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Service Manual for the Accutherm Ultra Printer

1. y g 3 3V ESV Power Supply and Soft Start 24 VDC from internal BGA BGA Figure B 1 Printer Block Diagram power brick GTECH Technical Training and Support Services GTECH Spare Parts and Tools The following spare parts can be ordered by FST s in the field More details for servicing continue in the next sections that discuss warranty and non warranty service Table C 1 Spare Parts and Tools Description Pack Top 73 0830 03 Part 1 in Figure C 1 Pack Bottom 73 0830 02 Part 4 in Figure 10 1 Power Cord IEC 60320 C5 TO C14 R A Part 2 in Figure C 1 CABLE USB 2 0 BLACK 32 9088 01E Power Supply 3 WIRE M280 ULTRA 50 0342 01E CARTON BROWN SHIPPING 73 0830 01 Part 3 in Figure 10 1 1 Phillips Screwdriver and extra 6 screws 91 Isopropyl Alcohol Cotton Swabs Service Manual for Accutherm Ultra Printer C i Table C 1 Spare Parts and Tools Description Soft Brush Power Cord Accutherm Ultra Printer i Figure C 1 Unpack Pack the Printer C ii GTECH Technical Training and Support Services Spare Parts and Tools In Warranty Service The Accutherm Ultra Printer is manufactured by Transact Technologies located in Ithaca New York The printer is under warranty for a period of time determined by the warranty agreement for your site Warranty agreements can be f
2. GTECH hardware products and peripherals require properly grounded outlets It is critical that this grounding requirement is enforced on all installations of GTECH hardware products and peripherals Service Manual for the Accutherm Ultra Printer 2 1 Installation Instructions The following steps describe the procedure for installing the Accutherm Ultra printer 1 Remove the printer and cables from its packaging Accutherm Ultra Printer Figure 2 1 Remove Accutherm Ultra from Packaging 2 2 GTECH Technical Training and Support Services Installation 2 Move the Strain Relief lever Figure 2 2 to the left and then plug the power cord into the power connector located at the rear of the printer Strain Relief Figure 2 2 Plug Power Cord into Printer Service Manual for the Accutherm Ultra Printer 2 3 2 4 3 Plug the printer s USB data cable into the Main Controller PCB located on the bottom of the Accutherm Ultra Figure 2 3 Main Controller PCB USB connection Note how the USB cable routes through the plastic guides on the bottom of the printer Figure 2 3 Plug USB Cable into Printer GTECH Technical Training and Support Services Installation 4 Plug the Accutherm Ultra s USB data cable into the USB connector on your terminal See Figure 2 4 and Figure 2 5 for GT1200 and GT1100 connections USB Figure 2 4 GT1200 USB Connection USB Figure 2 5 GT1100 USB Connec
3. Print data is sent from the controller board as a serial data stream at 8 MHz The head elements are then activated by signals from the main controller board to form the image on the paper The Accutherm Ultra uses a two level energy control system to compensate for dot history with all timing controlled by the controller board electronics The head also contains a thermistor which is used to monitor the temperature of the head substrate Dot energy is continually adjusted based on head temperature supply voltage dot history and paper sensitivity The print head connects to the controller through a 28 position Flexible Flat Cable FFC Service Manual for the Accutherm Ultra Printer 1 7 Paper Motion Paper motion is accomplished by a hybrid 1 8 degree step motor running at a maximum speed of approximately 3000 steps per second The gear train is designed such that one motor step equals 0833mm of paper motion resulting in a paper feed speed of 250 mm sec 10 in sec Cutter The cutter mechanism consists of a rotary blade mounted to the mechanism which operates against a fixed blade located in the paper cover The rotary blade is driven by a 7 5 degree tin can step motor mounted to the mechanism frame acting through a lever arm and follower The rotary blade home position is determined by means of an optical sensor located on the controller board and a flag located on the cutter drive gear The motor operates one direction to activ
4. The REN is used to determine the quantity of devices which may be connected to the telephone line Excessive REN s on the telephone line may result in the devices not ringing in response to an incoming call In most but not all areas the sum of the REN s should not exceed five 5 0 To be certain of the number of devices that may be connected to the line as determine by the total REN s contact the telephone company to determine the maximum REN for the calling area For Digital Data Services DDS modems use Facility Interface Codes 04DU5 24 04DU5 48 04DU5 96 04DU5 19 and Service Order Code 6 0F If the terminal equipment causes harm to the telephone network the telephone company will notify you in advance that temporary discontinuance of service may be required But if advance notice isn t practical the telephone company will notify the customer as soon as possible Also you will be advised of your right to file a complaint with the FCC is you believe it is necessary The telephone company may make changes in its facilities equipment operations or procedures that could affect the operation of the equipment If this happens the telephone company will provide advance notice in order for you to make the necessary modifications in order to maintain uninterrupted service Service Manual for Accutherm Ultra Printer D iii If trouble is experienced with this equipment please contact the following for repair and or warranty in
5. 5 Remove Platen Gear 4 J Figure 7 23 Remove Stacking Gear Retaining Ring and Platen Gear 6 Remove one 1 4 Thread Forming Screw 7 Remove the Right Platen Bearing Retainer Figure 7 24 Remove Screw and Right Platen Bearing Retainer 7 22 GTECH Technical Training and Support Services Disassembly 8 Remove one 1 4 Thread Forming Screw 9 Remove the Left Platen Bearing Retainer Figure 7 25 Remove 4 Screw and Left Platen Retainer 10 Remove Stacker Bearing 11 Remove two 2 4 Thread Forming screws Figure 7 26 Remove Stacker Bearing and Two 2 4 Screws Service Manual for the Accutherm Ultra Printer 7 23 12 Remove Right Side Plate Assembly 13 Remove Platen Stripper and L R Platen Bearings Figure 7 27 Remove Right Side Plate Assy Platen Stripper and L R Platen Bearings 14 Remove Fixed Blade Spring Figure 7 28 Remove Fixed Blade Spring 7 24 GTECH Technical Training and Support Services Disassembly 15 Remove Latch Arm Hub 16 Remove Retaining Ring Figure 7 29 Remove Latch Arm Hub and Retaining Ring Position remaining assembly in a vertical orientation for remaining disassembly Figure 7 30 Position Remaining Assembly Vertically Service Manual for the Accutherm Ultra Printer 7 25 17 Remove Knife Pivot Shaft 18 Remove Latch Arm Pivot 19 Remove Fixed Blade Assembly Figure 7 31 Remove Knife Pivot Shaft Latch Arm Pivot and Fixed Blade
6. Strobe timing dot energy control is calculated and applied to the print head by the MCF5253 For each line of dots printed the head is energized twice to compensate for dot history The MCF5253 provides a watchdog timer that is gated in the FPGA with the strobe signals to protect the thermal print head from overheating All head interface lines are buffered and resistance matched to the connecting ribbon cable Motor Controllers Both the paper feed and cutter step motors are controlled by an Allegro A3988 DMOS motor driver that provides two dual bridge bipolar PWM micro stepping motor drivers These drivers operate from the 24 volt supply and apply up to 1 5A phase of output current The drivers are micro step capable the controller must provide both phase and current level information to the driver Stepper motor control lines are driven by FPGA outputs latched from MCF5253 processor The paper feed motor is set for a maximum motor current of 1A phase Control lines operate this stepper motor in 1 4 step mode up to approx 500 equivalent full steps sec followed by modified half step mode up to 3600 equivalent full steps sec The cutter motor circuit is also set for a maximum current level of 1A phase Control lines operate this stepper motor in modified half step mode up to approx 1000 equivalent full steps sec The stacker motor is controlled by a dedicated Allegro A3983DMOS micro stepping motor driver with translator The driv
7. Table C 9 Assembly Lower Mechanism Number Description ee Kart 1 ARM ROTARY Part 28 09780 16 2063 01E 2 ASSY KNIFE MOTOR Part 28 00760 20 1248 01 3 ASSY PCB ACCUTHERM ULTRA 28 09185L 24 1788 01E 4 ASSY PAPER PATH Part 28 09735 15 3746 01E 5 ASSY PRINT HEAD Part 28 09677 24 1789 01E 6 BEARING COMPENSATION VALIDATION 16 2066 01E Part 25 07499 7 BEARING KNIFE ROTATIVE Part 25 09784 12 1026 01E 8 BUSHING SLACKER Part 28 09669 13 1028 01E 9 CABLE FLAT FLEXIBLE Part 28 04036 32 1406 01 10 GEAR COMBO 48 28 IDLER Part 28 03705 16 1814 01 11 COVER GEAR Part 28 09674 16 2067 01E 12 FRAME ASSY MECHANISM Part 28 09689 15 3747 01E 13 GEAR 24 TOOTH Part 28 03703 16 1815 01 14 GEAR 36 18 TOOTH Part 28 03780 16 1808 01 15 GEAR 45 24 TOOTH Part 28 03782 16 1807 01 16 GEAR COMBO 26 46 DRIVE Part 28 03707 16 1813 01 17 GUIDE SLACKER Part 28 09685 16 2068 01E 18 BLADE KNIFE ROTATIVE Part 28 09776 15 3748 01E 19 ASSY FEED MOTOR M280 ULTRA Part 28 09683 24 1790 01E 20 NUT M3 HEX W LOCKWASHER Part 98 0621 10 1368 01 21 PIN KNIFE ARM Part 28 09786 16 2069 01E 22 GROUND PRINT HEAD RIGHT Part 28 09711 11 4268 01E 23 GROUND PRINT HEAD LEFT Part 28 09712 11 4269 01E 24 RETAINER E RING 25 DIA 10 2146 01E 25 RETAINER E RING 125 DIA 10 2147 01E C xiv GTECH Technic
8. 7 15 7 Remove E Clip 8 Remove Knife Arm 9 Remove Rotative Blade Pin 10 Remove three 3 Gears Figure 7 15 Remove E Clip Knife Arm Rotative Blade Pin and Three 3 Gears 11 Remove Two 2 4 Thread Forming Screws 12 Remove Print Head Ground Figure 7 16 Remove Two 2 4 Thread Forming Screws and Print Head Ground 7 16 GTECH Technical Training and Support Services Disassembly 13 Remove Paper Path Assembly from Frame being careful not to damage sensor flags Reassemble by reversing the previous steps taking care that the locating bosses are aligned with the mating holes in the frame Figure 7 17 Remove Paper Path Assembly from Frame When reassembling the Thermal Print Head Cable ensure the cable is centered in the mating connector on the PCB Service Manual for the Accutherm Ultra Printer 7 17 Remove Stacker Guide Assembly from the Printer Mechanism Assembly REMEMBER TO USE ESD PRECAUTIONS 1 Unhook Left Right Validation Compensation Springs and remove springs Figure 7 18 Unhook Validation Springs and Remove 2 Slide Stacker Shaft to the right to remove 3 Remove two 2 Transport Rollers 7 18 GTECH Technical Training and Support Services Disassembly Figure 7 19 Slide Stacker Shaft to Right and Remove then Remove Two Transport Rollers 4 Remove Stacker Guide from Frame being careful not to bend the frame tabs Reassemble reversing the above steps Ensure the Compe
9. Assy 7 26 GTECH Technical Training and Support Services Disassembly 20 Ensure Latch Arm Hub is in proper location for reassembly Figure 7 32 Check Location of Latch Arm Hub Reverse Steps 1 through 20 for reassembly When installing Platen Striper and Bearings ensure the Striper locating bosses are aligned with the mating holes in the Left and Right Side Plates and then tighten screws Platen should spin freely when assembly is complete Service Manual for the Accutherm Ultra Printer 7 27 GTECH Troubleshooting Introduction to Troubleshooting 4 New These steps are a general guideline for Field Service Technicians to follow in the event of a specific fault After each step the printer should be checked to determine whether or not the step cleared the fault If the fault is not cleared with the first step the next step is performed in an attempt to clear the fault on the printer If the fault cannot be cleared the printer should be sent for repair Prior to performing any of the FST or RLT steps that follow ensure that the printer s warranty status has been determined If a printer is still In Warranty you may only perform cleaning procedures in an attempt to clear a fault disassembly procedures are not allowed Any hard failures must be sent to the OEM for repair These steps are a general guideline for RLT s to follow in the event of a specific fault After each step the printer should be checked
