Printronix PrintCart User Manual
PrintCart
User’s Manual
PrintCart
User’s Manual
251755-001F
Trademarks
Printronix is a registered trademark of Printronix, Inc.
All other trademarks are the property of their respective owners.
Product Warranty
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.
Communication Notices
This device complies with Part 15 of the FCC Rules. 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.
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la Class A est conform à la norme NMB-003 du
Canada.
Emergency Disconnect Procedure
In an electrical emergency disconnect the AC input line cord from any
external power source and disconnect the AC output line cords from any
equipment powered by the cart.
Unterbrechung der Stromversorgung im Notfall
Bei einem Notfall im Bereich der Elektro-Installation die
Spannungsversorgungskabel von allen externen Spannungsquellen sowie
die Spannungsversorgungskabel von allen über das Cart mit Spannung
versorgten Geräten abziehen.
Notice of Copyright
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.
Copyright © 2007, 2010 Printronix, Inc. All rights reserved.
Specifications subject to change without notice.
Table of Contents
1 Quick Start And Setup .......................................... 7
Quick Start ............................................................................................. 7
Unpacking ....................................................................................... 7
Safety Inspection............................................................................. 9
Equipment Setup ................................................................................... 9
Mechanical Installation .................................................................... 9
Electrical Installation ..................................................................... 10
Startup ................................................................................................. 11
Operating Limitations ........................................................................... 12
2 PrintCart.............................................................. 15
Overview.............................................................................................. 15
PrintCart Layout................................................................................... 16
3 Operation ............................................................ 21
Line Power Operation .......................................................................... 21
Battery Power Operation ..................................................................... 23
PrintCart Operating Duration......................................................... 23
Indicator Panel..................................................................................... 24
Gaining Access To The Printer............................................................ 26
Slide The Tray To Service Position ............................................... 26
Load Media Or Ribbon .................................................................. 26
PrintCart Features ............................................................................... 27
PrintCart Accessories .......................................................................... 27
4 Troubleshooting .................................................. 31
Safety................................................................................................... 31
PrintCart Safety Features .................................................................... 32
Troubleshooting Guide ........................................................................ 33
5 Maintenance........................................................ 37
Power Equipment Access .................................................................... 37
Serviceability Inspection ...................................................................... 40
Battery Replacement ........................................................................... 40
Inverter Replacement .......................................................................... 42
Fuse Replacement............................................................................... 43
Display Fuse ................................................................................. 43
Main Fuse ..................................................................................... 43
Power Cord Replacement.................................................................... 44
Wheel Replacement ............................................................................ 45
Caster Wheels............................................................................... 45
Fixed Wheels ................................................................................ 45
Hand Grip Replacement ...................................................................... 46
A Specifications ...................................................... 47
Physical Specifications ........................................................................ 47
Electrical Specifications ....................................................................... 48
B Wiring Schematics .............................................. 49
120V/60Hz ........................................................................................... 49
230V/50Hz ........................................................................................... 50
C Spare Parts ......................................................... 51
D Glossary .............................................................. 53
E Contact Information ............................................. 55
Printronix Customer Support Center.................................................... 55
Printronix Supplies Department ........................................................... 55
Corporate Offices................................................................................. 56
1 Quick Start And Setup
Quick Start
Unpacking
WARNING
IMPORTANT
Dismounting the cart from the pallet requires strength. Two people is
recommended for the task.
1. Place the pallet on a flat, level surface, leaving enough room to roll the
PrintCart off the pallet.
2. Remove the two cardboard protective shipping sleeves and set them
aside.
3. Remove the plastic wrap and shipping bag from the PrintCart.
Make sure the caster brake is set.
4. Cut the bands holding the unloading ramps.
5. Lift and remove the ramps off the locating pins.
6. Reverse the ramps and engage the locating pin in the angled blocks on
the end of the pallet. See
Figure 1.
Locating Pin
Ramp
Figure 1. Reversing the Ramps and Engaging the Locating Pin
7
Chapter 1 Quick Start
7. If necessary set the caster brake on the PrintCart.
8. Cut the shipping restraint tie wraps on all turnbuckles.
9. Insert a screwdriver through the center of each turnbuckle housing and
loosen the turnbuckle until you can remove the hook from the eyelet.
