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.
Table of Contents 1 Quick Start And Setup .......................................... 7 Quick Start ............................................................................................. 7 Unpacking ....................................................................................... 7 Safety Inspection............................................................................. 9 Equipment Setup ...................................................................................
5 Maintenance........................................................ 37 Power Equipment Access.................................................................... 37 Serviceability Inspection ...................................................................... 40 Battery Replacement ........................................................................... 40 Inverter Replacement .......................................................................... 42 Fuse Replacement...............................
1 Quick Start And Setup Quick Start Unpacking WARNING 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. IMPORTANT Make sure the caster brake is set. 4. Cut the bands holding the unloading ramps. 5.
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. Shipping Restraint Hook Turnbuckle Housing Figure 2. Loosening the Turnbuckle from its Housing 11.
Safety Inspection 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.
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 For Printronix thermal printers, the four rubber pads on the bottom of the printer must be removed. 3.
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 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.
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.
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.
Chapter 14 1 Operating Limitations
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.
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.
Document Holder (2) Refuse Bin Rear Loop-Handle and Terminal Protector Printer (not included) Power Equipment Compartment Media/Ribbon Storage Power Compartment Latch Power Cord 8” Fixed Wheel (2) Figure 6. Rear Left View of the PrintCart Power Status Indicator Battery Status Indicator Figure 7.
Chapter 2 PrintCart Layout Inverter Setup Switches AC Output GFCI Grounding Lug (AC) Inverter Display Main Inverter Indicator Power/Mode Switch External Display Panel Connector Positive Battery Cable Input Negative Battery Cable Input Main AC Input Power Circuit Breaker (15A) Battery Charger Circuit Breaker (8A) Figure 8.
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.
Chapter 20 2 PrintCart Layout
3 Operation Line Power Operation When the line cord is connected to a wall receptacle, AC line power is transferred by an Automatic Transfer Switch (ATS) directly to the cart equipment. There is a short delay in applying line power (approximately 20 seconds for the 120V and 8 seconds for the 230V) to permit the plug to be secured in the receptacle. The transfer happens quickly so operation of the connected equipment is not interrupted.
Chapter 3 Line Power Operation • 120V – as charging progresses, yelow and green bars illuminate individually with each 10-15% increase in charge state. • 230V – the two red bars light when the charger is in Stage 1 (30-75% charge). When the charger enters Stage 2 (76-98% charge), the two yellow lights also illuminate. The two green lights illuminate together when the charger enters Stage 3 (greater than 98% charge). When all SoC lamps are illuminated, the PrintCart is fully charged.
PrintCart Operating Duration Battery Power Operation When the PrintCart is unplugged from the AC outlet, the power system automatically switches equipment to inverter power via the automatic transfer switch. NOTE: The PrintCart equipment does not have to be turned off and there will be no significant power interruption to the equipment. The Battery Powered mode indicator (yellow) on the display indicates that the battery is now providing power.
Chapter 3 Indicator Panel Indicator Panel Colored LEDs on the indicator panel displays operational status. The display is arranged in two sections: battery indicator (state of charge) on the left and power status (operating mode) on the right. Battery Indicator (gas gauge) Power Status Mode Indicators Figure 10. Display Panel Layout Indicator Colors NOTE: All power status mode indicators will not display simultaneously. Battery Indicator (at full battery charge) Battery Powered Mode Figure 11.
PrintCart Operating Duration Fault Mode Battery Indicator (discharged battery, flashing red gas gauge) Line Powered Mode Figure 13. Discharged Battery, Operating on Inverter NOTE: When the battery is discharged, the alarm timer activates (flashing red gas gauge) and the battery operates on inverter. An illuminated Fault mode LED indicates that either the charger or the inverter are not operating correctly.
Chapter 3 Gaining Access To The Printer If the cart is unplugged prior to the reset, the timer controlled shutdown will resume from its previous activation and shut down the cart when the remaining time expires. If both timers have previously expired, the cart will shut down immediately. • If the FAULT (red) mode LED illuminates, that indicates there is apower irregularity.
Load Media Or Ribbon PrintCart Features Wheel Brake/Lock The PrintCart is equipped with a wheel brake/lock on one of the front casters. When applied, the brake prevents the wheel from rotating and the lock prevents the caster from pivoting. Set this brake when using the PrintCart on a non-level surface or loading ramp. This feature is standard on all PrintCarts. Wheel Brake/Lock Figure 14.