10. ESD precautions This includes the items mentioned throughout this section wrist straps anti static mats anti static vacuum cleaners and antistatic bags e ESTs in the field must be grounded by a wrist strap connected to the terminal which in turn is connected to earth ground when servicing that terminal and all boards being transported must be stored enclosed within static dissipative packaging e RLTs must work in a static safe environment The workbenches must have anti static mats which are connected to earth ground and the RLT must observe proper ESD precautions utilizing static wrists straps and proper anti static packaging Note Vacuum cleaners are generators of static electricity When purchasing a vacuum cleaner choose one with an antistatic nozzle Such as the one recommended in the Spare Parts and Tools Chapter If unable to purchase antistatic vacuum cleaners the nozzle of the hose must be wrapped with antistatic conductive tape from the nozzle to the handle The picture below shows a properly grounded technician Notice that the technician is grounded to the anti static mat and the mat is grounded to earth ground at the AC outlet GTECH Technical Training and Support Services Handling Precautions When servicing the terminal in the field the FST first must ground himself to the terminal chassis which is powered off and connected to earth ground as shown in the picture below GTECH Manufacturing Specific
11. by a 5 second repeating blink pattern Refer to Soft Errors on page 5 4 for specific error information Out of Paper 1 Change the paper Refer to Loading Paper on page 3 6 2 Swap the printer Paper Low Error 1 Change the paper Refer to Loading Paper on page 3 6 2 Swap the printer Service Manual for the Accutherm Ultra Printer 8 3 Problem Action Printer Status Cover Open 1 Close the printer cover securely LED is 2 Swap the printer blinking 7 contin Jam Detected 1 Open the receipt cover and clear any jammed paper Refer to Clearing a Paper Jam on page 8 10 2 Swap the printer Missed Top of Form 1 Clean top of form sensor with 91 isopropyl TOF alcohol and cotton swabs 2 Swap the printer Invalid Command 1 Turn the printer off wait 60 seconds then turn it on again 2 Swap the printer Printer Head Over 1 Ensure that the printer is being operated in the Temperature proper room temperature not too hot or too cold 2 If necessary move the printer to a warmer cooler location 3 Swap the printer Power Problem 1 Turn the printer off wait 60 seconds then turn it on again 2 Swap the printer Hard Errors Hard errors have a similar pattern to Soft errors only they are slower and repeat every 10 seconds In general they occur during level 0 diagnostics and are not recoverable In all cases of Hard Errors swap the printe
12. e 1 Phillips screwdriver e 5 5mm nut driver or wrench Disconnect the Power Cable To disconnect the power cable 1 Unplug the power connector located at the rear of the printer 2 Move the strain relief to left while disconnecting the cable Figure 7 1 SIP OES Strain Relief Figure 7 1 Disconnect Power Cable 7 2 GTECH Technical Training and Support Services Disassembly Disconnect the USB Communications Cable To disconnect the USB data cable Unplug the USB cable from the Main Controller PCB located on the bottom of the printer Figure 7 2 USB cable connector Note that the USB cable is routed along the bottom of the printer via plastic guides QO lt D z z E Figure 7 2 Disconnect USB Cable Service Manual for the Accutherm Ultra Printer 7 3 Remove the Cover Assembly To remove the cover assembly 1 Open the Paper Cover Assembly and remove the Paper Roll if present 2 Turn the printer over and remove the four 4 6 screws holding the Base to the Midframe Figure 7 3 6 Screws Figure 7 3 Remove Screws Holding Base to Midframe 7 4 GTECH Technical Training and Support Services Disassembly 3 Unscrew two 2 6 thread forming screws holding Mid frame to Paper Bucket Figure 7 4 6 Screws Figure 7 4 Remove Screws Holding Midframe to Paper Bucket 4 Lift and rotate the Mid frame Cover Assembly sideways and then separate it from the Base Assemb
13. for Accutherm Ultra Printer C ix Assembly Paper Bucket 16 2056 01E Table C 6 Assembly Paper Bucket 16 2056 01E Number Description we or cna nat 1 ASSY PAPER BUCKET 28 09872 16 2056 01E 2 ROLLER EPIC 950TRANSPORT 95 04907 16 2071 01E 3 SHAFT IDLER PAPER BUCKET 28 09862 16 2083 01E C x GTECH Technical Training and Support Services Spare Parts and Tools Assembly Mid Frame 16 2055 01E Table C 7 Assembly Mid Frame 16 2055 01E ae Mfg Part GTECH Part Number Description Niinber N mber ASSY MIDFRAME 28 09950 16 2055 01E 1 LENS LED 28 09869 13 1040 01E 2 MIDFRAME PRI NTER 28 09840 Substitute entire ASSY 16 2055 01E 3 PLUNGER MIDFRAME 28 09873 17 1151 01E 4 SPRING PLUNGER 28 09874 17 1150 01E Service Manual for Accutherm Ultra Printer C xi Assembly Paper Cover Table C 8 Assembly Paper Cover Mfg 28 09955 Number Description aa cinerea Port 1 ASSY GROUND WIRE M280 ULTRA 28 09177L 30 0133 01E 2 ASSEMBLY KNIFE FRAME ASSY 28 09730 15 3737 01E 3 COVER PAPER 28 09845 16 2057 01E 4 DEFLECTOR PAPER 28 09870 16 2058 01E 5 WINDOW PAPER COVER 28 09867 16 2062 01E C xii GTECH Technical Training and Support Services Spare Parts and Tools Assembly Lower Mechanism 30 27 33 2 4 3 23 4 19 41 35 9 31 29 pec 10 32 j 25 16 Service Manual for Accutherm Ultra Printer C xiii
14. he Soy m e 1 Table C 3 Printer Assembly Number Description THe Part Number 1 ASSY BASE 16 2054 01E 2 ASSY MIDFRAME 16 2055 01E 3 ASSY PAPER BUCKET 16 2056 01E Service Manual for Accutherm Ultra Printer C vii Table C 3 Printer Assembly Number Description sine nae 4 COVER PAPER SeeTable C 8 Assembly Paper Cover 16 2057 01E Mfg 28 09955 on page C xii TY WRAP 3 3 8 MFG Part 98 0941 10 2155 01E 6 MECHANISM ASSEMBLY LOWER SeeTable C 9 24 1786 01E Assembly Lower Mechanism on page C xiv 7 RETAINER SLACKER SPRING 11 4271 01E 8 SCREW 6 20 X 3 8 THD CUT PHD PHPS 10 1366 01 9 TAB FASTON 187 X 019 MFG 98 03968 10 1369 01 10 SPRING SLACKER LEFT 17 1144 01E 11 SPRING SLACKER RIGHT 17 1145 01E 12 POWER SUPPLY 3 WIRE CEC COMPLIANT 50 0432 01E Table C 4 MISC COMMON Number Description oe Fant CARTON BROWN SHIPPING Part 90 7579 10 1369 01 POWER CORD IEC320 C5 TO C14 STRAIGHT 98 10562L PACK BOTTOM Part 28 09964 73 0830 02 PACK TOP Part 28 09965 73 0830 03 6 X 18 X 1 4 TAP PHD PHPS 7 MO67883 03 C viii GTECH Technical Training and Support Services Spare Parts and Tools Assembly Base 16 2054 01E x 2 Table C 5 Assembly Base 16 2054 01E ar Mfg Part GTECH Part Number Description Nanber Number 1 ASSY BASE 28 09855 16 2054 01E 2 FOOT RUBBER BLACK 98 04248 10 2159 01E Service Manual
15. is equipped with a universal input power supply that is designed to operate worldwide without modification Supply Supply Voltage Voltage Range Frequency Rating VAC VAC Hz Power Consumption 100 240 90 264 47 63 20 watts 1 4 GTECH Technical Training and Support Services Introduction Standard Printer Features Standard features of the Accutherm Ultra printer include e High speed 10 inches per second thermal receipt printing e Black dot Top of Form and Paper Low Sensing capabilities e Jam Detection e Multiple barcode printing capabilities e 2of5 e EAN 8 e EAN 13 e UPC A e 30f9 e UPC E e Codabar e Code 128 e Code 93 e PDF417 2D Stacked e Data Matrix e RSS GS1 e Print Line Width of 640 dots 8 dots mm centered on 3 25 in 82 5 mm Paper e Uptoa 7 5 in 190 mm Diameter Paper Roll e Long life auto ticket cutter e Standard variable length stacking module capable of handling from 2 75 to 10 inch 70 to 254 mm length tickets e Ticket stacking capability greater than 75 tickets e Modular printer design for easy servicing e Internal Auto Ranging 90 264 VAC Power Supply e Power and Error LED Indicator e User Flash Memory e 1M bytes User Graphics Memory e 128K bytes User Data Memory e Font System Flash Memory e 2M bytes for Fonts and System files Service Manual for the Accutherm Ultra Printer 1 5 1 6 Manual configuration mode Self test diagnostics e Load
16. printer connected before starting the download program Otherwise the download program will not see the USB port 6 Run Download exe POSjet Firmware Downloader 7 Select the USB001 port or the active USB port from the drop down menu ers UltiaD ownload P 51 07_000_154 cbt er Abort Download Panter information read oul of printer 8 Click Get Printer Information to verify that you can communicate with the printer 9 To select firmware version a click the Select file to download button b Open the file containing the files you exported to the PC c Double click PK5107_000_162Full cbt file and select Download Now DO NOT INTERRUPT THE DOWNLOAD The firmware file will be transferred to the printer It is self verifying and will not be activated if it is incorrect The download program is not aware of the verification process and assumes it loaded correctly You MUST wait at least 10 seconds after the download program says it s done as the printer takes 5 or 10 more seconds to finish writing the update to flash The easiest way to tell when the printer is done is to press the Get Printer Information button after the download and when the printer responds it s done 6 2 GTECH Technical Training and Support Services Download ADDITONAL INFORMATION The update has not yet occurred so the old revisions will be displayed but that s OK You can now power cycle th
17. to determine whether or not the step cleared the fault If the fault is not cleared with the first step the next step is performed and so on until the fault is cleared or until the problem is further identified Performing the steps in this chapter may VOID the warranty and is therefore PROHIBITED until advised by Management Service Manual for the Accutherm Ultra Printer 8 1 Troubleshooting Steps for FST s Problem Action Printing Colored stripe on the 1 Check the paper level Incorrectly receipt 2 If paper is low change the paper Refer to Loading Paper on page 3 6 3 Clean the Top of Form Paper Low sensor with 91 isopropyl alcohol and cotton swabs See Cleaning the Top of Form Paper Low Sensor on page 9 3 4 Swap the printer Print is light or spotty 1 Make sure the paper is loaded correctly Refer to Loading Paper on page 3 6 2 Ensure the use of the recommended thermal receipt paper 3 Swap the printer Vertical column of Swap the printer print is missing Receipt does not come 1 Open the receipt cover and clear any jammed all of the way out paper Refer to Clearing a Paper Jam on page 8 10 2 Swap the printer Printer starts to print 1 Open the receipt cover and clear any jammed but stops while the paper Refer to Clearing a Paper Jam on page receipt is being 8 10 printed 2 Swap the printer Receipt is not cut 1 Open the receipt cover and cle
