Galileo ADP 4100 Installation And Operator's Manual

ADP 4100 Printer

Installation and Operations Manual

© 2007 Unimark Products, LLC. a Microcom Corporation Company.

This documentation contains confidential information proprietary to Unimark, Inc. Use, disclosure,

reproduction, copying and transfer of this documentation and the copyrights and proprietary information

embodied herein is permitted only for purposes authorized in, and subject to the terms an d conditions of, the

License Agreement provided by Unimark, Inc. Other Use, disclosure, reproduction, copy or transfer is

permitted only with the prior written permission of Unimark, Inc.

Galileo International, L.L.C. obtained written permission from Unimark to reproduce contents of the Unimark

XP Installation and Operator’s Manual 71U-1429-100 © 20 07 Unimark Products, LLC. for the ADP 4100

printer. No part of this publication may be reproduced or transmitted without prior written permission of

Galileo International, L.L.C. or Unimark, Inc.

ADP 4100 Installation and Operators Manual

4/07

Table of Contents

FCC ...........................................................................................................................................................3

FCC Emission Interference....................................................................................................................3

Note........................................................................................................................................................3

ADP 4100 Printer..........................................................................................................................................4

Introduction................................................................................................................................................4

Operating Tips .......................................................................................................................................5

Warnings and Cautions..........................................................................................................................5

Box Contents .........................................................................................................................................6

Product Specifications ...........................................................................................................................7

Printing system...................................................................................................................................7

Magnetic encoding.............................................................................................................................7

Document handling............................................................................................................................7

Interface .............................................................................................................................................7

Control Panel......................................................................................................................................7

Physical..............................................................................................................................................8

Environmental ....................................................................................................................................8

Installation .................................................................................................................................................8

Unpacking..............................................................................................................................................8

Bin Full Feature..................................................................................................................................9

Attaching the Ticket Catcher............................................................................................................10

Location and Setup ..........................................................................................................................10

Plugging in the Unit..........................................................................................................................12

Host Interface Specification.................................................................................................................13

Hardware Interface...........................................................................................................................13

Data Structure..................................................................................................................................13

Front Panel ..........................................................................................................................................14

Keypad Display/Layout ....................................................................................................................14

Basic Operator Level Menu.................................................................................................................15

Adjustments Menu...............................................................................................................................16

Basic Unit Operation and Setup..............................................................................................................17

Powering the Unit On and Off..............................................................................................................17

Loading Ticket Stock............................................................................................................................18

Operating Under a CRS or Airline Host...................................................................................................20

Clearing Stock Jams................................................................................................................................21

Cleaning ..................................................................................................................................................24

Using the Cleaning Card......................................................................................................................24

Periodic Inspection...............................................................................................................................25

Cleaning External Surfaces.................................................................................................................26

Cleaning Inside the Enclosure.............................................................................................................26

Cleaning the Encoder Drive and Idler Rollers......................................................................................27

Cleaning the Print Head and Platen ....................................................................................................29

Troubleshooting.......................................................................................................................................30

Basic Scenario Failure Analysis ..........................................................................................................30

Basic Alert Messages..........................................................................................................................31

Thermal Print Head Replacement...........................................................................................................34

Customer/Technical Support...................................................................................................................36

Return Authorization/Customer Service..............................................................................................36

Technical Support....................................................................................................................................37

Warranty Statement.................................................................................................................................38

Alerts and LCD Messages.......................................................................................................................40

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SCOPE.................................................................................................................................................40

POWER UP SEQUENCE MESSAGES...........................................................................................40

FIRMWARE UPDATE MESSAGES.................................................................................................40

STOCK JAM MESSAGES ...............................................................................................................41

STOCK STATUS MESSAGES ........................................................................................................43

AEA ERROR MESSAGES...............................................................................................................44

NORMAL PROCESS MESSAGES..................................................................................................47

COMMUNICATION ERROR MESSAGES.......................................................................................47

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ADP 4100 Printer

FCC

FCC Emission Interference

This device complies with Part 15 of the FCC Rules. Operation is
subject to the following two conditions:

1. This device may not cause harmful interference,
and,

2. This device must accept any interference received, including
interference that may cause undesired operation.

Any changes or modifications not expressly approved by Unimark
could void the operator’s authority to operate the equipment under
these conditions and rules.

Note

This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
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 their own cost.

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ADP 4100 Printer

Introduction

The XP is a state-of-the-art Airline Ticket and Boarding (ATB) pass
printer (hereafter referred to as the Unit), capable of high speed
printing and incorporating standard ATB features such as magnetic
data encoding and revalidation. The Unit has two RS-232
Asynchronous Serial Communication ports to interface to the host
system. The ports are configured as DTE requiring a null modem
cable connection to a DTE host system. Other interface options are
available or can be developed such as Ethernet, USB, or Modem.

The Unit is designed to set on the floor. There are multiple caster
options available, allowing the Unit to be easily moved around in
airport and travel agency environments.