10. Unhook the opposite end from the PrintCart frame. See Figure 2.
Turnbuckle
Housing
Shipping
Restraint
Hook
PrintCart
Figure 2. Loosening the Turnbuckle from its Housing
11. On the opposite side of the PrintCart, repeat steps 9 and 10 to completely
disengage the shipping restraints.
12. Release the caster brake. Grasp the hand grips and pull the PrintCart
down the unload ramps to the work surface.
Hand Grip
Ramp
Figure 3. Moving the PrintCart to the Work Surface
13. Replace the unloading ramps on the pallet and store the pallet and
turnbuckles for future re-use.
8
Safety Inspection
1. Inspect the PrintCart for damage that may have occurred during
shipment.
2. Open the power compartment door and verify that the batteries are
securely restrained and the battery cable connections are tight.
3. Verify that the charger/inverter is held securely in place. If any
components have loosened during shipment, secure them before
applying power to the PrintCart.
Equipment Setup
Mechanical Installation
NOTE: If applicable, first install the terminal to the PrintCart. Access to the
Safety Inspection
underside of the work surface will be restricted after printer
installation.
Terminal Installation
1. Follow the manufacturer’s installation instructions to install the wireless
terminal.
The PrintCart is equipped with a central mounting rail under the stainless
steel work surface. This mount is predrilled with 2 rows of 5/16” holes on 1
inch centers. The size and spacing coincides with the hole pattern that
mates with the Symbol VRC 8900 series terminals bracket; it may fit
several others. The right-most row of holes is centered on the PrintCart
frame. The left-most row of holes is centered between the left edge and
the barcode scanner storage slot on the right rear of the PrintCart.
2. If the utility drawer is installed, remove the drawer by fully extending the
drawer and disconnecting the slide latch. This will provide access to the
mounting rail and provide additional overhead clearance.
3. Determine the appropriate mounting location and suitability of the desired
mounting bracket.
4. Find the holes (minimum of 2) that will properly position the terminal and
mark them on the underside.
5. Use the predrilled mounting rail as a template and drill up through the top
work surface using a power hand drill from below.
6. Secure the bracket to the PrintCart according to the manufacturer’s
instructions.
9
Chapter 1 Equipment Setup
Printer Installation
1. Set the wheel lock on the caster wheel to prevent the PrintCart from
moving.
2. Lift the spring loaded handle located on the side of the slide out tray and
pull the tray out over the side of the PrintCart to the fully extended
position.
NOTE: The slide out tray clicks into place when the tray is fully extended.
IMPORTANT
WARNING
For Printronix thermal printers, the four rubber pads on the bottom of
the printer must be removed.
3. Tip the printer onto the left side (side with power compartment cover) and
unscrew the rubber pads. If necessary, use pliers to improve grip.
4. Install the four black rubber vibration mounts that are provided with the
PrintCart.
5. Tip the printer back upright.
The next step requires two people; one person to support the printer,
the other to align the mounts.
6. Carefully lift the printer and set it on the slide out tray, aligning the
threaded vibration mounts with the holes in the tray. The printer’s control
panel should face the end of the PrintCart with the hand grips.
7. Secure the printer to the tray using the four supplied lock nuts.
8. Lift the spring loaded handle and slide the tray back under the top work
surface of the PrintCart. It should click into a retracted and locked
position.
Electrical Installation
The electrical cable for the PrintCart equipment is routed through the right
rear leg into the power compartment.
10
Printer Hook-Up
The printer power cable is preinstalled in the PrintCart.
1. Connect the power cable to the printer. Make sure the cord is slightly
slack to provide a small service loop during movement of the slide out
tray.
2. Test the service loop length by extending the printer shelf and verify that
enough slack is available.
3. Bundle and secure any excess cord in the power compartment.
Electrical Installation
Terminal Hook-Up
1. Install the power supply for the terminal in the pocket provided behind the
two slot notebook bin. See
Figure 4.
Pocket
Two Slot
Notebook Bin
Startup
Figure 4. Installing Power to the Terminal
If this accessory is not included with the PrintCart:
2. Locate power supply in the power compartment to the left of the inverter.
3. Connect an AC power cord to the power supply and connect it to the
remaining receptacle by routing it down through the right rear leg into the
inverter compartment.