18. wireless option for the GT1200 uses and approved Azurewave Technologies mini PClIe module Model AW NE762H FCC ID VQF RT3090 1T1R operating in the 2 4GHz frequency range and is in compliance with the 802 11 b g n communication protocol standards For a complete list of approved companies refer to GTECH part number 55 0115 01E Service Manual for Accutherm Ultra Printer D v GTECH Acronyms amp Abbreviations AC aka AL APB AT BERT BIOS bps CCD CCFT CCITT CE CFR CIS CPLD CPU CSA Alternating Current Also known as Analog Loopback Analog Processing Board Advanced Technology Bit Error Rate Tester Basic Input Output System Bits per Second Celsius Charge Coupled Device Cold Cathode Fluorescent Tube The International Telegraph and Telephone Consultive Committee Conformite Europeene CE marking w in the European Union EU Code of Federal Regulations Contact Image Sensor Complex Programmable Logic Device Central Processing Unit Canadian Standards Association Service Manual for Accutherm Ultra Printer E i CSU DSU CTR CTS CTs dB dBa dBm DC DCD DCE DDS degrees C DFMA DIMM DMA DOC dots mm DPB dpi DPST DRAM DSR DTE DTR DUART ECO ECP EDO EEPROM EEROM EFT EIDA EIDE EMC EMI EPA EPLD EPP EPROM A modem that is typically used with AT amp T DDS service or a similar service provided by another carrier Common Technical Regulation Clear to Send Color Touch
19. you don t lose or forget to replace the ground bracket Figure 7 8 Remove Printer Mechanism Assembly from Base Assembly 7 8 GTECH Technical Training and Support Services Disassembly Remove the Main Controller PCB Assembly from the Printer Mechanism Assembly REMEMBER TO USE ESD PRECAUTIONS To remove the Main Controller PCB Assembly from the Printer Mechanism Assembly 1 2 Unplug all connector Harness Assemblies from the Main Controller PCB See callouts 5 and 6 in Figure 7 6 on page 7 6 Make sure that the Power Supply cable is unplugged See Figure 7 7 on page 7 Unplug the Thermal Print head Ribbon Cable from the Main Controller PCB See callout 2 in Figure 7 9 on page 7 10 When reassembling the Thermal Print head Cable make certain that the full length of the connector is seated firmly and centered in the mating connector on the Controller PCB and Thermal Print Head Otherwise you could cause the print head to burn out Unscrew the four 4 M3 screws callout 3 in Figure 7 6 on page 7 6 holding the Shield PCB and the Main Controller PCB Assembly to the Printer Mechanism Assembly Service Manual for the Accutherm Ultra Printer 7 9 Figure 7 9 Removing Main Controller PCB Assembly from Printer Mechanism Assembly 7 10 GTECH Technical Training and Support Services Disassembly Remove the Print Head Assembly from the Printer Mechanism Assembly Lower Print Mechanism REMEMBER TO USE ESD PRECAUTI
20. CH ARM ASSY 28 09819 15 3741 01E 34 SPRING LATCH BAR 28 09740 17 1138 01E 35 SPRING FIXED BLADE ULTRA 28 10637 17 1139 01E 36 COVER STACKER MOTOR 28 09697 16 2060 01E 37 STRIPER PLATEN 28 09741 16 2061 01E C xviii GTECH Technical Training and Support Services Spare Parts and Tools Assembly Paper Path 15 3746 01E Table C 11 Assembly Paper Path 15 3746 01E Number Description CTECH Pan Number 1 FLAG PAPER OUT COVER OPEN 16 2064 01E Part 28 10197 2 GUIDE PAPER BOTTOM 16 2065 01E Part 28 09736 3 SPRING FLAG EXTENSION 17 0943 01 Part 28 03952 Service Manual for Accutherm Ultra Printer C xix Tools List e 1 Phillips head screwdriver e Multimeter e Flat head screwdriver e Needle nosed pliers e Cotton Swabs e 91 Isopropyl Alcohol 5 5mm Nut Driver or Wrench C xx GTECH Technical Training and Support Services GTECH Product Safety amp Approvals Safety Instructions e The terminal may only be installed by qualified trained personnel e Field Service Manuals and Retailer Reference Guides for the terminal are provided at the time of training e If the terminal was stored in a cold environment condensation can occur In order to prevent condensation wait for the terminal to acclimate to the temperature for 3 to 4 hours before opening the package e Verify that the terminal nominal voltage matches the voltage of the local line to which it is being i
21. D BLADE GTECH ASSY 28 06806 15 1462 01 6 BEARING PLATEN RETAINER 28 09827 17 1134 01E 7 BEARING PLATEN M280 28 09752 17 1135 01E 8 BEARING PLATEN 950 SERIES 95 04963 17 1136 01E 9 BRACKET KNIFE SPRING 28 09748 17 1137 01E 10 BRACKET LATCH ARM 28 09771 16 2085 01E 11 BUTTON PAPER COVER 28 09850 16 2059 01E 12 RING E 188 DIA 98 1390 10 1370 01 13 GEAR 30 TOOTH 28 09698 13 1025 01E 14 GEAR 30T DRIVE 28 09701 13 1026 01E 15 GEAR PLATEN 28 09744 13 1027 01E 16 ASSY M280 ULTRA STACKER MOTOR 28 09173L 24 1785 01E 17 HUB LATCH 28 09738 15 3740 01E 18 KNIFE FRAME 28 09729 11 4273 01E 19 LATCH ARM 28 09772 12 1035 01E 20 LATCH ARM ASSY 28 09819 15 3741 01E 21 PLATE SIDE LEFT ASSY 28 09767 15 3743 01E 22 PLATE SIDE RIGHT ASSY 28 09765 15 3744 01E 23 PLATEN 28 09825 15 3745 01E 24 RETAINER E RING 25 DIA 520 9800006 10 2146 01E 25 RETAINER E RING 125 DIA 520 9800002 10 2147 01E 26 RETAINER E RING 156 DIA 520 9800003 10 2148 01E Service Manual for Accutherm Ultra Printer C xvii Table C 10 Assembly Knife Slacker 15 3737 01E Number Description Mig Fart CTECH Ta Number Number 27 ROLLER PAPER 28 09762 11 42740 01E 28 SCREW 2 PLASTIC THREAD FORMING 98 09826 10 2149 01E 29 SCREW 4 PLASTIC THREAD FORMING 98 7608 10 1376 01 30 SCREW M2 6 X 4 PHD PHPS 98 1182 10 2151 01E 31 SCREW M3 X 6MM PHPS PHD 98 0611 10 2165 01E 32 SHAFT LATCH 28 10718 12 1022 01E 33 LAT
22. LATCH RIGHT ACCTHRM Ultra 16 1810 01 ASSY STACKER FRAME PIN STD ACCTHRM SUP 16 1803 01 LATCH LEFT ACCTHRM Ultra 16 1797 01 ASSY LFT BEARNG PLATE PLNGR ACCTHRM SUP 16 1796 01 ASSY RT BEARNG PLATE PLNGR ACCTHRM SUP 16 1805 01 LEVER COVER RELEASE ACCTHRM Ultra 16 1798 01 ASSY BASE FRAME ACCTHRM Ultra 16 1815 01 GEAR 24 TOOTH ACCTHRM Ultra GTECH Technical Training and Support Services Spare Parts and Tools GTECH P N Description 16 1814 01 GEAR COMBO 48 28 IDLER ACCTHRM Ultra 16 1813 01 GEAR COMBO 24 26 DRIVE ACCTHRM Ultra 16 1811 01 HOLDER HEAD SPRING ACCTHRM Ultra 16 1809 01 GEAR COMBO 14 28 ACCTHRM Ultra 16 1808 01 GEAR 36 18 TOOTH ACCTHRM Ultra 16 1807 01 GEAR 45 24 TOOTH ACCTHRM Ultra 16 1806 01 ROLLER IDLER ACCTHRM Ultra 16 1802 01 STACKER PAPER ACCTHRM Ultra 16 1801 01 FLAG PAPER OUT COVER OPEN ACCTHRM SUP 16 1794 01 ASSY PAPER COVER ACCTHRM Ultra 17 0946 01 SPRING COMP PRINT HEAD ACCTHRM Ultra 17 0945 01 SPRING COMP STACKER TENSION ACCTHRM SUP 17 0944 01 SPRING LATCH ARM EXT ACCTHRM Ultra 17 0943 01 SPRING EXTENSION PAPER STACKER 17 1150 01 SPRING PLUNGER 17 1151 01 PLUNGER MIDFRAME 20 1247 01 ASSY PRINT HEAD ACCTHRM Ultra 20 1249 01 ASSY LINE FEED MOTOR ACCTHRM Ultra 20 1248 01 ASSY KNIFE MOTOR ACCTHRM Ultra 24 1791 01 ASS Y M280 ULTRA TOF SENSOR 32 1282 01 CORD PWR IEC60320 C7 TO C18 R A Ultra 50 0291 01 POWER SUPPLY 24V ACCTHRM Ultr
23. ONS To remove the Print Head Assembly from the Printer Mechanism Assembly 1 2 Rotate the Knife Stepper motor gear train until the Rotary Knife Blade is parallel to the bottom of the Printer Mechanism Assembly Home position Orient the Printer Mechanism Assembly so that the Print head Assembly faces you as shown in Figure 7 10 on page 12 Push on the Print Head Assembly until the upper set of alignment pins escape from the alignment slots in the Paper Path Assembly Push down on the Print Head Assembly and then rock the Print Head Assembly toward you You should now be able to easily remove the Print Head Assembly When removing the Print Head assembly be careful not to lose the small tension spring behind it When reinstalling make certain that the Rotary Knife Blade is parallel to the bottom of the Printer Mechanism Assembly Home Position or you may do damage to the blade or the printer may fail to restart without running it through a power cycle Service Manual for the Accutherm Ultra Printer 7 11 Position the Print Head Assembly to face you Figure 7 10 Remove Print Head Assembly from Printer Mechanism Assembly GTECH Technical Training and Support Services Disassembly Remove the Rotary Knife from the Printer Mechanism Assembly Lower Print Mechanism REMEMBER TO USE ESD PRECAUTIONS To remove the Rotary Knife from the Printer Mechanism Assembly Rotate the Knife Arm forward until it clear
24. Off Head Connection Fault 16 Blinks On Off NOTE When the YELLOW and RED LEDs are illuminated at the same time the LED will illuminate as ORANGE AMBER Service Manual for the Accutherm Ultra Printer 5 5 Extended Diagnostics Accutherm Ultra Extended Diagnostics are performed using the diagnostics on the terminal to which the printer is connected The printer may also be tested using the general Terminal Qualify Diagnostics and further tested through the Extended Diagnostics Peripherals menu 5 6 GTECH Technical Training and Support Services GTECH Download Downloads occur automatically via the terminal application to which the printer is connected Should the RLT need to update the firmware manually please contact your Field Services Engineering FSE Representative or send an email to Field Services Engineering to obtain the latest and greatest firmware version for your site Service Manual for the Accutherm Ultra Printer 6 1 AccuTherme Ultra Firmware Install Procedure 1 Connect the printer data cable to printer and USB port in PC 2 Connect the power cable to printer do not connect to AC power yet 3 Press and hold the diagnostics button while applying power to printer 4 The LED on the front of printer will flash slowly Release the diagnostics button printer is in download mode Transact boot loader 5 The USB Link is active and will communicate with the PC You must have the
25. Raise the paper cover to the Open position 3 Grasp the jammed paper and gently pull to un jam it from the inside of the printer 4 Advance the paper roll so that the jammed portion and a few additional inches are outside of the printer 5 Close the paper cover firmly so that latches securely 6 The paper will feed automatically to align itself and the printer will automatically cut off the excess paper 8 10 GTECH Technical Training and Support Services GTECH Preventive Maintenance General Cleaning Be sure to follow ESD precautions when performing maintenance on r the printer This is stressed particularly when performing any cleaning of the print head as ESD discharge directly onto the print head can ote cause failures Once the unit is opened the paper path is accessible for cleaning or clearing paper Use a soft brush to clean the paper dust from inside the printer The paper dust should also be removed from the sensor optics Service Manual for the Accutherm Ultra Printer 9 1 Cleaning the Print Head TO BE PERFORMED BY RLT ONLY USING ESD PRECAUTIONS After printing the print head can be very hot Be careful not to touch it and let it cool down before you clean it Do not damage the print head by touching it with your fingers or any hard object If streaking on the printed ticket is evident the thermal print head may need to be cleaned Figure 9 1 This can be with a cotton swab moiste
26. TECHNOLOGY TRAINING amp SUPPORT SERVICES GTECH S p A 10 Memorial Boulevard Providence RI 02903 Service Manual for the Accutherm Ultra Printer 2 ACU 003 01 January 2014 Copyright Windows is a registered trademark of Microsoft Corporation in the United States and other countries All other trademarks in this document are owned by or licensed to GTECH S p A or Spielo International Canada ULC and are registered or pending registration in the United States and other countries This document is the property of GTECH S p A Providence RI and Spielo International Canada ULC It contains confidential and trade secret information This document including all information within it may not be used transferred reproduced published or disclosed in whole or in part directly or indirectly except as expressly authorized by an officer of GTECH S p A pursuant to written agreement Copyright 2014 GTECH S p A and Spielo International Canada ULC All rights reserved GTECH Revision History This document describing the Accutherm Ultra has a revision number Each time this document is updated the document revision number is updated The number below represents the current revision of this manual Service Manual for the Accutherm Ultra Printer 2 ACU 003 01 For future documentation revisions the last two digits of the number above will increment by 1 for example when revision 01 is revised the last two digit