The Unit transport mechanism accepts full size ATB coupons (8 and
7-3/8 inch stock). The Unit has three input bins. Bins A and B are
internal secured locations for ATB ticket stock. Both A and B bins can
hold up to 1000 ATB documents. Bin C is external which is typically
unsecured and used for mini ITIN stock. An optional Bin C shelf is
available as well as a Bin C box which can be secured. The
printed/encoded coupons are automatically presented at the exit bin
on the front of the Unit. The Unit has an internal reject bin for
coupons which cannot be properly encoded or are otherwise
damaged and unusable.

The Unit’s front control panel incorporates control/function keys,
indicator LEDs, and an alpha-numeric character display. The display
provides Unit status and activity information as well as providing
visible feedback when the operator or service provider is navigating
through the menu system.

The Unit uses an auto switching power supply which allows automatic
operation in both 110 and 220VAC environments.

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ADP 4100 Printer

Operating Tips

y Read and follow all warning instruction labels on the Unit itself.
y Do not operate your Unit near water or spill liquid of any kind into

it.

y Do not use a damaged power cord. Do not put anything on it or

place it in an area where it will be walked on. If the power cord
becomes damaged or frayed, replace it immediately.

y Do not insert anything into the ventilation slots or openings as this

can result in damage to the Unit.

y Only trained technicians should attempt to service the Unit if in

need of repair.

Warnings and Cautions

The Unit is designed to operate safely and effectively under normal
circumstances with both enclosure doors closed. However, some of
the procedures presented in this manual, such as cleaning and
clearing ticket jams, must be completed while the left door of the
enclosure is open. When the left door of the Unit is open, the
operator is exposed to moving mechanisms and components.

WARNING

For your safety, a warning notice will appear before any procedure
involving moving components. Each warning notice will be prefaced
by the international safety alert symbol and warning label. The
warning text will explain the precautions to take involving the
procedure being followed.

CAUTION

You may damage some of the components in the Unit during
maintenance procedures if you do not take specific precautions.
When a component is subject to damage, a caution notice will appear
before the step. Each caution notice will explain the potential damage
and specify the appropriate precautions.

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Box Contents

Items Included (contents vary with customer configuration):

1. XP Unit

2. Keys

3. AC Power Cord

4. XP Manual or Product CD

5. Optional items such as ticket catchers, Bin C options, and
interface cables and adaptors/gender changers

6. Sample Test Stock

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Product Specifications

Printing system

- Method: Direct Thermal

- Resolution: 203DPI

- Speed: Up to 50 documents per minute

- Font:Contains Andale from Agfa Monotype Corporation®

Magnetic encoding

- Stock type: ATB1 and ATB2 tickets with and without magnetic

stripe

- Encoding specification: Conforms to IATA specification

1722C, Attachment C

- Encoding format: Four tracks Read/Write verification (210

bpi)

- Pre-Encoding: Standard pre-read of magnetically encoded

SCN numbers

Document handling

Interface

- Types: ATB1 and ATB2, 8 and 7-3/8 inch stock

- Source: Two internal (Bins A and B); 7-3/8 and 8 inch stock.

One external (Bin C); 8 inch stock only

- Revalidation: One front input feed slot; 7-3/8 and 8 inch stock

- Reject: One internal reject bin

- Exit: One stock path exit point at the front below the

revalidation slot

- RS-232: Two Asynchronous Serial Communication ports (DB-

25F DTE standard)

- Ethernet: *Optional network interface (RJ-45) with TCP/IP and

Web Server functionality

- USB: *Optional Universal Serial Bus interface

- Modem:*Optional Modem Phone Line (RJ-11/RJ-12) interface

- RF: *Optional RF antenna mount

*Not part of the Standard XP configuration
**Other interface options can be developed as necessary

Control Panel

- Keys: Eight momentary push button keys (see “Front Panel”

section for details)

- LEDs: Four indicator LEDs (see “Front Panel” section for

details)

Display: 2 row by 20 column (2x20) alpha numeric (see “Front

-

Panel” section for details)

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ADP 4100 Printer

Physical

Environmental

Installation

- Dimensions: 11-5/8” wide, 23-1/2” high (without casters), 21-

3/4” deep

- Weight: 50lbs (23 kg), Standard Configuration

- Shipping Container Dimensions: (See “Installation” section)

- Operating Temperature:40 to 104°F (4 to 40°C)

- Storage Temperature:-4 to 140°F (-20 to 60°C)

- Relative Operating Humidity:5 to 95%, non-condensing,

without degraded performance

- Relative Storage Humidity: 5 to 95%, non-condensing,

without damage to components

Unpacking

Inspect the shipping container for evidence of in-transit damage, such
as being dropped, crushed, or punctured. If damage is evident,
contact the carrier directly to specify the nature and extent of damage.
If the container is free of damage, remove the Unit from the shipping
container by opening the side panel marked “OPEN THIS END”. Pull
the Unit (secured with packing foam pieces) from the container and
remove the foam from the Unit.

The keys are in a package attached to the rear of the Unit.