Chapter 3 PrintCart Accessories Document Holders A factory or field installable dual document/notebook holder allows local storage of documents. The holders are recessed to prevent damage when the PrintCart is moved close to other objects. Document Holders Media Storage Compartment Figure 16. Dual Document Holders and Media Storage Compartment Media Storage Compartment A media storage compartment is either factory or field installable.
Load Media Or Ribbon Utility Drawer A utility drawer is available to store up to 8 1/2 x 11” size paper as well as other small items. This allows the top work surface to be kept clutter free. Power Cord The power cord is wrapped on a hanger on the left side of the power compartment (see Figure 18 on page 29). The line cord exits the power compartment through a hole with a grommet around it, in the center of the cord hanger.
Chapter 30 3 PrintCart Accessories
4 Troubleshooting Safety During any troubleshooting activities that require access to the power compartment, you must disconnect the input AC power cord from any external AC outlet and set the inverter main switch to the OFF (center) position. This removes the presence of any high voltage AC power. Always work on a level, dry area with the caster brake set to prevent accidental PrintCart movement. IMPORTANT WARNING WARNUNG Allow only trained personnel access to the power compartment.
Chapter 4 PrintCart Safety Features • Der Kontakt zwischen positiven und negativen Anschlüsse ist unbedingt zu vermeiden (Kurzschluss). Kurzschlüsse können Akkus dauerhaft schädigen und einen Brand oder Verletzungen verursachen. • Den Akku keinesfalls an den Ausgangsleitungen fassen, um ihn zu entfernen oder anzuheben. Fassen Sie den Akku stets am Gehäuse oder an den integrierten Griffen. • Akkus den lokalen Vorschriften entsprechend entsorgen.
• For the 120V PrintCart input, there is a 15 ampere main circuit breaker mounted on the inverter connector panel. It controls all input power to the PrintCart and when tripped, interrupts both charger power and passthrough (ATS) power. • For the 230V PrintCart input, there is no main breaker. There are separate breakers for the charger and transfer power. The transfer breaker is 4/6 Amperes and is located to the right of the charger breaker.
Chapter 4 Troubleshooting Guide Table 3. Troubleshooting Problems Symptom No AC output in battery mode. AC input is not present. 1. Battery mode LED (yellow) is off. No AC output in battery mode. AC input is not present. (continued) 1. Battery mode LED (yellow) is off. 34 Possible Cause Corrective Action Battery is below shutdown threshold and has shut off inverter power to prevent battery damage.
Table 3. Troubleshooting Problems Symptom AC input is connected but not shown as available. AC input is connected and available but the charger is not charging. 1. Line mode LED (green) is off. Possible Cause Input circuit breaker is tripped (top push button breaker). Disconnect load and reset input circuit breaker by pressing it back in. If charger operates, reconnect and switch loads on one at a time. Power is not present in wall socket.
Chapter 36 4 Troubleshooting Guide
5 Maintenance Power Equipment Access Gain access to the power equipment through tool latchable doors on the front and rear of the PrintCart. Inside the power compartment, the power system is divided into two separate replaceable subpallets. The battery subpallet (BSP) contains the two batteries, the main fuse battery and the quick disconnect battery. The power equipment subpallet (PESP) contains the inverter/charger, a GFCI duplex outlet (120V version), and a power quick disconnect cable to the BSP.
Chapter 5 Power Equipment Access 7. Loosen the AC grounding lug and remove the green grounding wire that runs to the PrintCart frame. 8. Open the front door of the PrintCart and unplug the battery main quick disconnect. 9. Disconnect the AC input cord according to the model you have. 120V PrintCart a. Unwind the extension cord and expose the plug connector stored inside the cord wrap. b. Raise and disconnect the coupled plugs. c. Push the plug through the grommet hole, back into the power compartment.
Battery Subpallet (BSP) Removal 1. If the PrintCart is plugged into an AC outlet, disconnect the plug from the outlet. 2. Open the rear access door. 3. Shut off the inverter/charger main switch located on the front of the inverter. 4. Open the front door and disconnect the main battery quick disconnect and hang it so it is out of the way. 5. Disconnect the display power cord quick disconnect and move it to the side. 6. Remove the two side restraining bolts that hold the BSP in place.