27. Training and Support Services Handling Precautions The same packing material is used for unpacking and packing the printer Description Packset M280 GTECH EPS Figure A 1 Cord Power IEC 60320 Figure A 1 Carton EPS Foam Figure A 1 Figure A 1 Unpacking and Packing the Printer Service Manual for Accutherm Ultra Printer A 1x GTECH Diagrams The following page includes the block diagram for the Accutherm Ultra Printer Please contact FSE Engineering should you need additional information Service Manual for the Accutherm Ultra Printer B i Paper Feed Motor Print Head Stacker Motor Step Motor Driver Allegro A3983 400ma Dual Step Motor Driver Allegro A3988 1000ma Print Head A Buffer IN Print Head Voltage Control rOQu T Off board sensors reflective Top Cover EEPROM ja Clock Oscillator 1 5V ri r TOF Current A Adjust L Beeper Feed Be Sa eee Switch Cut gt OnBoard Home Test Operator Cries switch Interface sensors l Interruptive Paper H gt MCF5353 Processor BGA Cover H a y n RS232 L _ Driver Not Populated N USB Protection USB Clock Address Data Bus
28. Western Electric Transport Controller Board External Transmit Clock Zero Insertion Force Service Manual for Accutherm Ultra Printer E v
29. a 51 1653 01 ASSY M280 CNTRLR BD ACCTHM Ultra 51 1654 01 ASSY M280 RS485 INTFC ACCTHRM Ultra Service Manual for Accutherm Ultra Printer C v Ordering Spare Parts from Assembly Drawings In the event that additional spare parts are needed the following section provides assembly drawings and GTECH part numbers To order spares in this manner ensure that the following considerations are made when referencing these drawings e GTECH P N 97 1824 XX is the Bill of Materials that contains all printer spare parts for each model number The last two digits represented by a XX above will vary by model You should substitute the XX for the 2 digit suffix on your printer model e The parts list included in this section include all available mechanical parts for the Accutherm Ultra printer It is possible that replaceable parts are incorporated into a larger assembly in which you must replace the whole assembly rather than just an individual component e The part numbers and SAP descriptions in the following tables match the part description in the assembly drawings that they accompany Match the description and select the GTECH part number F The controller board GTECH P N 51 1653 XX is repairable and should be returned to CRF for repair A small number of boards can be ote purchased as seed stock C vi GTECH Technical Training and Support Services Spare Parts and Tools Printer Assembly 2 3 8 10 7 6 i
30. able Enhanced Diagnostics USB interface built into main controller PCB GTECH Technical Training and Support Services Introduction Mechanism Paper Feed Motor Print Head Stacker Motor This section explains the Accutherm Ultra s theory of operations Off board sensors reflective Top Cover Step Motor Driver Allegro A3 983 400ma OnBoard Home Test Operator On board Switch Interface sensors Interruptive Paper H MCF5353 rg BGA Dual Step Motor E Pe RP S Driver eves J RS232 Allegro A3988 Ei Mle a ae ee l I P Driver ag Toone i Populated G A EEPROM ja f is USB Protection f Clock USB o Oscillator fo Clock ni Debug Header Address Data Bus e BV 24 VDC 1 5V aa ey tom i i lt 7 Power Supply P mulie i y 7 7 Z and Soft Start internal ee power brick Voltage Control BGA BGA Print Head Program Header Figure 1 1 Printer Block Diagram Print Head The print head in the Accutherm Ultra is a high speed thick film device configured as single row of 640 dots spaced at 8 dots mm for a total printable width of 80mm 3 15
31. al Training and Support Services Spare Parts and Tools Table C 9 Assembly Lower Mechanism Number Description eae Fart 26 RETAINER E RING 156 DIA 10 2148 01E 27 ROLLER SLACKER Part 28 09948 16 2070 01E 28 ROLLER EPIC 950 TRANSPORT Part 95 04907 16 2071 01E 29 SCREW 4 PLASTIC THREAD FORMING 10 2150 01E 30 SCREW M 3 X 6 MM SEMS PHD PHPS 10 2153 01E Part 98 02215 31 SHAFT TENSIONER Part 28 09691 12 1024 01E 32 SHAFT SLACKER Part 28 09692 12 1025 01E 33 SHIELD PCB Part 28 09833 11 4270 01E 34 SPRING PRINT HEAD COMPRESSION 17 0946 01 Part 28 03765 35 SPRING VALIDATION COMPENSATION LEFT 17 1142 01E Part 25 07772 36 SPRING VALIDATION COMPENSATION R 17 1142 01E Part 25 07773 Service Manual for Accutherm Ultra Printer C xv Assembly Knife Slacker 15 3737 01E y 25 saN 31 AA pe f 3 32 26 35 N amp 4 By S 4 ps S i 28 20 21 6 GTECH Technical Training and Support Services C xvi Table C 10 Assembly Knife Slacker 15 3737 01E Spare Parts and Tools Number Description Sits vei ae Pant 1 6 X 18 X 1 4 TAP PHD PHPS MO067883 03 10 2144 01E 2 ASSY JAM SENSOR M280 ULTRA 28 09151L 20 1307 01E 3 ASSY M280 ULTRA TOF SENSOR 28 08445L 24 1791 01E 4 DRIVE SHAFT ASSY 28 09749 15 3738 01E 5 MOLDED FIXE
32. ar any jammed paper Refer to Clearing a Paper Jam on page 8 10 2 Swap the printer One side of receipt is Swap the printer missing 8 2 GTECH Technical Training and Support Services Troubleshooting Problem Action Printer Is Not No Power 1 Check that the terminal has power Working 2 Check that printer cables are properly connected on both ends 3 Ensure the latch and receipt cover is closed 4 Verify the printer configuration and re configure if necessary 5 Ensure that the printer is being operated in the proper room temperature not too hot or too cold If necessary move the printer to a warmer cooler location 6 Swap the Power Supply Refer to Remove the Power Supply from the Base Assembly on page 8 7 7 Swap the printer Printer Status LED is blinking During Normal operation the Power LED remains on unless an error is indicated There are two classes of errors soft and hard Soft errors are recoverable without power cycling the printer Hard errors cannot be recovered from without removing power from the printer correcting the problem and then reapplying power Error Indicators e Power Green e Error Red e Paper Yellow Note When the Indicators for Error and Paper are both illuminated an Orange Amber color displays Soft Errors Soft errors may be recovered by the host or by opening and closing the printer cover The following soft errors are indicated
33. ate the cutter and then reverses direction to return the cutter to its home position with a total cut cycle time of approximately 350 ms Sensors There are two types of sensors used on the Accutherm Ultra printer One type is mounted directly on the controller board and is activated by mechanical flags on the mechanism These sensors are optical interruptive type and are used to detect Cutter Home Paper Out and Cover Open conditions The second type are mounted in the printer mechanism and are connected by harnesses to the controller These are optical reflective sensors which are used to detect black marks and paper low stripes on the reverse side of the paper as well as the presence of tickets in the printer The black mark paper low detection sensor can be auto calibrated using on board diagnostics Power Supply The power supply for the Accutherm Ultra is a small universal input fully enclosed module located within the printer cabinet The 24 VDC output of the supply connects to the controller board by means of a cable The AC input connector on the supply is accessible from the rear of the printer and accepts a Standard C6 style 3 wire power cord 1 8 GTECH Technical Training and Support Services Introduction Control Electronics Overview The printer has a main controller board containing microprocessor FPGA memory motor drivers and sensor conditioning circuits used to control the mechanism The basic system clock was
34. ation GTECH assemblies comply with IEC 61000 4 2 recommendations for severity typically in excess of level three IEC stands for International Electrotechnical Commission The specification is for Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment Part two specifies electrostatic discharge requirements and states that our equipment must withstand 15KV air discharges and 8KV contact discharges Both positive and negative polarity discharges must comply Service Manual for Accutherm Ultra Printer A Vil PACKAGING General Packaging Procedures A viii Package and ship all modules or devices in the packaging in which they were received from the manufacturer whenever possible Make sure that the packaging is in good condition and not damaged from previous shipping or handling Circuit boards offer special problems and should be inspected for delicate components and sharp objects Contact Manufacturing Engineering for assistance if needed All precautions must be made to insure that product that is shipped is not deformed or altered due to packaging used Consideration must be given to the fragileness of the product that is shipped for total coverage of protective materials Appropriate sized labels elastic bands or ESD tape must be used for securing ESD bags Staples cannot be used Multiple Circuit Card Assemblies must be placed in a single static shielding bag only if they are mechanically se
35. chosen to be 19 6608 Mhz This clock is multiplied in the main processor with a PLL to maximize execution speed and used by the FPGA for optimum thermal print head load speed External communications is USB only Processor and Memory The processor used in the Accutherm Ultra is a Motorola ColdFire MCF5253 running at 140 Mhz with integrated USB controller The processor interfaces through a 16 bit external bus to a 64Mb Synchronous Dynamic Ram SDRAM 32Mb of Flash Memory 8Kb of EEPROM and a 2 910 logic element Field Programmable Logic Array FPGA The processor contains general purpose I O pins which are used to directly control many of the printer functions including e Status LEDs e USB Communications e Print Head Data and Timing e Print Head Temperature and Voltage monitoring e Programming the FPGA The remaining printer functions are controlled though the FPGA including e Stacker motor control e Cutter motor control e Paper feed motor control e Thermal print head loading and protection Service Manual for the Accutherm Ultra Printer 1 9 Print Head Interface Print data is formatted by the MCF5253 and transmitted to the FPGA through a byte serial memory mapped I O interface for each dot row This interface allows rapid transmission of data with minimal software overhead Once the transmission is completed the FPGA parses loads and latches the data into the print head registers using two simultaneous serial channels
36. d can radiate radio frequency energy and if not installed and used in accordance with the instruction manual 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 Industry Canada This Class A digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations Cet appareil numerique de la classe A respecte toutes les exigences du Reglement sur le materiel brouilleur du Canada European Union 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 GTECH Technical Training and Support Services Product Safety amp Approvals Telecom ote Caution To reduce the risk of fire use only No 26 AWG or larger telecommunication line cord Attention Pour r duire les risques d incendie utiliser uniquement des conducterurs de t l communications 26 AWG au de section sup rleure Only for equipment bearing an FCC part 68 label This equipment complies with Part 68 of the FCC rules On the equipment is a label that contains among other information the FCC registration number and Ringer Equivalence Number REN for this equipment If requested this information must be provided to the telephone company