4. Bundle and secure any excess cord.
5. Route the DC power cable from the terminal to the power supply and
secure all excess cable length (terminal P/S pocket behind the letter bin).
Make sure all PrintCart equipment has been installed and power cords have
been routed and connected to the inverter.
1. Check that the equipment power switches are in the OFF (0) position.
The PrintCart is now prepared for start-up.
2. Open the power compartment front door (hand grip end) and connect the
main inverter power/battery cable to the connector on the battery
subpallet.
3. Open the power compartment rear door and locate the inverter operating
switch on the upper-right of the inverter.
4. Slide the switch left to the “AUTO/INVERT” position. The inverter will
begin producing power as indicated by the yellow mode indicator on the
inverter.
11
Chapter 1 Operating Limitations
5. Close and latch the rear door.
Inverter and battery status are indicated on the LED display panel located on
the front of the PrintCart adjacent to the hand grips. The batteries in a new
PrintCart arrives nearly fully charged. Battery state of charge “gas gauge”
shows all LED’s lit, (2 red, 2 yellow, and 2 green). If all of the battery status
LED’s are not lilt, charge the PrintCart prior to use.
Power is available when the inverter is in the auto position; the equipment
may now be switched on. If the connected equipment does not receive power,
perform the following:
• 120V units
Examine the GFCI duplex outlet to the left of the inverter. If the trip
indicator lamp located on the right side of the GFCI is illuminated, the
GFCI has faulted. Reset the GFCI by depressing the RESET button
between the two plugs.
• 230V units
Examine the “Load C/B” (load circuit breaker) located above the inverter
output receptacles. If it extends beyond the mounting more that a couple
of millimeters, it has faulted. Reset the load circuit breaker by pressing it
in.
Close and latch the power compartment door.
Operating Limitations
When the cart is not in service, leave it plugged in to maintain battery charge.
Otherwise, charge the cart battery every 90 days.
CAUTION
Recharge the batteries as soon as possible after use. Failure to quickly
recharge batteries can result in permanent battery damage. Batteries
left in a discharged state for extended periods may be so damaged that
they will not accept a charge and recharging them could be dangerous.
Any attempt to recharge partially discharged batteries left for an
extended time requires frequent supervision to ensure that venting or
excessive heating does not occur.
Do not charge a fully discharged battery at a rate greater than 1/10 of the
amp-hour capacity. This cart is equipped with fail safe controls to
prevent full discharge. If the batteries become fully discharged, possibly
due to long term inactivity, switch the inverter/charger to slow charging
mode to revive them. Slow charging prevents further damage to the
battery and reduces the risk of battery out-gassing or destructive
heating if the battery is damaged beyond recovery.
12
Electrical Installation
120V/60Hz Models
Eight switches are located on the top center of the RV750ULHW inverter/
charger front panel. The far left switch is for charge rate. The down (normal)
position is fast (45A) charge; the up position is slow (11A) charge. Use the UP
position to recharge fully discharged batteries. If the batteries accept a full
charge without excessive heating or out-gassing, the capacity selector can be
retuned to the full (down) setting.
230V/50Hz Models
A red button labeled “Sleeping Mode” is located on the right side of the
charger (blue device at the bottom of the power module). Depressing this
button reduces the charge rate to approximately 1/3 the normal rate. If the
batteries accept a full charge without excessive heating or out-gassing, the
sleep mode button can be retuned to the full or out position.
WARNING
CAUTION
If the batteries become excessively hot or emit a detectable odor, the
batteries are damaged beyond repair and are dangerous to use. Stop
charging immediately. Remove the batteries from service and dispose
of them according to local regulations.
Do not charge the batteries at a rate greater than 1/4 of the amp-hour
capacity. For example, a 100 amp-hour battery should be charged no faster
than 25 amps (or a pair of 100 amp-hour batteries no faster than 50A).
The charger on this cart provides the maximum recommended charge rate for
the batteries with which it is equipped.
Do not use additional or larger chargers to speed recharging.
Permanent battery damage will occur and the potential for catastrophic
failure is high.
Before connecting or disconnecting the batteries, turn off battery powered
electrical equipment and disconnect both the main DC disconnect and display
power cable.
Make sure that battery terminal covers are in place to prevent accidental
shorts between the battery and surrounding frame or equipment.
Use insulated tools to service any power connections that cannot be
disconnected from battery power.
