.............................................522
Paper Guide Leaf, Front, Center, Outer.........................................524
Paper Out Sensor, Adjustment ......................................................524
Paper Tension, Horizontal..............................................................524

Table of Contents
Replacement Procedures .....................................................................525
List of Removal / Installation Procedures.......................................525
Belt, Paper Feed Timing ................................................................526
Control Panel Assembly.................................................................527
Cover Assembly, Top, Pedestal Models ........................................527
Paper Feed Motor ..........................................................................528
Paper Guide Leaf, Center ..............................................................529
Paper Guide Leaf, Front.................................................................529
Paper Guide Leaf, Outer ................................................................529
Paper Out Sensor ..........................................................................530
Shaft, Splined.................................................................................532
Shaft, Support ................................................................................536
Tractor (L/R)...................................................................................537
Tractor Assembly Support Gate.....................................................537
Illustrated Parts Lists ............................................................................539
Illustrations of ZTP Components....................................................539
F Paper Specifications And Forms Design ............ 555
Introduction...........................................................................................555
General Paper Specifications ...............................................................556
Paper Guidelines ..................................................................................557
Terms And Definitions....................................................................557
Environmental Considerations .......................................................559
Form Types ....................................................................................559
Form Weight...................................................................................559
Form Thickness..............................................................................559
Form Evenness ..............................................................................559
Tractor Pin Engagement ................................................................559
Methods Of Forms Attachment ......................................................560
Chaff Content .................................................................................561
Form Design Checklist..........................................................................562
Summary ..............................................................................................565
Storage And Handling .................................................................... 565
G Maintenance Manuals For P5000 Printers......... 567
H Customer Support .............................................. 573
Printronix Customer Support Center.....................................................573
Printronix Supplies Department ............................................................573
Corporate Offices..................................................................................574

17
1Maintenance Overview
Printronix P7000 Printers
P7000 printers are the latest line matrix printers to feature PSA3™ (Printronix
System Architecture, third generation). This innovative printer architecture
puts all data and printer control electronics one of two available “Hurricane”
controller boards: V5 and V6. Up to 32 MB of flash memory on this board
permits rapid access to stored printer control languages (emulations) and
very fast processing of print data. A variable-speed shuttle and micro-step
paper feed control enable P7000 printers to print a wide range of horizontal
and vertical dot densities, making these printers ideal for high-volume print
jobs.
The controller board, card cage, and some parts of the ribbon drive system in
P7000 printers are new designs and are not electrically or mechanically
compatible with earlier Printronix line matrix printers. (For maintenance
information about earlier Printronix printers, see page 567.)
The principal differences among the various P7000 models are the number of
hammers on the hammer bank, whether the printer is mounted on a pedestal
or housed in a floor cabinet, and the maximum possible print speed. In this
manual, all items described apply to all models except where noted. (See
Table 1 on page 19.)
Although technically sophisticated, a P7000 printer is easy to use. The
mechanical controls that the operator can adjust are colored blue for quick
identification. The operator can select every printer function either at the
printer control panel or by sending control codes to the printer in the data
stream from the host computer. For added security—and to protect special
printer configurations—the operator can program which key combination
locks and unlocks the ENTER key on the control panel.
Optional Features Enhance Graphics and Forms Handling
The PGL ® and VGL Printronix emulations, bundled together as IGP ® , are
easy to use but highly versatile graphics programming languages that load
into the printer’s memory and simplify the creation of graphic images. The
PSA3 architecture enables multiple emulations and graphic options to be run
without additional graphic processors or protocol converters.
Depending upon the model, various types of paper stacker are available to
handle any throughput requirements. (See “Forms Handling” on page 21.)