Retain original shipping carton and foam for future use.
Accessories Kit

After the Unit has been removed from the shipping container, remove
the Accessories Kit from the Bin A/B location on the left side. The
Accessories Kit consists of the power cord, ticket catcher, Operator's
Manual or Product CD, and some sample stock for testing. The exact
contents of the kit are subject to change without notice.

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Bin Full Feature

The Bin Full Bale allows the Unit to sense when the ticket catcher is
full (approximately 125 tickets). Under this condition a front control
panel alert is set and ticket printing is automatically halted. The alert
condition is cleared and printing is resumed as soon as the tickets are
removed. To enable the Bin Full feature, simply place your index
finger against the top left side of the bin full bale and push slightly to
the right while pulling out. This action moves the bin full bale from the
locked storage position to the operating position. The bin full bale
should move freely up and down.

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ADP 4100 Printer

Attaching the Ticket Catcher

Remove the ticket catcher from the Accessories Kit. Hold the catcher
by the sides, between your thumb and fingers, with the open end of
the catcher facing up. Set the bottom of the catcher into the bottom of
the opening in the front of the Unit. Gently squeeze the sides of the
ticket catcher and push it into place. Let go of the ticket catcher and it
will remain in place.

Location and Setup

Handle

The Unit can incorporate a handle located on the front just below the
user interface keypad. The handle is designed to assist the operator
when rolling the Unit out to load stock and for service and product
support. The handle is not to be used to lift Unit, which could result in
product damage.

Bin C Shelf

The Unit can incorporate a shelf to support stock for the Bin C input.
The shelf is located on the rear of the Unit. During shipment it is
stored in the locked upright location. During on-site installation, the
shelf can be pulled down from the top and let down to the horizontal
(down) location. A support chain will limit the downward swing of the
shelf.

Choose a location that provides at least 1-inch of open space
between surfaces adjacent to the Unit’s sides, front, and top. This
space is required to allow for proper ventilation of the Unit. At least 3
inches of space is required behind the Unit for cabling and airflow.

Position the Unit so adequate space is provided on both the left and
right sides to open the doors. Alternately verify that the Unit can be
moved (or rolled) to an open area where the doors can be fully
opened. The left and right doors must be able to swing open 90º to
load ticket stock or to perform routine maintenance.

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y Do not install the Unit where it will be exposed to direct sunlight.

Sunlight may affect the optical sensors resulting in stock loading
difficulties. Direct sunlight can also affect the readability of the
front panel display.

y The Unit is intended for indoor use only. Place the Unit on a firm

solid surface. If placed on an unsteady surface, it may fall and
become damaged.

y To protect the Unit from overheating, do not block openings on the

enclosure. Do not place the Unit on or near a heat source, such as
a radiator or heat register.

y The Unit uses a grounded 3-prong power cable as a safety feature,

which will only connect to a grounded wall outlet. If the power cable
cannot be plugged into the outlet, contact an electrician to have the
outlet replaced. Do not use an adapter to defeat the grounding
feature.

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ADP 4100 Printer

Plugging in the Unit

The Unit has the following physical connections:

1. POWER: An IEC 320 power connection accepting 110/220VAC
(50/60Hz).

2. COMM 1 and COMM 2: RS-232 interface connections. These
connections are DB-25 female pin connectors and are configured
as DTE. A null modem cable quickly interfaces the Unit to a
standard connection on a typical PC-based host system.

Optional Connections

3. Ethernet: An optional RJ-45 connection is available for Ethernet­based connections providing TCP/IP and Web Server
connectivity.

4. USB: An optional Universal Serial Bus connection is available for
USB connectivity.

5. Modem: An optional RJ-11/RJ-12 connection is available for
modem (phone line) based connections.

6. RF: An optional antenna mount is available for RF based
connectivity.

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Host Interface Specification

Hardware Interface

The Unit has two RS-232 Asynchronous Serial Communications ports
to interface to the Host system. The physical connection is provided
using two DB-25 female pin connectors marked COMM 1 and COMM

2. The ports are configured as DTE connections and can be used to

connect to an associated DTE host using a null modem cable. The
pinout below provides the basic cabling requirements to connect the
Unit to a PC-type host system (table shown assumes the host system
uses a DTE DB-9 connector).

Host (DTE) PC/AT or equivalent Signal Flow

Pin #, DB-9 Signal Name Signal Name Pin #, DB-25F

1 CD N/A
2 RxD

3 TxD
4 DTR
5 Signal GND N/A Signal GND
6 DSR
7 RTS
8 CTS
9 RING

⇐
⇒
⇒

⇐
⇒
⇐
⇒

XP (COMM 1 and 2)

TxD
RxD

DSR

DTR
CTS
RTS

2
3
6
7

20

5

4,11

Data Structure

1200 - 115,200 7, 8

The connection from pin 11 to RTS enables the Unit to function with
existing customer cabling. This connection can be removed if
necessary.

The Unit may also have optional hardware interfaces including
Ethernet, USB, and Modem. Custom firmware interfaces can be
written for these and the existing serial interface.