37. d the ground connection the wrist strap does not increase your risk of suffering a shock hazard The 1 Megohm resistor limits the current to a safe value for low voltage circuits MYTH We don t take precautions and we don t have ESD problems at our depot FACT You may not realize the damage that you are causing but it is there GTECH Engineering can determine if hard and intermittent failures are due to ESD damage by examining individual components but such damage is not something that a technician can readily identify MYTH The GTECH terminal is not susceptible to static damage FACT Our terminals can be damaged or destroyed by static discharge just like any other electronic device ESD Precautions Checklist Recommended Devices Wrist straps at the bench Wrist strap tester Only tools or parts made out of conducting materials i e no plastic solder vacuums tweezers etc 3M anti static vacuum cleaners Static dissipative mats connected to earth ground for bench tops and flooring Static dissipative bags boxes bins and or totes for handling PCBs bags and totes must remain closed during transport no part of the item can stick out of the bag or the bag is ineffective Static free floor mats static dissipative shelving and 3M black conductive PCB storage bags used at all times stockroom GTECH Technical Training and Support Services Handling Precautions Precautionary Practices Minimize handling
38. e precautions presented in this chapter whenever e Performing any work on a PCBs and equipment containing PCBs e Removing subassemblies or components What is ESD Becoming Static is the electrical charge created by the friction of two dissimilar materials moving against each other Electro Static Discharge or ESD is the unintended dissipation of that charge typically by short circuiting the charge to another device or to ground Our bodies can create as much as 25 000 volts of static electricity across our 100 to 250 picofarads of capacitance to ground In the worst case work environment voltages on some objects could exceed 50 000 volts This more than exceeds the static tolerance threshold of most transistors resistors op amps and digital computer chips Some MOS families for instance can be damaged by a charge as low as 150 volts Usually the damage is such that it goes undetected for some time but eventually creates either an intermittent or hard failure in the field Insulators or non conductors of electricity pose the greatest static discharge threat to electronic devices because of their inability to bleed their static charges Static Safe Equipment or component failures that result from ESD can be difficult to identify but can be avoided at minimal cost with proper handling techniques A static electricity safe workplace is an environment in which anything that can generate static charges is eliminated or i
39. e printer Wait at least 10 seconds before re connecting printer power for printer power supply to completely discharge Verify that the new firmware is active by opening and closing the cover then reading the printout Service Manual for the Accutherm Ultra Printer 6 3 GTECH Disassembly Warranty Information The Accutherm Ultra Printer is under warranty from the manufacturer Prior to performing any printer disassembly you MUST verify that the printer is out of warranty with your Technical Services Manager Performing any of the steps in this chapter may VOID warranty and is therefore PROHIBITED until advised by Management Caution The Power Supply is the only sub assembly approved to be replaced in the field FST after warranty All other subassemblies must only be replaced by an RLT Before disassembling any part of the printer be sure the power is z turned off The Controller Board the Thermal Print Head and the SS Interface Board can be damaged by static electricity Observe ESD precautions Wear a grounded wrist strap and use a static mat or other protected work surface Service Manual for the Accutherm Ultra Printer 7 1 plastic components when replacing screws turn the screw counter Thread Forming Screws To prevent stripping the mating holes in clockwise until a click is heard then tighten normally Required Tools The following tools are required to disassemble the Accutherm Ultra printer
40. eaverscees C vii Assembly Base 16 2054 O1E eee eeeeceeereeeeteeeees C ix Assembly Paper Bucket 16 2056 O1E oo C x Assembly Mid Frame 16 2055 01B ee C xi Ass mbly Paper COver ice Gsc aiesiceuecaccavtcadees ania C xii Assembly Lower Mechanism cscceesseeeeeeeee C xiil Assembly Knife Slacker 15 3737 O1B 0 C xvi Assembly Paper Path 15 3746 O1B c cece C xix MG ONS TAST oho ee i le als ieee C xx TOC iv GTECH Technical Training and Support Services Appendix D Product Safety amp Approvals Safety Instructions s3c5cs ciaanisgetcvanvanepentadete Rosameectumacioes D i Radio Interference jis sccesstenes dei useaciassapeaniiones dea eeeatenes D ii e Renee eee rere eee eee rere aie reer oe D ii Industry Canada ssenseeeeeeeeeeeeesseesseesseeesseersseessese D ii European UniOn i eria s D ii DEINO o eer AE NE EE TET D iii PCO hosii a naa E AR Ea est D iii Industry Canada 4 aes cateucssads fosakeas jae dantee es ennaades D iv Replaceable Batteries vcs sciiaicissccdiaseccsisasecaseteasnecenents D v Wireless Device Opion 3 cs0iauncseeovevgsees oesevese anne D v Appendix E Acronyms amp Abbreviations Service Manual for the Accutherm Ultra Printer TOC v GTECH Introduction The Accutherm Ultra Printer is a stand alone thermal printer designed for use with GTECH Lottery Terminals for printing lottery receipts Service Manual for the Accutherm Ultra Printer 1 1 Ov
41. er cooler location 6 Swap the Power Supply Refer to Remove the Power Supply from the Base Assembly on page 7 7 7 Swap the printer Hard Errors Hard Errors have a similar pattern to Soft errors only they are slower and repeat every 10 seconds In general they occur during level 0 diagnostics and are not recoverable Refer to Hard Errors on page 5 5 for specific error information In all cases of Hard Errors replace the printer mechanism See Remove the Printer Mechanism Assembly from the Base Assembly on page 7 8 Service Manual for the Accutherm Ultra Printer 8 7 Loading Paper Follow the instructions below to load a new roll of paper into the Accutherm Ultra printer Reference the photos that follow each step for the illustrated procedure 1 Press back on the gray cover latch button and raise the paper cover to the open position 2 Tear off the first layer of the paper roll Place the paper roll into the printer so that the paper unwinds from the bottom front 3 Leave a few inches of paper outside of the printer 8 8 GTECH Technical Training and Support Services Troubleshooting 4 Close the paper cover firmly so that it latches securely Paper will feed automatically to align itself and then the printer will automatically cut off the excess paper Service Manual for the Accutherm Ultra Printer 8 9 Clearing a Paper Jam 1 Press back on the cover latch button 2
42. er is configured to operate the stacker motor in modified half step mode at a maximum current of 500ma phase and is matched for stepping speeds to receive tickets passed off from the paper feed motor 1 10 GTECH Technical Training and Support Services Introduction Sensor Interface There are three on board infrared optical interruptive sensors which are activated by plastic flags attached to the mechanism These devices have an open collector photo transistor output and provide a low level signal when blocked The output switches to a high level when the sensor is unblocked by a flag The outputs of these sensors are buffered with Schmitt triggers before being presented as inputs to the MCF5253 The state of these sensors is as follows Table 1 1 Sensor State Sensor Blocked Unblocked OP1 Cutter home Cutter not home OP2 Paper cover closed Paper cover open OP3 Paper present Paper not present The controller board also has connections for two external optical reflective sensors One sensor is used to detect the Top of Form TOF mark and paper low stripes on the back of the paper The other sensor is used to detect paper jam JAM conditions The LED current of the TOF Paper Low sensor is adjustable by the processor in 8 steps from 8ma to 21ma and is auto calibrated using diagnostics resident in the printer The output of this sensor is presented in analog form to the MCF5253 s AD converter for calibration and Schmi
43. erview of Accutherm Ultra 1 2 Print Line Width 640 dots 8dots mm centered on 82 5 mm 3 25 in paper 7 5 inch diameter paper roll Jam Detection Full cut auto cutter Ticket Stacker with capability gt 75 tickets User Flash Memory e 1M bytes User Graphics Memory e 128K bytes User Data Memory Font System Flash Memory e 2M bytes for Fonts and System files Manual configuration mode Self test diagnostics e Loadable Enhanced Diagnostics Internal Auto Ranging 90 264 VAC power supply USB interface built into main controller PCB Power and Error LED Easy paper loading GTECH Technical Training and Support Services Introduction Mechanical Specifications 8 81 223 77 mm 13 26 336 8 mm 6 5 165 1 mm e Height 8 81 223 77 mm e Width 6 5 165 1 mm Depth 13 26 336 80 mm e Weight Approximately 4 9 lbs 2 22 kg Interface Type USB e Printer Type Fixed 80 mm linear thermal head Service Manual for the Accutherm Ultra Printer 1 3 Environmental Specifications e Operating Temperature Range 5 C 50 C 41 F 122 F Shipping Storage Temperature Range 10 C 50 C 14 F 122 F e Operating Humidity Range 10 90 40 C 104 F non condensing only e Shipping Storage Humidity Range 10 90 non condensing only excluding paper Electrical Specification AC Power Requirements The Accutherm Ultra Printer is designed to be AC self powered The printer
44. formation GTECH Corporation 55 Technology Way West Greenwich RI 02817 Telephone 401 392 1000 If the trouble is causing harm to the telephone network the telephone company may request that you remove the equipment from the network until the problem is resolved GTECH Corporation must make any necessary repairs to modem portion of this equipment in order to maintain valid FCC registration Do not attempt to repair or service your modem return it to GTECH Corporation This equipment cannot be used on public coin service provided by the telephone company Connection to Party Line Service is subject to state tariffs Industry Canada ote Only for equipment bearing an Industry Canada label The Industry Canada label identifies certified equipment This certification means that the equipment meets certain telecommunications network protective operational and safety requirements The Department does not guarantee the equipment will operate to the user s satisfaction Before installing this equipment users should ensure that it is permissible to be connected to the facilities of the local telecommunications company The equipment must also be installed using an acceptable method of connection In some cases the company s inside wiring associated with single line individual service may be extended by means of a certified connector assembly telephone extension cord The customer should be aware that compliance with the above co