Chapter 5 Serviceability Inspection Serviceability Inspection NOTE: Only trained personnel should perform this inspection/maintenance. Periodically open the power compartment and inspect the internal components for signs of loose connections, excessive dirt and dust buildup, or any other condition that is out of the ordinary. Clean the cooling fan intake and exhaust ports on the inverter every six months. Other ventilation features should also be serviced at that time.
To Replace Batteries 1. Lift the protective covers on the battery (-) terminals and remove the bolts and washers holding the cables in place. See Figure 21 on page 42. 2. Perform the same operation on the battery (+) terminals. Be sure to save all nuts, bolts and washers removed. 3. Loosen and remove the battery clamp knob. 4. Lift the clamp plate, cables, fuse and disconnects from the battery pallet as a single unit. 5.
Chapter 5 Inverter Replacement Battery Clamp Knob Battery (-) Protective Covers Battery (+) Protective Covers Clamp Plate, Cables, Fuse, and Disconnects Figure 21. Replacing the Battery Inverter Replacement Make sure other causes for power failure are eliminated before replacing the inverter, (see Table 3, Troubleshooting Problems on page 33). Simple inspection may prevent unnecessary replacements.
Display Fuse Fuse Replacement There are two fuses on the PrintCart: • Display Panel Fuse – located between the front most battery terminals in an in-line holder. • Main Fuse – located on top of the battery clamp plate inside a black plastic housing. An open fuse means an abnormal situation exists in the power system. Excessive equipment loading or possible short circuits may exist.
Chapter 5 Power Cord Replacement Power Cord Replacement The AC line cord (power cord) is designed to be user replaceable. The connection between the external cord and the inverter input cord is located in the cord hanger on the side of the PrintCart. 1. Completely unwrap the cord from the storage hanger. 2. Lift the plug connector out of the hanger recess. 3. Remove the cord coupling and disconnect the two cords. 4. Obtain a proper replacement extension cord and reverse this procedure to reinstall.
Caster Wheels Wheel Replacement Caster Wheels Removal Recommended replacement caster wheels are specified in the repair parts section (see “Spare Parts” on page 51). 1. Prevent the PrintCart from rolling by placing a 3/4 inch (approximately 19 mm) thick board behind the fixed wheel. 2. Elevate and support the entire end of the PrintCart, lifting the caster end approximately 1 inch off the ground. 3. Remove the three 5/16 Nylock retaining nuts (1/2 inch open end wrench). 4. Remove the caster wheel.
Chapter 5 Hand Grip Replacement Hand Grip Replacement 1. Remove the hand grips by placing your fingertips on the innermost shoulder of the grip and pulling it straight off the steel handle. If that is too difficult, insert a small flat screwdriver blade under the grip to loosen it and stretch the grip away from the steel handle. 2. Twist the grip while pulling it off. 3. Install the new grip onto the handle by pushing only on the end of the grip.
A Specifications Physical Specifications Characteristic North American (120V/60 Hz) European (230V/50Hz) Operating Height (SS top/barcode storage) 40 in./47 in. (101.6 cm/119.4 cm) Width (frame/wheels) 21 in./22 in. (53.3 cm/55.9 cm) Length (SS top/handles) 25 in./36 in. (63.5 cm/91.5 cm) Weight (without printer or terminal) 280 lbs (127 kg) Printer Shelf Load Capacity 70 lbs (32 kg) Work Surface Stainless Steel 21 in. (53.3 cm) wide x 25 in. (63.
Appendix A Electrical Specifications Electrical Specifications Characteristic North American (120V/60 Hz) European (230V/50Hz) Battery Capacity 2 x 100 Amp-hour Recharge time to recover 60+% charge Battery Type Sealed Lead Acid, Absorbed Glass Mat (AGM) Charger/Inverter Type RV750ULHW APSX600 AC Inverter Output 120V/60 Hz/750 w 230V/50 Hz/600 w 12VDC Charger Capacity 45A 45A Input Current (Maximum) 15A (@ 120VAC) 8A (@ 230VAC) Input Plug NEMA 5-15 male 3-prong plug (fixed) User selec
B Wiring Schematics 120V/60Hz Figure 26.