The Unit uses an asynchronous serial data transmission method.
Data is sent based on any combination of the following:

Baud Data Length Parity Stop Bit

None, Even, Odd, Mark,

Space

1, 2

ADP 4100 Printer Installation and Operators Manual, April 2007 13

ADP 4100 Printer

Front Panel

Keypad Display/Layout

You will find the following elements in this display.

1. ONLINE - Indicates that the Unit is in the online state. The
ONLINE LED also flashes when the Unit is receiving and
transmitting data.

2. STOCK: Indicates that the Unit is out of stock.

3. ALERT - Notifies the operator of a condition that needs immediate
attention.

4. POWER - Indicates that the Unit is powered.

5. The front control panel character display: Provides the operator
with information about the Unit’s state. The display is also used to
navigate the Unit’s menu system, allowing the operator to change
settings and address conditions to which the Unit has alerted the
operator.

6. ONLINE - Used to change the Unit state from ONLINE (ready to
receive data from the host and print) to OFFLINE (standby state).

7. ⇐⇒⇑⇓ - Arrow keys are used to navigate through the menu
system. The up and down arrow are also used to change the
display contrast/intensity while the Unit is in the ONLINE state.

8. ENTER - Used to access the Unit’s menu system. Pressing this
key moves the operator up one menu level or selects a particular
setting.

9. RESET - Used to clear alert messages and conditions.

10. EXIT -Pressing this key moves the operator back one menu level
or cancels a particular operation.

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ADP 4100 Printer

Basic Operator Level Menu

Menu structure may change depending on the specific customer
firmware version.

Online/Offline (1)

Print Configuration

Print Sample

Print Tests

Adjustments (2)

Service Menu (3)

Test Pattern

Print Head Profile (4)

Cleaning Card (5)

1. Press the ONLINE key to take the Unit off-line, and then press the
ENTER key to access the menu system.

2. See Adjustments sub menu tree for further details.

3. Service menu is password protected. See Service sub menu
trees for further details.

4. Print head profile checks element resistance and then prints
results. Profile algorithm takes approximately 20 sec.

5. See Operator's Manual "Cleaning" Section for complete process
details.

ADP 4100 Printer Installation and Operators Manual, April 2007 15

ADP 4100 Printer

Adjustments Menu

Menu structure may change depending on the specific customer
firmware version.

Adjustments

Left Margin (dots)

Top Margin (dots)

Contrast

Contrast Front Feed

Print Speed

Burst Position Adjust

Print Sample

Enter Value (-50 to +50)

Enter Value (-50 to +50)

Enter Value (01 to +10)

Bin A:xx B:xx C:xx

Enter Value (01 to 10)

5 Inches Per Second

6 Inches Per Second

7 Inches Per Second

8 Inches Per Second

Enter Value (-30 to +30)
Bin A:xx B:xx C:xx

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ADP 4100 Printer

The following elements are part of this menu:
y Left Margin shifts the entire printed image left and right (staple

stub direction).

y Top Margin shifts the entire printed image to the top and bottom

edges.

y Contrast sets print darkness (individual settings for each bin).
y Contrast Front Feed is the setting for the reval slot input.
y Print speed selects the ticket stock speed through the print head

path area.

y Burst position adjustment (individual settings for each bin).

Basic Unit Operation and Setup

This Unit has been configured at the factory to meet each customer's
requirements. Use the following procedures to power on the Unit and
load ticket stock. If any difficulties are experienced with any of these
procedures, please refer to the “Troubleshooting” section for help.

CAUTION!

To prevent damage, immediately toggle the power switch to the O
(OFF) position if the Unit does not indicate RAM TEST status on the
display within 2-3 seconds after power is applied.

If the display does not show ONLINE status within 30 seconds, refer
to the “Troubleshooting” section for help.

Powering the Unit On and Off

y To power-up the Unit, locate the power switch below the front

control panel on the front of the Unit and toggle it to the I (ON)
position. As soon as the Unit is powered on, it will begin
performing an internal self-test procedure that may take up to 10
seconds.

y To power-down the Unit, simply toggle the power switch to the O

(OFF) position.

ADP 4100 Printer Installation and Operators Manual, April 2007 17

ADP 4100 Printer

Loading Ticket Stock

CAUTION

Take caution when opening the left side door. Refer to “Installation”
section for details on how the left side door opens and the space
required.

WARNING

To prevent personal injury, do not wear loose clothing or jewelry and
do not stick fingers into transport mechanism when loading ticket
stock. The transport mechanism contains moving parts.

To load ticket stock, follow these steps:
Note: Read the entire procedure before loading ticket stock.

1. Verify the power switch is in the I (ON) position.

2. Unlock the door on the left side of the Unit and swing it open.

3. Rotate the ticket stock box until the arrows on the side of the box
point up.

4. Remove the box top (see the figure on the next page for an
example of ticket stock loading).

Note: The example shown on the next page is a standard ARC
box design. Ticket stock box nomenclature varies from stock
supplier and controlling agencies. Check with the ticket stock
supplier for details.