45. is agency approval ensures that the device does not cause excessive interference with other devices likely to be found in a commercial environment This agency approval ensures that the device when connected to the telephone network will not harm the network or network personnel Flash Bank Bit Number Floppy Disk Drive Flat Flex Cable First in First out Flash Page Field Service Technician Grand Unified Boot Loader GTECH Universal Tracking System Hard Disk Drive Hertz Cycles per Second Integrated Circuit Identification Inches Institute of Printed Circuits Inches per Second Infrared Industry Standard Architecture International Standards Organization International Telecommunications Union formerly the CCITT Kilobyte Kilogram Local Area Network Liquid Crystal Display Loop Current Sense Light Emitting Diode Low Insertion Force ine Printer Low Voltage Differential Signal milli Amperes Memory Address Megabyte Micro controller Unit Service Manual for Accutherm Ultra Printer E iii MDP MIDI mm mm sec MMX ms MTBF MTTR ns NVRAM OCR OEM OH OM OS OTP PC PCB PCI PCMCIA PFD PIT PSTN PTC RAM RAP RDCLK RDL RI ROM RS232 RTS RxD SA SAW SCC SIMM SO DIMM SPDT SPGA SPKR E iv Modem Data Pump Musical Instrument Digital Interface Micrometer Millimeter per second Multimedia Extensions Millisecond Meantime Between Failures Mean Time to Replace Nanosecond Non vo
46. latile Random Access Memory Optical Character Recognition Original Equipment Manufactured Off Hook Open Architecture Modular Package Operating System One Time Programmable Personal Computer Printed Circuit Board Peripheral Communications Interface PC Memory Card International Association Power Fail Detect generated by power supply Paper in Throat Public Switched Telephone Network Positive Temperature Coefficient Type Fuse Random Access Memory Read After Print Receive Data Clock Remote Digital Loopback Ring Indicator Read Only Memory EIA RS232 Electrical Standard Request to Send Receive Data Stand Alone Surface Acoustic Wave Serial Communications Controller Single In Line Memory Module Small outline DIMM Single Pole Double Throw Staggered Pin Grid Array Speaker GTECH Technical Training and Support Services SRAM TDCLK TFT TTL TUV TxD UART UL us USB VAC VCC VDC VFD VGA Vpen Vrms WAN WE XPB XTCLK ZIF Acronyms amp Abbreviations Static Random Access Memory Transmit Data Clock Thin Film Transistor Transistor Transistor Logic Technischer Uberwachungs Verein Transmit Data Universal Asynchronous Receiver Transmitter Underwriter s Laboratory microsecond Universal Serial Bus Volt Voltage Alternating Current 5V Supply Voltage Voltage Direct Current Vacuum Fluorescent Display Video Graphics Array Voltage Program Enable Voltage root means squared Wide Area Network
47. leshooting 8 1 Troubleshooting Steps for FST S oeer 8 2 Troubleshooting Steps for RLT S 8 5 Loading PAPE csinos te tar qunataeayeap enn s 8 9 Clearing a Paper Jain scisscccdsatssnsieatvethcsartecsdecetactianess 8 11 Chapter 9 Preventive Maintenance General Cleanings aea sias 9 1 Cleaning the Print Head sseeeeeeeeeeeeeeeeererrerersee 9 2 Cleaning the Top of Form Paper Low Sensot 9 3 Cleaning the Jam Detection Sensor eee 9 4 Cleaning the Plate myx isc cietes ete ines cede 9 4 Service Manual for the Accutherm Ultra Printer TOC iii Appendix A Handling Precautions ESD HANDIEIN G sucrer a naai A ii What 18 ESD viccicssvacedecssussacassaeactissusactasopeadeaserertaes A ii Becoming Static Safe icseecsosg sszessederscvastencendestqus A ii ESD Induced Failure Modes eeeeeeeseeeeeseeees A iil Typical Symptoms of ESD Damage A iil Common False Assumptions Concerning ESD A iii ESD Precautions Checklist cee eeeeeeeeeeeeeeeeee A iv GTECH Manufacturing Specification A vil PACKAGING eoni noieta ash A viii General Packaging Procedures ceseeeeeeeee A viii Appendix B Diagrams Appendix C Spare Parts and Tools In Warranty Service 26 aaa iGo a aes C iii Post Warranty SS Cl V ICE ie nese tessa Ol on ceas casaees C iv Ordering Spare Parts from Assembly Drawings C vi Printer Assembly 3 cccisaspaceatesecesctessactavastecsde
48. ly as shown Figure 7 5 Figure 7 5 Separate Midframe Cover from Base Assembly Service Manual for the Accutherm Ultra Printer 7 5 5 Unplug the Top of Form Harness Assembly Anti Jam Sensor Harness Assembly Stacker Motor Harness Assembly and Power Supply Connector from the Main Controller PCB Assembly 6 Unplug the Ground Wire from the Printer Mechanism Figure 7 6 Unplug Harness Assemblies 7 6 GTECH Technical Training and Support Services Disassembly Remove the Power Supply from the Base Assembly Power Supply Release Clip and Plug Power Supply Figure 7 7 Remove Power Supply 1 Unplug the Power Supply from the Main Controller PCB Assembly To do so press on locking clip to release the plug from the PCB Assembly see inset 2 Lift the Power Supply out of the Base Assembly When you reinstall the Power Supply make sure that the label faces inward otherwise it will not plug in correctly Service Manual for the Accutherm Ultra Printer 7 7 Remove the Printer Mechanism Assembly from the Base Assembly REMEMBER TO USE ESD PRECAUTIONS To remove the Printer Mechanism Assembly from the Base Assembly 1 Remove four 4 6 Thread Forming Screws holding the Printer Mechanism Assembly to the Base Assembly 2 Rock the Printer Mechanism Assembly and then slide it forward and out from the Base Assembly Slacker springs will separate from the bushings Printer Mechanism 6 Screws Make sure
49. mmon result of ESD The device becomes temperature sensitive input thresholds shift output levels and drive ability degrade etc Increased failure rates are also typical Normal stresses such as temperature swings power surges or another zap could permanently disable a device previously exposed to ESD even if no symptoms existed from the first exposure Common False Assumptions Concerning ESD e MYTH Only MOS devices are ESD sensitive FACT All semiconductor materials are sensitive to ESD Some devices are just more sensitive than others e MYTH A component cannot be damaged once it is installed in a board FACT It may be even more susceptible to induced fields due to the antenna effect of the etch or wire connected to it e MYTH If the device works after I replaced it I got lucky and did not damage it FACT Most failures are not catastrophic and only reveal themselves as intermittent or latent failures e MYTH A grounded metal table top is a good anti static work surface FACT A much better way to dissipate electrostatic fields is to use an anti static mat and a 1 Megohm discharge current limiting resistor connected to earth ground so that the charge is drained in a controlled manner Service Manual for Accutherm Ultra Printer A iil MYTH Wrist straps present a personal shock hazard when working on live circuits because they ground your body FACT As long as the 1 Megohm resistor is connected between the strap an
50. n Overview of Accutherm Ulltra cccccccccccceeeeeereees 1 2 Mechanical Specifications 1 3 Environmental Specifications 0 0 cee eeeeeeeeeeeeeeeeees 1 4 Electrical Specification ancccieecsseceecianscctsaectadedantecdsetaccee 1 4 Standard Printer Features eeeeeeeeeeeeeeeeeereeerererrrrreree 1 5 Mecham SMi snas niai na i OA AER 1 7 Print Head soeter a eenias aia 1 7 Peper Motion seisena aa 1 8 CUE irse aa aran e ai 1 8 SENSO Saesson tae E a EE EEES EESE 1 8 Power SUpply csiisissicssiniiiissisiisre issii sisisrnsiinn 1 8 Control ElectroNiC Ssss 1 9 OVELVICW cccecessccccecccscssssssecececeescsesesseseeeceeeseesneaeees 1 9 Processor and Memory iie ccssseeiees ees eensis 1 9 Print Head Interface ccccccccccceceesssseceeeeeeeeeenes 1 10 Motor Controllers ccccccccesesssessssssessssesssesserees 1 10 Sensor Mnterlace c 16ssssdeseeveedacssbovdeesesiacsestavverdenter s 1 11 Power Supply Circuitry cicccccccesssteeccetetecdecesceetaieans 1 11 Communications Interface cceceeseeceeceeeeeeees 1 12 Chapter 2 Installation Introduction ccccecccccccecessessssececececeesesssseaeeeeeeeesenes 2 1 Installation Instructions cc cccccccccessssssseeeeeceeeesenes 2 2 Loading Paper ssccisiedecsascadeesczdincoeadiaucceieseebetedadecdnaiede 2 6 Chapter 3 Configuration Chapter 4 Operation Chapter 5 Diagnostics Printer Self Vest422 G 4 2 Ae ee eats 5 2 Self Test Modes c
51. nd configuration Please see Chapter 5 Diagnostics and Chapter 8 Troubleshooting for information on problems encountered with powering up and using the printer Service Manual for the Accutherm Ultra Printer 4 1 GTECH Diagnostics The Accutherm Ultra Printer provides printer self test and diagnostics features This chapter provides information about these tests e Printer Self Test on page 5 2 e Normal Operation Errors on page 5 4 e Extended Diagnostics on page 5 6 Service Manual for the Accutherm Ultra Printer 5 1 Printer Self Test The Accutherm Ultra printer is configured with two self test operations e The first occurs each time the printer cover is closed and paper is present after which a receipt is printed that contains a header and the printer firmware revision and serial number e The second self test is available by pressing the Service button as shown in Figure 5 1 on the underside of the printer at which time the printer enters self test mode Service Button Figure 5 1 Service Button Underneath Printer When servicing the printer you should verify the firmware version and serial number that are printed on the receipt 5 2 GTECH Technical Training and Support Services Self Test Mode Diagnostics Pressing the Service button on the underside of the printer activates the self test mode that provides several print tests plus access to the printer configuration and factor
52. nditions may not prevent degradation of service in some situations Repairs to certified equipment should be made by an authorized Canadian maintenance facility designated by the supplier Any repairs or alterations made by the user to this equipment or equipment malfunctions may give the telecommunications company cause to request the user to disconnect the equipment GTECH Technical Training and Support Services Product Safety amp Approvals Users should ensure for their own protection that the electrical ground connections of the power utility telephone lines and internal metallic water pipe system if present are connected together This precaution may be particularly important in rural areas Users should not attempt to make such connections themselves but should contact the appropriate electric inspection authority or electrician as appropriate The Load Number LN assigned to each terminal device denotes the percentage of the total load to be connected to a telephone loop which is used by the device to prevent overloading The termination on a loop may consist of any combination of devices subject only to the requirement that the total of the Load Numbers of all the devices does not exceed 100 Replaceable Batteries There is a risk of explosion if a battery is replaced by an incorrect type Always dispose of used batteries according to the instructions on the particular type of battery Wireless Device Option The
53. ned with 91 isopropyl alcohol Figure 9 1 Cleaning Print Head Use ESD Precautions 9 2 GTECH Technical Training and Support Services Preventive Maintenance Cleaning the Top of Form Paper Low Sensor Clean the Top of Form Paper Low sensor with a cotton swab moistened with 91 isopropyl alcohol Figure 9 2 Cover Open and Top of Form Paper Out Indicators Paper Low Sensor Figure 9 2 Clean TOF Sensor and Check Paper Out Indicators Service Manual for the Accutherm Ultra Printer 9 3 Cleaning the Jam Detection Sensor Clean the Jam Detection Sensor with a cotton swab moistened with 91 isopropyl alcohol Figure 9 3 Cleaning the Platen Use a cloth dampened with alcohol to wipe the platen of any debris as needed Figure 9 3 Platen Jam Detection Sensor Figure 9 3 Cleaning the Jam Detection Sensor and Platen 9 4 GTECH Technical Training and Support Services GTECH Handling Precautions This chapter explains the proper handling of Electrostatic Discharge ESD sensitive modules and devices the proper transport of terminals and other parts how terminals and devices should be packaged for returns to depots or retailers and the proper storage of extra or backup devices and parts Service Manual for Accutherm Ultra Printer A i ESD HANDLING All GTECH Printed Circuit Boards PCBs are static sensitive In order to prevent damage to electronic components through ESD please take th