This design concept consists of a 2 part control system. A "relay" PCBA manages AC power switching and a display/control PCBA for control logic and display functions. The relay PCBA is located in the cart power module interconnected compartment where equipment and cabling can connect directly. The display/control PCBA is located in the top front left corner of the cart where it is visible to the user. It is linked to the relay PCBA with a 7 ft. Cat 5 network cable.
C Spare Parts Description Capacity Style Printronix PN Battery, AGM 100 Amp Hr NB Terminal 205235-001 Battery Charger (230VAC) 12v @ 45A 230V 50 Hz 205327-001 750 Watt-120V 120V 60 Hz 205394-001 600 Watt 12VDC Input 205334-001 100 A Bolt through tab 205296-001 Display Fuse 2A Std Blade 205297-001 Display Fuse 1A ATC Blade 211014-001 Output Breaker 5A - 230V Push to Reset 211040-001 Input Breaker 8A - 230V Push to Reset 211041-001 5 inch Caster 300 lbs Bolt on Plate
Appendix C 52
D Glossary AC Alternating Current, current that reverses direction periodically. The output of the inverter system or a wall receptacle is AC power. AGM Absorbed Glass Mat, the type of lead acid battery used in the PrintCart. The electrolyte in the battery is absorbed into a fiberglass sheet in proximity to the lead plates. Amp Ampere, a measure of electrical current. One coulomb of charge per second equals 1 Amp. Amp-Hour A term used to describe the charge storage capacity of a battery.
Appendix D 54 Electrolyte An ionic solution, usually distilled water and sulphuric acid, that enables the flow of electrons in a battery from the negative plate to the positive plate. Fuse An electrical device designed to melt, break, or open when electrical current flowing through it exceeds the specified amount. Its purpose is to protect electrical circuitry from damage caused by excessive current flow. Inverter An electrical device that converts direct current (DC) into alternating current (AC).
E Contact Information Printronix Customer Support Center IMPORTANT Please have the following information available prior to calling the Printronix Customer Support Center: • • • • Model number Serial number (located on the back of the printer) Installed options (i.e.
Appendix E Corporate Offices Corporate Offices Printronix, Inc. 14600 Myford Road P.O. Box 19559 Irvine, CA 92623-9559 Phone: (714) 368-2300 Fax: (714) 368-2600 Printronix, Inc. Nederland BV P.O. Box 163, Nieuweweg 283 NL-6600 Ad Wijchen The Netherlands Phone: (31) 24 6489489 Fax: (31) 24 6489499 Printronix Schweiz GmbH 42 Changi South Street 1 Changi South Industrial Estate Singapore 486763 Phone: (65) 6542 0110 Fax: (65) 6546 1588 Printronix Commercial (Shanghai) Co. Ltd 22F, Eton Building East No.
Index Numerics F 120V/60Hz Wiring Schematics, 49 Fixed Wheels, replacement, 45 230V/50Hz Wiring Schematics, 50 Fuse Replacement, 43 A display fuse, 43 main fuse, 43 Accessories, 27 H refuse bin, 27 B Hand Grip, replacement, 46 I Barcode Scanner Storage Slot, 28 Battery Power Operation, 23 PrintCart operating duration, 23 Indicator Panel, 24 Inverter Replacement, 42 L Battery Replacement, 40 Battery Subpallet Removal, power equipment, 39 C Layout, PrintCart, 16 Limitations, operating, 12
Mechanical Installation, 9 operation, 21, 23 printer, 10 operation duration, 23 terminal, 9 overview, 15 Media Storage Compartment, 28 O physical specifications, 47 power cord, 29 power cord replacement, 44 Operating Limitations, 12 power equipment access, 37 Operation printer access, 26 battery power, 23 quick start, 7 line power, 21 safety, 31 PrintCart, 23 safety features, 32 Overview, PrintCart, 15 safety inspection, 9 P Physical Specifications, 47 Power Cord, 29 replacement, 44 Pow
Specifications electrical, 48 physical, 47 Startup, 11 Subpallet Removal, power equipment, 37 Supplies Department, 55 T Terminal hook-up, 11 installation, 9 Troubleshooting, 31 guide, 33 U Unpacking, PrintCart, 7 Utility Drawer, 29 W Wheel Brake, 27 Wheel Lock, 27 Wheel Replacement, 45 caster wheels, 45 fixed wheels, 45 Wiring Schematics, 49 120V/60Hz, 49 230V/50Hz, 50 59
*251755-001* 251755-001F