5. Place the box(s) into the selected bin locations with the printable
side of the first ticket facing down, and the magnetic stripe (if
applicable) on the back of the ticket against the inner wall.

Note: The printable side of direct thermal stock has a heat
sensitive coating. Although it is obvious which side of ATB ticket
stock is the printable side, it may not be as easy to determine on
blank itinerary stock.

6. To determine which side of the direct thermal stock is the printable
side, rub your fingernail or a hard object across the surface of the
ticket. The printable side will show a dark mark and the non­printable side will not.

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WARNING

To prevent personal injury, be prepared to release ticket stock
when the bin input senses that ticket stock has been inserted.

The paper drive motors will begin to run and the ticket stock will
quickly move a short distance as the stock is positioned for
loading into each bin input.

Be aware of this abrupt action and release the ticket stock when
the bin motor grabs onto the ticket stock and pulls it into the bin
input.

7. Insert ticket stock into selected bin inputs, staple stub first and
oriented as shown above. Note that the magnetic stripe (if
applicable) must be against the inner wall as shown. Release
ticket stock when the bin motor begins to pull the ticket stock into
operating position. Refer to diagram on the left side door (internal
panel) for more detail.

8. When all selected paths have been loaded with ticket stock, close
and lock the left side door.

9. If the Unit is in the Off-line state, press the ONLINE key to resume
operation.

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ADP 4100 Printer

Operating Under a CRS or Airline Host

Each CRS (Computer Reservation System) or Airline host has a
unique way of working with ATB Units. The Unit was designed to
work with all major CRS. If a problem occurs while operating the Unit
with your CRS connection, refer to the “Troubleshooting” section for
help.

All host connections, set-up, and print adjustments should be
completed before attempting to go on-line with the CRS.

After the Unit is powered on and loaded with ticket stock, complete
the following instructions to go on-line:

1. Observe the front panel display. The top line of the display should

show “ONLINE”. The exact wording on the display may vary
depending on the specific customer firmware version.

2. If the Unit is not on-line, press the ONLINE key. If the Unit will not
go on-line, refer to the “Troubleshooting” section for help.

3. Once the Unit is on-line, contact the CRS and request that a
document be sent to the Unit.

4. Observe the front panel for an indication that the Unit is receiving
data. The ONLINE LED will flash when the Unit receives and
Transmits data.

5. Verify that the test document is printed after the CRS data
transmission is complete and that the document is printed
correctly. If the document is correct, the Unit is ready to use.

6. If no document was printed or the document was not printed
correctly, make sure the host data communications cable is
secure and is connected to the correct port on the rear of the Unit.
If there is still a problem, refer to the “Troubleshooting” section for
help.

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ADP 4100 Printer

Clearing Stock Jams

The figure below defines the paper path areas in the transport
mechanism.

To clear a ticket stock jam, use the following procedure:

1. Note the location of the jam indicated on the display and refer to
the figure above to locate the corresponding area where the jam
occurred.

2. Press the RESET key. The Unit will attempt to clear the jam.

3. If the Document Path Jam message is cleared, press the ONLINE
key to continue operation.

4. If the jam condition persists, complete the following procedure:

WARNING

To prevent personal injury, REMOVE POWER before manually
clearing ticket stock jams.

5. Toggle the power switch to
cord from the rear of the Unit.

CAUTION

Take caution when opening the left side door. Refer to
“Installation” sectionfor details on how the left door opens and the
space required.

O (OFF) and disconnect the power

ADP 4100 Printer Installation and Operators Manual, April 2007 21

ADP 4100 Printer

6. Unlock the door on the left side of the Unit and swing it open.

WARNING

To prevent personal injury, do not touch motors when clearing
ticket stock jams. After extended Unit use, motors may become
hot to the touch.

CAUTION

To prevent damage, do not hit or scratch the print head and
encoder components when clearing ticket
stock jams. Contact with hard objects can easily damage the print
head and encoder components.

CAUTION

To prevent damage, do not touch the print head or encoder
components unless standard electrostatic discharge (ESD)
handling precautions are taken.

7. Using the three lower knurled knobs, attempt to move the stock
back out of the Bin A, B, and C input paths. Using the two larger
knurled knobs, attempt to move the stock through the encoder,
print, exit, and revalidation path areas.

8. If you cannot remove the stock using the knurled knobs, remove
the ticket stock causing the jam through the openings in the path
either through the side areas or bottom of the transport
mechanism.

9. Make sure that all the pieces of the ticket stock are removed from
the transport mechanism and all sensors are cleared before
continuing. Refer to the following two figures for sensor locations.

10. Plug the power cord back into the Unit, toggle the power switch to
I (ON), and reload the ticket stock as described in the “Basic
Operation and Setup” section.