13
Chapter 1 Operating Limitations
14
2 PrintCart
Overview
The PrintCart is a wireless, cordless work platform capable of transporting
several pieces of electrically powered equipment to a work site. On site, the
PrintCart can operate indefinitely on line power or for an extended period of
time (depending on equipment) on battery power. The PrintCart is designed to
support continuous operation of all connected equipment without shutting
down.
The PrintCart contains three separate levels:
Bottom Level
The bottom level is the power compartment, which houses the power storage,
power conversion equipment, and the electrical safety devices that ensure
safe PrintCart operation.
Middle Level
The middle level contains the printer and storage of materials and waste. The
printer shelf is mounted on slides that permit a thermal printer to extend out
the right side of the PrintCart for service. To the left of the printer shelf is a
refuse bin, document holders, and a media storage bin. Above the printer is a
utility drawer.
Top Level
The top level has a stainless steel work area which supports electronic
wireless terminal mounting and installation of a barcode scanner storage slot.
The power compartment is enclosed and latched with a mechanism that
requires a tool to open to prevent incidental access. It contains two sealed
lead acid batteries for electricity storage. Power is provided by a combination
device called an inverter/charger. Inversion is the process of using the 12 volt
direct current stored in the batteries and converting it to a suitable alternating
current at a voltage and frequency for operating equipment mounted on the
PrintCart. The PrintCart operating voltage can be 120 volts AC @ 60 Hertz
(North American standard) or 230 volts AC at 50 Hertz (European standard).
Operating voltage is specified at the time of order and can be changed by
swapping out the Power Equipment Subpallet (PESP).
15
Chapter 2 PrintCart Layout
The battery charge function is performed in the inverter/charger. When AC
line power is applied, the inverter charger automatically transfers (switches)
power directly to the PrintCart equipment and begins charging the batteries.
The charger provides power to the batteries in three separate stages to
optimize the storage capacity and battery life.
The PrintCart can support multiple pieces of electrical equipment. The
primary intent is to support one Printronix four inch or six inch thermal printer
on the printer shelf. The PrintCart includes an installation kit consisting of four
bolt-on shock mount isolators for securing the printer to the shelf.
The top work area can be used for any application but is intended for use with
a wireless terminal and barcode scanner. The barcode scanner storage bin
can be mounted on the right rear of the work surface. On the front left is a
display panel with integral controller. The display panel has a set of battery
charge status LEDs that report the battery state of charge. It also has a set of
stop light LEDs that display the inverter/charger mode status.
Additionally, there is an alarm to alert the user to recharge the batteries. The
built-in controller monitors power consumption and signals the user when the
batteries need recharging. The controller provides progressive alarms to the
user, indicating that there is a warning period to permit completion of the
current task, progressing to a shorter shutdown period. This indicates that the
PrintCart will soon enter automatic shutdown if not connected to line power for
recharging.
PrintCart Layout
Hand Grip (2)
Printer (not included)
Battery Access Door
Status Display
Barcode Scanner
Storage Slot
Stainless Steel
Work Surface
Brake/Locking
Caster
16
Figure 5. Front Right View of the PrintCart
Document Holder (2)
Rear Loop-Handle and
Terminal Protector
Printer (not included)
Power Equipment
Compartment
Power Compartment
Latch
Refuse Bin
Media/Ribbon
Storage
Power Cord
8” Fixed Wheel (2)
Figure 6. Rear Left View of the PrintCart
Power Status
Indicator
Battery Status
Indicator
Figure 7. Display Panel
17
Chapter 2 PrintCart Layout
AC Output GFCI
Inverter Setup
Switches
Inverter Display
Indicator
External Display
Panel Connector
Main Inverter
Power/Mode Switch
Grounding Lug
(AC)
Negative Battery
Cable Input
Positive Battery
Cable Input
Battery Charger
Circuit Breaker (8A)
Main AC Input Power
Circuit Breaker (15A)
Figure 8. Power Pallet Features and Safety Devices (120V)
18
Cart Equipment Outlet
AC Power Inverter
AC Input Circuit
Breaker (8A)
AC Output Circuit
Breaker (5A)
Battery Charger Module
Battery Charger Sleep
Mode Button Location
Figure 9. Power Module Features and Safety Devices (230V)
19
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