18
Chapter 1 Printronix P7000 Printers
Order The Correct Spares
When you replace worn or damaged printer components, make sure you
order the correct spares for the model you are servicing. The next section
shows you how to identify a P7000 printer.
How To Identify A P7000 Printer
A P7000 printer has a black or gray finish and the PSA3 logo on the printer
cover. Every printer also has a model number, which is an alphanumeric code
that identifies the printer type, its housing, and its maximum rated print speed.
The model number and serial number of the printer are on the identification
label next to the input/output ports at the rear of the printer. Figure 1 shows
how to inpret a model number.
Figure 1. How to Interpret a Model Number
Table 1 lists the models in the P7000 series. Remember that the speeds
listed are the highest attainable under controlled test conditions. The speed of
printing for “real world” print jobs is affected by the interaction of many
variables and varies from print job to print job. For more information, see
“Printing Rates” on page 372.
Printronix Line
Matrix Printer
P7000 Printer
P7002H
Housing Code:
0= Pedestal
2= Floor Cabinet
Speed Rating:
02 = 200 lines per minute (lpm)
03 = 300 lpm
05 = 500 lpm
06 = 600 lpm
08 = 800 lpm
10 = 1000 lpm
15 = 1500 lpm
20 = 2000 lpm
00 = 133 inches per minute (ipm)
H= H-Series printer
HD = High Definition printer
ZT = Zero Tear printer

How To Identify A P7000 Printer
19
Table 1. P7000 Printers
Model Number Maximum
Print Speed Enclosure Hammer Bank
P7002H 200 lpm Pedestal 28 Hammers
P7002HZT 200 lpm ZT Pedestal 28 Hammers
P7202H 200 lpm Cabinet 28 Hammers
P7003H 300 lpm Pedestal 60 Hammers
P7003HZT 300 lpm ZT Pedestal 60 Hammers
P7203H 300 lpm Cabinet 60 Hammers
P7005 500 lpm Pedestal 28 Hammers
P7005ZT 500 lpm ZT Pedestal 28 Hammers
P7205 500 lpm Cabinet 28 Hammers
P7006H 600 lpm Pedestal 102 Hammers
P7006HZT 600 lpm ZT Pedestal 102 Hammers
P7206H 600 lpm Cabinet 102 Hammers
P7008H 800 lpm Pedestal 126 Hammers
P7008HZT 800 lpm ZT Pedestal 126 Hammers
P7208H 800 lpm Cabinet 126 Hammers
P7010 1000 lpm Pedestal 60 Hammers
P7010ZT 1000 lpm ZT Pedestal 60 Hammers
P7210 1000 lpm Cabinet 60 Hammers
P7015 1500 lpm Pedestal 102 Hammers
P7015ZT 1500 lpm ZT Pedestal 102 Hammers
P7215 1500 lpm Cabinet 102 Hammers
P7220 2000 lpm Cabinet 126 Hammers
P7000HD 133 ipm Pedestal 126 Hammers
P7000HDZT 133 ipm ZT Pedestal 126 Hammers
P7200HD 133 ipm Cabinet 126 Hammers

20
Chapter 1 Printronix P7000 Printers
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 1.) H-Series printers have specially designed platens and unique
shuttle assemblies which are only used in H-Series and HD Series printers.
These assemblies are not interchangeable with any other Printronix printers.
HD Printers
HD (High Definition) printers use a Windows printer driver with the LQ1600K
emulation to print scalable alphabetic characters in high resolution print
quality. Using the same shuttles mechanisms as the P7X08H H-Series
printers, HD models print alphabetic character sets as graphic page images
instead of in linear character streams. For this reason, the speed of HD
printers is measured in inches per minute (ipm) instead of lines per minute
(lpm). (See Table 1 and Figure 1.)
Zero Tear Pedestal (ZTP) Printers
Zero Tear Pedestal (ZTP) printers are models equipped with special
hardware and software that permits them to print small jobs or single sheets
without losing a sheet between print jobs. A ZTP printer automatically
presents the current print line to a tear bar when it finishes printing and
presents the perforation of the last form printed to the tear bar. When it
receives more data from the host computer, the printer pulls the form down to
the print station and resumes printing.
ZTP printers are covered in Appendix E (page 507).
Table 2. H-Series Character Sets
Character Set Where Used
GB China
BIG-5, with an additional 3000 Cantonese characters Hong Kong
BIG-5
TCA
DCI (1st and 2nd segments)
DCI (3rd segment)
CNS
Taiwan
KSC 5601 South Korea