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ADP 4100 Printer

Stock Sensors on Outer Wall

Stock Sensors on Inner Wall

ADP 4100 Printer Installation and Operators Manual, April 2007 23

ADP 4100 Printer

Cleaning

This section defines basic cleaning procedures for the Unit. Although
the Unit will perform dependably right out of the box, periodic
inspection and cleaning should be performed to keep it in good
working order.

To prevent damage, Unimark recommends that qualified service
technicians perform these tasks.

The following inspection/cleaning procedures are presented
separately for clarity, but may be performed at the same time:

Note: The Unit contains electronic circuitry, solenoids, and motor­driven mechanisms that all generate a small amount of heat. In
normal operation, the enclosure may feel warm, particularly on the top
surface, however it should not feel or smell hot.

WARNING

To prevent personal injury, remove power before performing
preventive maintenance.

To prevent damage, do not touch the print head or encoder
components unless standard electrostatic discharge (ESD) handling
precautions are taken.

Using the Cleaning Card

The Cleaning Card is saturated in a 99% Isopropyl Alcohol cleaning
solution, and has been designed to be fed through the transport
mechanism and clean the print head, print head platen, and encoder
drive wheels. Cleanings cards are available from Unimark by calling
customer service at [phone]. The part number for the
cleaning card is 700-5014-600 (single), or the card may be ordered as
a kit of five (-605K), twenty-five (-625K), etc.

Do not remove the card from the sealed pouch until you are ready to
insert the card into the Unit.

CAUTION

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ADP 4100 Printer

To use the cleaning card, follow these steps:

1. Power the Unit on.

2. Take the Unit off-line (press the ONLINE key).

3. Press the ENTER key to enter the menu system.

4. Press the UP/DOWN arrow key until the “Print Tests” menu
appears.

5. Press the ENTER key to access this menu.

6. Press the UP/DOWN arrow key until the “Cleaning Card” option
appears.

7. Press the ENTER key.

8. Tear open the pouch containing the cleaning card.

9. Insert the cleaning card into the front revalidation slot of the Unit.
The Unit will automatically move the cleaning card through the
encoder, print head, and exit path areas of the Unit.

10. Wait until all motors stop running before using the Unit, and allow
at least one minute for the cleaning solution to evaporate.

Periodic Inspection

11. Press the ONLINE key and place the Unit back in the on-line
state.

Every three months (more often in high-volume applications), inspect
the Unit for unusual wear or damage to components. The inspection
will take less than 10 minutes.

1. Carefully inspect the outer surfaces of the Unit’s enclosure for
signs of excessive internal heat buildup. Visual evidence of
excessive internal heat buildup may be confirmed by observation
of discoloration or warping of the covers surrounding the
electronic components.

2. Examine the Unit’s external and internal surfaces, ventilation slots,
transport mechanism, and exposed components for dust buildup.
All dust should be removed at least every three months to
maintain performance.

3. If cleaning is required, complete the recommended cleaning
procedures listed in the following sections.

ADP 4100 Printer Installation and Operators Manual, April 2007 25

ADP 4100 Printer

Cleaning External Surfaces

CAUTION

To prevent damage, use only mild commercial cleaning solutions or a
mild solution of soap and water to clean the EXTERNAL surfaces of
the Unit’s enclosure. The enclosure can be damaged by strong
solvents.

Use the following procedure to clean the external surfaces of the Unit:

1. Vacuum the dust accumulation from the ventilation slots and other
external surfaces of the Unit.

2. Dampen a soft cloth or paper towel with a mild solution of soap
and water or a mild commercial cleaner and wipe the surface.

3. Dry the cleaned area with a clean, dry cloth or paper towel.

Cleaning Inside the Enclosure

Dust is produced from ticket stock passing through the transport
mechanism. Use the following procedure to clean inside the Unit
enclosure (left paper stock side):

1. Toggle the power switch to O (OFF) and unplug the power cord
from the rear of the Unit.

CAUTION

Take caution when opening the left side door. Refer to

26 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer

“Installation” section for details on how the left door opens and the
space required.

2. Unlock the door on the left side of the Unit and swing it open.

3. Back the ticket stock all the way out of the transport mechanism
by turning the knurled knobs shown in the figure above.

4. Remove ticket stock as necessary and vacuum dust from inside of
Unit.

5. Using compressed air, blow the dust from ticket stock path
grooves in transport mechanism.

6. Using compressed air, blow the dust off the sensors in the ticket
stock path. Refer to the diagram on the left side door (internal
panel) or the sensor location figures in the “Clearing Stock Jams”
section.

7. After all cleaning is complete, plug the power cord back into the
rear of the Unit, toggle the power switch to I (ON), and reload the
ticket stock. Refer to the “Basic Unit Operation and Setup”
section.

Cleaning the Encoder Drive and Idler Rollers

Use the following steps to manually clean the encoder drive rollers:

ADP 4100 Printer Installation and Operators Manual, April 2007 27

ADP 4100 Printer

1. Toggle the power switch to O (OFF) and disconnect the power
cord from the rear of the Unit.

CAUTION

Take caution when opening the left side door. Refer to
“Installation” section for details on how the left and right side doors
open and the space required.