54. nsation Bearings the shaft and rollers move freely in the frame Service Manual for the Accutherm Ultra Printer 7 19 Remove Platen from the Knife Stacker Assembly REMEMBER TO USE ESD PRECAUTIONS To remove the platen from the knife stacker assembly 1 Remove the Platen Gear 2 Loosen 4 thread forming screw typ left right sides 3 Remove 4 thread forming screw typ left right sides 4 Remove Bearing Retainer typ left right sides 5 Slide Platen Stripper and L R bearings forward to remove from side plates Figure 7 20 Remove Platen from Knife Stacker Assembly When installing Platen Stripper and Bearings ensure the Stripper locating bosses are aligned with mating holes in the L R Side Plates and then tighten screws Platen should spin freely when assembly is completed 7 20 GTECH Technical Training and Support Services Disassembly Remove Fixed Blade from the Knife Stacker Assembly REMEMBER TO USE ESD PRECAUTIONS To remove the fixed blade from the Knife Stacker Assembly 1 Remove 6 6 thread forming screws retaining knife stacker assembly to the cover Figure 7 21 Remove 6 Screws 2 Remove knife stacker assembly from the paper cover Remove wire harnesses from the wire retention features in the cover Figure 7 22 Remove Knife Stacker Assembly from Paper Cover Service Manual for the Accutherm Ultra Printer 7 21 3 Remove Stacking Gear 4 Remove Stacking Gear Retaining Ring
55. nstalled e This terminal is equipped with a safety tested power cable and may only be connected to a grounded power outlet e Ensure that the power outlet to which the terminal is being connected is freely accessible e Always grip the cable plugs to remove them from outlet never pull the power or data cables from the sockets by the cables e Lay leads and cables so that no one can stand on or trip over them Service Manual for Accutherm Ultra Printer D i e Data transmission lines must not be connected or disconnected during a thunderstorm e Ensure that no objects e g jewelry paper clips etc are allowed to drop inside the terminal e Inthe case of an emergency e g damaged housing operating elements or power cable entry of moisture or objects switch off the terminal pull out the power cable and contact the responsible customer support department e Repairs or modifications to the terminal may only be carried out by qualified trained personnel e Unauthorized opening of the terminal and repairs may result in considerable danger as well as jeopardize the warranty coverage Radio Interference FCC This equipment has been tested and found to comply with the limits for a Class A digital device persuant 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 an
56. of components Keep parts in static dissipative packaging until ready for use Use ESD protective containers for handling and transporting small components Handle IC s by the body not the leads Do not slide static sensitive devices over any surface Eliminate static generators from your work area for example plastic vinyl styrofoam etc Use a static free workstation whenever handling parts in the office in the field or anywhere Recommended Handling Example A typical scenario for a technician at a bench to properly retrieve parts from a stock area is as follows NOTE You the technician are seated at a bench connected to electrical ground via a wrist strap The bench surface has a clean grounded static dissipative bench mat connected to earth ground All tools are conductive When rising from the bench to retrieve a PCB for example disconnect the wrist strap Proceed to the storage location and back to the bench keeping the board in the existing closed static dissipative packaging Re attach the wrist strap remove the board from the bag and install it in the terminal which is sitting on the static dissipative mat After leaving and returning to the static dissipative area always reconnect to a static wrist strap connected to electrical ground before touching any static sensitive parts Service Manual for Accutherm Ultra Printer A v Proper Grounding Technique RLTs and FSTs must follow proper
57. ound in Documentum Webtop in the Field Service Engineering Cabinet Field Service Engineering gt F SE Warranty Information All warranty documents are listed in Part Number order Service Manual for Accutherm Ultra Printer C ili Post Warranty Service C iv The Accutherm Ultra is serviced by GTECH RLTs during the post warranty period please refer to the warranty agreement referenced above for warranty duration Contact Field Service Engineering for a parts list specific to your jurisdiction Table C 2 Accutherm Ultra Spare Parts Post Warranty GTECH P N Description 10 1374 01 SCR M3X6 PNH PH 10 1368 01 NUT M3 10 2159 01 FOOT BLACK RUBBER BLACK 11 3174 01 FRAME KNIFE ACCTHRM Ultra 11 3178 01 FRAME MAIN ACCTHRM Ultra 11 3177 01 GROUND KNIFE ACCTHRM Ultra 11 3175 01 GROUND ESD PLATEN ACCTHRM Ultra 11 3173 01 BRACKET TOF SENSOR ACCTHRM Ultra 12 0921 01 CLUTCH ASSY MOLDED ACCTHRM Ultra 12 0922 01 ASSY STACKER SHAFT STD ACCTHRM Ultra 12 0920 01 PIN DOWEL ACCTHRM Ultra 12 0919 01 SHAFT LATCH ACCTHRM Ultra 12 1035 01 LATCH ARM 15 1462 01 ASSY CUTTER BLADE ACCTHRM Ultra 15 1459 01 ASSY TOF SENSOR ACCTHRM Ultra 15 1461 01 ASSY PLATEN ACCTHRM Ultra 15 1458 01 ASSY PAPER JAM SENSOR ACCTHRM Ultra 15 1464 01 ASSY LEFT BEARING PLATE ACCTHRM Ultra 15 1457 01 ASSY POWER SUPPLY FERRITE ACCTHRM SUP 15 3741 01 LATCH ARM ASSY 16 1804 01
58. parated with conductive or anti static foam No movement between assemblies can occur As a priority Circuit Card Assemblies must be transported in slotted conductive totes with dividers spaced for tight capture If boards are very short anti static bubble wrap or anti static foam is used to prevent movement from slotting during handling When conductive totes dividers are not available static shielding bags protect Circuit Card Assemblies Separation of Circuit Card Assemblies by means of anti static bubble or thin polyethylene foam sheeting is required Fragile parts must be cushioned from one board to another and no puncturing of ESD protection is allowed All IC s must be placed in anti static tube holders that are cut to size then placed in static shielding bags for transit in kit or sales orders Shielding bags must be fully closed and sealed Static shielding bags may be replaced by conductive DIP tube shippers or bin boxes IC s that will not fit an IC tube must be placed in conductive foam All IC legs are inserted in foam without deforming then placed in static shielding bags for transport in kit or sales orders Shielding bags must be carefully closed and sealed properly IC s must not be placed loose in bags Parts which mark or scratch easily must use supplier packaging or must be separated by thin foam polybag material or corrugated in a similar fashion to the original supplier packaging GTECH Technical
59. r 8 4 GTECH Technical Training and Support Services Troubleshooting Troubleshooting Steps for RLT s Problem Action Printing Colored stripe on the 1 Check the paper level Incorrectly receipt 2 If paper is low change the paper Refer to Loading Paper on page 8 8 3 Clean the Top of Form Paper Low sensor with 91 isopropyl alcohol and cotton swabs Print is light or spotty 1 Make sure the paper is loaded correctly Refer to Loading Paper on page 8 8 2 Ensure the use of the recommended thermal receipt paper 3 Clean thermal print head with 91 isopropyl alcohol and cotton swabs 4 Check thermal print head cable connections 5 Replace the printer mechanism Refer to Remove the Printer Mechanism Assembly from the Base Assembly on page 7 8 Missing Print Replace the print head Refer to Remove the Print Head Assembly from the Printer Mechanism Assembly Lower Print Mechanism on page 7 11 Vertical column of print is missing Replace the print head Refer to Remove the Print Head Assembly from the Printer Mechanism Assembly Lower Print Mechanism on page 7 11 Receipt does not come all of the way out Open the receipt cover and clear any jammed paper Refer to Clearing a Paper Jam on page 8 10 Printer starts to print but stops while the receipt is being printed Open the receipt cover and clear any jammed paper Refer
60. r gt Yellow Soft Errors Soft errors may be recovered by the host or by opening and closing the printer cover All of these errors are indicated by a 5 second repeating blink pattern Soft Error State Indicators Power Green Error Red Paper Yellow Powering Down Fast Blink On Off Cover Open 4 Blinks On Off Print Head Over Temp 9 Blinks Slow Blink Off Power Bad 2 Blinks Slow Blink Off Out of Paper 2 Blinks On On Jam 5 Blinks On Fast Blink Missed Top of Form TOF 6 Blinks Off Fast Blink Invalid Command 7 Blinks On Fast Blink Paper Low Error On On Slow Blink Paper Low On Off Slow Blink Electronic Journal Low On Off 2 Blinks 5 4 GTECH Technical Training and Support Services Diagnostics Hard Errors Hard errors have a similar pattern to Soft errors only they are slower and repeat every 10 seconds In general they occur during level 0 diagnostics and are not recoverable Hard Error State Indicators Power Green Error Red Paper Yellow EEPROM read fault 2 Blinks On Off EEPROM write fault 3 Blinks On Off Error Vector Taken 4 Blinks On Off Knife Error 5 Blinks On Off Flash File system Error 7 Blinks On Off Flash Read Write Error 9 Blinks On Off Dynamic Memory Allocation 10 Blinks On Off Font system Fault 11 Blinks On Off Static Memory Allocation 12 Blinks On Off Communications Fault 14 Blinks On Off Kernel Fault 15 Blinks On
61. rne beanie hie aie ess 5 3 Normal Operation Errors 00 0 0 ceeceeceeeseeeeneeeseeeeees 5 4 Extended Diagnostics csc icciicit csstieecciotesteeiaseten 5 6 Chapter 6 Download AccuTherm Ultra Firmware Install Procedure 6 2 Chapter 7 Disassembly Warranty Information eee eeeeeeeeeeseeenseenneeeeees 7 1 Required Tools onin e ee eee 7 2 Disconnect the Power Cable 0 ieee eeeeereeeeeeeee 7 2 Disconnect the USB Communications Cable 7 3 Remove the Cover Assembly ccssccesseeeeeseeeeeees 7 4 Remove the Power Supply from the Base PASSEMIDIY tet vssee o a a A aaia 7 7 Remove the Printer Mechanism Assembly from the BasecAsseniD lysis seule tere oi ae eee es 7 8 Remove the Main Controller PCB Assembly from the Printer Mechanism Assembly 45 7 9 TOC ii GTECH Technical Training and Support Services Remove the Print Head Assembly from the Printer Mechanism Assembly Lower Print Mechanism 7 11 Remove the Rotary Knife from the Printer Mechanism Assembly Lower Print Mechanism 7 13 Remove Paper Path Assembly from Printer Mechanism atte stata ters tte a a A 7 14 Remove Stacker Guide Assembly from the Printer Mechanism Assembly eeeeeeeeeeeeeeeee 7 18 Remove Platen from the Knife Stacker Assembly 7 20 Remove Fixed Blade from the Knife Stacker ASSE MOIY iss cea ertsi ean tion detwastasance e dun Eain neay 7 21 Chapter 8 Troubleshooting Introduction to Troub