2. Unlock the door on the left side of the Unit and swing it open.

3. Back the ticket card stock all the way out of the transport
mechanism.

4. Dampen a lint-free cloth with a 99% Isopropyl Alcohol cleaning
solution.

5. Hold the cloth firmly against one of the bottom drive rollers with
one hand while turning the knurled knob clockwise with the other.
Turn the knob a few times and remove the cloth. The cloth will be
discolored from the dust/ink buildup on the roller.

6. Dampen another area of the cloth and repeat this process until the
cloth no longer discolors. This will indicate the roller is clean.
Repeat until all bottom drive rollers are cleaned.

7. Dampen another area of the cloth. Hold the cloth against one of
the top idler rollers with one hand while turning the knurled knob
clockwise with the other. Turn the knob a few times and remove
the cloth. The cloth will be discolored from the dust/ink buildup on
the roller.

8. Dampen another area of the cloth and repeat this process until the
cloth no longer discolors. This will indicate the roller is clean.
Repeat until all top idler rollers are cleaned.

9. After all cleaning is complete, plug the power cord back into the
rear of the Unit, toggle the power switch to I (ON), and reload the
ticket stock. Refer to the “Basic Unit Operation and Setup”
section.

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ADP 4100 Printer

Cleaning the Print Head and Platen

Use the following steps to manually clean the print head:

1. Toggle the power switch to O (OFF) and disconnect the power
cord from the rear of the Unit.

CAUTION

Take caution when opening the left side door. Refer to
“Installation” section for details on how the left door opens and the
space required.

2. Unlock the door on the left side of the Unit and swing it open.

3. Back the ticket card stock all the way out of the transport
mechanism.

4. Dampen a foam swab in a 99% Isopropyl Alcohol cleaning
solution and apply it to the flat burn-line surface area of the print
head. This is the area that normally contacts the print head
platen. Move the swab back and forth across the print head until it
is clean.

5. Dampen a lint-free cloth with a 99% Isopropyl Alcohol cleaning
solution.

ADP 4100 Printer Installation and Operators Manual, April 2007 29

ADP 4100 Printer

Troubleshooting

6. Hold the cloth firmly against the print head platen while using your
other hand to turn the knurled knob in a clockwise direction. While
holding the dampened cloth against the platen, gradually move it
back and forth across the width of the platen, cleaning the entire
platen surface. The cloth will be discolored from the dust buildup
on the platen.

7. Dampen another area of the cloth and repeat this process until the
cloth no longer discolors. This will indicate the platen is clean.

8. After all cleaning is complete, plug the power cord back into the
rear of the Unit, toggle the power switch to I (ON), and reload the
ticket stock. Refer to the “Basic Unit Operation and Setup”
section.

When you cannot resolve your problem using the troubleshooting
techniques below, please contact the North American Help Desk
(NAHD) at 1-800-762-3490.

Basic Scenario Failure Analysis

Burst Failure

Bin C will not load stock

Encode Error

Not powering up properly or
stuck in self-test state

Scenario Possible Cause Corrective Action

Stock damaged and could not
burst/separate

Stock length setting does not match
stock being used

Burst positioning needs adjustment

Bin C is exposed to direct sunlight

Magnetic stock not loaded
Stock loaded in the wrong direction

Unit may have a hardware failure on
the transport mechanism PCBA
(Printed Circuit Board Assembly)

Remove stock from burst area and press
RESET key to continue

Check with CRS or Airline host and confirm
stock length setting

Check the burst position level for the selected
bin (in adjustments menu and listed on
configuration coupon). Adjust if appropriate
(more +pos number moves burst position
further into the transport mechanism, while a
more –neg number moves the burst position
towards the bin input.

Reposition the Unit so direct sunlight does not
shine into the Bin C input.

Load magnetic stock in selected bins
Load stock correctly (confirm magnetic stripe

location is against the inside wall)
Toggle the Unit’s power switch to the O (OFF)

position, wait a few seconds, then switch the
power switch to the I (ON) position and attempt
to power on again. If this does not correct the
problem, call the CRS or Airline host Help Desk
for assistance

30 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer

Scenario Possible Cause Corrective Action

Out of Forms

Not Operating
(display indicates Offline)

Not Operating
(display shows erroneous
characters)

Not Operating (display is
blank)

Not Printing
(ONLINE LED does not blink)

Not Printing on Ticket

Not printing in correct location
on the ticket

Print too Light or Dark

One of the selected bins is out of
stock.

The Unit is off-line or the ONLINE key
was pressed while Unit was on-line.

Paper jam in transport mechanism or
ticket stock path

Host system has detected an error
condition and has taken the Unit off­line

Unit may have a hardware failure on
the transport mechanism PCBA
(Printed Circuit Board Assembly)

The Unit is not powered on.