62. s drained of its charge Such a workplace employs conductive and static dissipative materials for its table tops floor surfaces clothing and material handling bins boxes and bags Machines tools and test fixtures should be properly grounded Technicians or anyone handling electronic components should wear wrist straps and even ankle straps at all times when working on or near ESD sensitive electronic modules PCBs and devices GTECH has created this chapter to help you identify ESD failures and to implement correct handling procedures Please read the following sections carefully GTECH Technical Training and Support Services Handling Precautions ESD Induced Failure Modes Radiated Electromagnetic Fields Radiated electromagnetic fields induce low level voltages in unshielded signal conductors These can cause intermittent unit halts from which the operator may recover Older products are more sensitive to these fields Products manufactured today are designed with covers and shielded external cables to protect them from most induced voltages Conducted Charges Conducted charges usually at points where the operator touches the unit may transfer directly to components and result in either intermittent or permanent failures Typical Symptoms of ESD Damage Hard failures such as blown semiconductor junctions cracked oxide layers fused metallization or bond wires can result from ESD however intermittent failures are the most co
63. s in the number above will become 02 Revision details are tracked in the table below Revision Description Date Writer 2 ACU 003 01 DRAFT for Review 9 13 2010 M Brown 2 ACU 002 02 Final for Delivery 11 02 2010 J Pearson 2 ACU 002_03 Updates from trainer 1 15 2014 J Pearson 2 ACU_003_01 Release as updated Service Manual 1 28 2014 J Pearson No provisions exist for automatic on site updates of this manual 2 ACU 003 01 RH i RH ii This manual is intended for use as a training guide Accordingly although we strive to be as accurate as possible at print time product information contained in this manual should not be construed as official product specification information or as legally binding promises of product performance Each chapter also has a revision level since chapters may be edited before new manuals are published If you believe your manual is out of date contact GTECH Learning Technology Services to obtain the latest edition level Stephanie Lataille Documentation Manager GTECH Technical Training and Support Services 401 392 7961 or ttssdocs gtech com To suggest or request updates to this manual please contact your Field Services Engineering FSE Representative or send an email to Field Services Engineering or ttssdocs gtech com and it will be forwarded GTECH Technical Training and Support Services Table of Contents GTECH Revision History Chapter 1 Introductio
64. s the Gear Cover Remove the outside E Clip allowing you to pull the arm off the shaft Remove the left and right E Clips from the Rotative Blade Remove the left and right bushings Press the Print Head in and down to provide access for the rotary knife blade removal oe ele Now you should be able to remove the rotary knife blade Figure 7 11 Remove Rotary Knife from Printer Mechanism Assembly Service Manual for the Accutherm Ultra Printer 7 13 Remove Paper Path Assembly from Printer Mechanism REMEMBER TO USE ESD PRECAUTIONS 1 Unplug Print Head cable from the PCB When reassembling the Thermal Print Head Cable ensure the cable is centered in the mating connector on the PCB 2 Remove the Print Head Assembly as shown in the section Remove the Print Head Assembly from the Printer Mechanism Assembly Lower Print Mechanism on page 7 11 Figure 7 12 Remove Print Head Cable and Print Head Assembly 7 14 GTECH Technical Training and Support Services Disassembly 3 Remove the two 2 4 Thread forming Screws 4 Remove the Print Head Ground Figure 7 13 Remove 2 Thread Forming screws and Print Head Ground 5 Unplug connectors 6 Remove two 2 M3 screws holding PCB Shield Knife Motor to frame Optional Replace one 1 M3 screw to hold the Motor in position for remaining disassembly Figure 7 14 Unplug Connectors and Remove Two 2 M3 Screws Service Manual for the Accutherm Ultra Printer
65. screen Decibels Adjusted Decibel Decibels referenced to 1 mWatt Direct Current Data Carrier Detect Data Communication Equipment Digital Service is a network service offered by AT amp T This is also an acronym for Digital Data Service Degrees Centigrade Design for Manufacturability and Assembly Dual In line Memory Module Direct Memory Access DiskOnChip dots per millimeter Digital Processing Board Dots per Inch Double Pole Single Throw Dynamic Random Access Memory Data Set Ready Data Terminal Equipment Data Terminal Ready Dual Universal Asynchronous Receiver Transmitter Engineering Change Orders Enhanced Capabilities Port Extended Data Out Electrically Erasable Programmable Read Only Memory Electronically Erasable Programmable Logic Device Electrical Fast Transients Enhanced Integrated Drive Electronics Extended Integrated Drive Electronics Electromagnetic Capability Electromagnetic Interference United States Environmental Protective Agency Electronically Programmable Logic Device Enhanced Parallel Port Erasable Programmable Read Only Memory GTECH Technical Training and Support Services ESD ETSI F FCC FCC Part 15 FCC Part 68 FBNK X FDD FFC FIFO FPG FST GRUB GUTS HDD LAN LCD LCS LED LIF LPTL LVDS mA MA MB MCU Acronyms amp Abbreviations Electrostatic Discharge European Telecommunications Standards Institute Fahrenheit Federal Communications Commission Th
66. tions 5 Install a paper roll into the printer see page 2 6 for paper loading instructions 6 Complete all required connections for the terminal 7 Apply power to both pieces of equipment Service Manual for the Accutherm Ultra Printer 2 5 Loading Paper Follow the instructions below to load a new roll of paper into the Accutherm Ultra printer Reference the photos that follow each step for the illustrated procedure 1 Press back on the gray cover latch button and raise the paper cover to the open position 2 Tear off the first layer of the paper roll Place the paper roll into the printer so that the paper unwinds from the bottom front 3 Leave a few inches of paper outside of the printer 2 6 GTECH Technical Training and Support Services Installation 4 Close the paper cover firmly so that it latches securely Paper will feed automatically to align itself and then the printer will automatically cut off the excess paper Service Manual for the Accutherm Ultra Printer 2 7 GTECH Configuration This chapter does not apply to the Service Manual for the Accutherm Ultra Printer as all printers are configured at manufacturing and updates are maintained via the lottery terminal to which it is connected Service Manual for the Accutherm Ultra Printer 3 1 GTECH Operation PLEASE NOTE There are no operating instructions for the Accutherm Ultra Printer other than installation a
67. to Clearing a Paper Jam on page 8 10 Service Manual for the Accutherm Ultra Printer 8 5 Problem Action Printing Receipt is not cut 1 Open the receipt cover and clear any jammed Incorrectly paper Refer to Clearing a Paper Jam on page contin 8 10 2 Check the connections to the Main Controller PCB 3 Replace the Main Controller PCB Assembly 4 Replace the printer mechanism Refer to Remove the Printer Mechanism Assembly from the Base Assembly on page 7 8 Sensors are not working properly 1 Open the printer 2 Remove the printer cover 3 Clean the optical sensors Paper Out Top of Form Paper Low Anti Jam and Paper Cover Opened with isopropyl alcohol and cotton swabs Printer Errors LED is blinking Error Indicators Power gt Green Error gt Red Paper gt Yellow Soft amp Hard Errors Soft Errors Soft errors may be recovered by the host or by opening and closing the printer cover All of these errors are indicated by a 5 second repeating blink pattern Refer to Soft Errors on page 5 4 for specific error information Out of Paper 1 Change the paper Refer to Loading Paper on page 8 8 2 Clean all sensors with 91 isopropyl alcohol and cotton swabs 3 Replace the Main Controller PCB Assembly Paper Low Error 1 Change the paper Refer to Loading Paper on page 8 8 2 Clean all sensors with 91 isoprop
68. tt trigger buffered on another input for fast reading during normal operation The LED current of the JAM sensor is fixed to approx 18ma Its output is Schmitt trigger buffered for fast reading by the MCF5253 processor Power Supply Circuitry There are four different power supply voltages used in the Accutherm Ultra Table 1 2 Power Supply Circuitry Voltage Derived From Used For 24 VDC Modular Power Supply Print Head Step Motors 3 3 VDC Derived from 24V using a buck Processor I O USB converter circuit communications SDRAM flash memory print head logic sensors Service Manual for the Accutherm Ultra Printer 1 11 Table 1 2 Power Supply Circuitry Voltage Derived From Used For 1 8 VDC Derived from 3 3V using an internal Processor core regulator resident in the MCF5253 1 5 VDC Derived from 3 3V using a TI FPGA core TPS73601 low drop linear regulator A power supply supervisor chip monitors the 3 3V and provides reset control for the processor and FPGA Communications Interface The communications interface is resident on the main controller PCB The Accutherm Ultra is available with one interface USB 1 12 GTECH Technical Training and Support Services GTECH Installation Introduction Follow the instructions in this chapter in order to properly install the Accutherm Ultra printer The Accutherm Ultra can be used with a number of GTECH terminals including the GT1100 and GT1200
69. y tests To access the printer test display 1 Press and hold the Service button to begin scrolling through the tests 2 To select a test release the Service button at the desired test prompt then follow the instructions The available printer test options include the following Print Test Ticket Prints a sample ticket Print GTECH Ticket Prints a GTECH sample ticket Configuration Enters Configuration mode User Stats Provides information for 3 Groups Group 1 e Number of Line Feeds e Characters Printed e Cover Opens sensor triggers e Paper Out sensor triggers Group 2 e Auto Cutter Cycles e Auto Cutter Faults e Auto Cutter REeHome Group 3 e Level 1 Jams e Level 2 Jams Print Head Test Prints a test pattern to verify that all print elements are working and clean Marker Calibration Verifies that the Top of Form marker sensing is working Continuous Print Prints the test ticket continuously to verify stacker functionality Service Manual for the Accutherm Ultra Printer 5 3 Normal Operation Errors During Normal operation the Power LED remains on unless an error is indicated There are two classes of errors soft errors and hard errors Soft errors are recoverable without power cycling the printer Hard errors are not recoverable without removing power from the printer correcting the problem and reapplying power e Error Indicators e Power gt Green e Error gt Red e Pape
70. yl alcohol and cotton swabs 3 Replace the Main Controller PCB Assembly Cover Open 1 Close the printer cover securely 2 Clean all sensors with 91 isopropyl alcohol and cotton swabs 3 Replace the Main Controller PCB Assembly 8 6 GTECH Technical Training and Support Services Troubleshooting Problem Action Printer Status Missed Top of Form 1 Clean all sensors with 91 isopropyl alcohol LED is blinking and cotton swabs contin 2 Replace the Main Controller PCB Assembly Jam Detected 1 Open the receipt cover and clear any jammed paper Refer to Clearing a Paper Jam on page 8 10 2 Clean all sensors with 91 isopropyl alcohol and cotton swabs 3 Replace the Main Controller PCB Assembly Invalid Command 1 Turn the printer off and then on again 2 Reload firmware Printer Head Over 1 Ensure that the printer is being operated in the Temperature proper room temperature not too hot or too cold 2 If necessary move the printer to a warmer cooler location 3 Replace the Main Controller PCB Assembly Power Problem 1 Check that the terminal has power 2 Check that printer cables are properly connected on both ends 3 Ensure the latch and receipt cover is closed 4 Verify the printer configuration and re configure if necessary 5 Ensure that the printer is being operated in the proper room temperature not too hot or too cold If necessary move the printer to a warm

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