Power line fuse may have blown or
power line circuit breaker may have
tripped

The Unit’s power supply may have
malfunctioned, or a printed circuit
board may be defective

The host is not communicating with
the Unit

The required hardware connection has
not been made or has been
misconnected

Ticket stock loaded incorrectly
Using thermal transfer (TT) ticket

stock
Print misalignment

Print contrast level is too low for the
stock being used

Print head location misadjusted

Load more ticket stock in the selected bins

Press the ONLINE key to place the Unit on-line

Clear the jam and load the ticket stock correctly.
Refer to the “Clearing Ticket Jams” section for
instructions

Most errors can be corrected by pressing the
RESET key, or restarting the Unit. If problems
persist, call the CRS or Airline host Help Desk
for assistance

Toggle the Unit’s power switch to the O (OFF)
position, wait a few seconds, then switch the
power switch to the I (ON) position and attempt
to power on again. If this does not correct the
problem, call the CRS or Airline host Help Desk
for assistance

Toggle the Unit’s power switch to the I (ON)
position

Check the fuse or breaker protecting the power
line going to the wall outlet used to power the
Unit. If OK, verify the wall outlet has power

Make sure power cable(s) are plugged in and
completely seated on both the wall outlet and
Unit ends. If this does not correct the problem,
call the CRS or Airline host Help Desk for
assistance

Make sure that the host communication cable is
connected and completely seated on the Unit

Check the host connection and verify that the
correct one has been installed. For example, if
using the serial RS-232 ports, make sure the
cable is connected to COMM1 and not COMM2
by mistake (some versions may use COMM2)

Load ticket stock in correct orientation
Load direct thermal (DT) ticket stock

Call the CRS or Airline host help desk for
assistance

Check the print contrast level for the selected
bin (in adjustments menu and listed on
configuration coupon). Adjust if appropriate

Call the CRS or Airline Host help desk for
assistance.

Basic Alert Messages

A front panel alert message occurs when the Unit detects a condition
that must have user intervention. These messages may also be
indicated by an audible tone and/or an LED flashing. Exact message
will vary depending on specific customer firmware.

ADP 4100 Printer Installation and Operators Manual, April 2007 31

ADP 4100 Printer

Alert Message Possible Cause Corrective Action

“Jam - Burst Failure”
“Clear, Press Reset”

“Jam – Bin A, B, or C”

“Clear, Press Reset”

“Clear, Press Reset”

“Clear, Press Reset”

“Clear, Press Reset”

“Clear, Press Reset”

“Communications Error”

“Bin(s) A,B,C Empty”
“Please Load Stock”

“Remove Coupons”

“Empty, Press any key”

“SCN Read Error”

“Missing PECTAB x”

“PT:xx Element:##”

“PT: Bad Header”

“# Stock Type Err”
“Missing Stock Type #”

“Jam – Encoder”

“Jam – Print”

“Jam – Exit”

“Jam – Reval”

“Online”

“Exit Bin Full”

“Reject Bin Full”

“Bin(s) A,B,C”

“Online”

“Online”

“Online”

“Online”

The following table describes typical alert messages that may occur,
the possible causes, and corrective actions to be taken.

Unit failed to burst or separate a
ticket from the stock source

Unit failed to move stock from Bin (as
indicated) to the proper location for
the burst operation or when loading
new stock

Unit failed to move the stock through
the encoder to the print head path
area

Unit failed to move the stock past the
print head to the exit path area

Unit failed to move the stock out the
exit point and clear the exit sensor
and rollers

Unit failed to move the stock from the
revalidation slot/path into the encoder
path area

There is a mismatch between the
host and Unit’s communication
parameters (baud, parity, data bits)

Indicated bin(s) are empty

Indicates that the exit bin is full

Indicates that the reject bin is full

Unit could not read SCN (Stock
Control Number) from the stock
installed in the indicated bin(s)

Unit could not print tickets because
the referenced format table
(PECTAB) was not in memory

Unit detected an error in the PECTAB
sent to Unit. xx is the PECTAB name
and ## is the element that has the
error.

Unit detected an error in element 00
(header element) of the PECTAB
being downloaded to the Unit.

Unit detected a mismatch between

OR

the stock type being called out in the
ticketing data stream and what is
setup in the Unit’s configuration for
each bin.

Press RESET key. Unit will attempt to clear the
jam itself. If it cannot clear the jam you may
have to manually remove the stock

Press RESET key. Unit will attempt to clear the
jam itself. If it cannot clear the jam you may
have to manually remove the stock

Press RESET key. Unit will attempt to clear the
jam itself. If it cannot clear the jam you may
have to manually remove the stock

Press RESET key. Unit will attempt to clear the
jam itself. If it cannot clear the jam you may
have to manually remove the stock

Press RESET key. Unit will attempt to clear the
jam itself. If it cannot clear the jam you may
have to manually remove the stock

Press RESET key. Unit will attempt to clear the
jam itself. If it cannot clear the jam you may
have to manually remove the stock

Check the host CRS parameters against the
Unit’s communication settings. Call the CRS or
Airline host Help Desk for assistance

Check bin location(s) indicated and load stock
as necessary

Remove stock from exit bin/catcher

Remove stock from reject bin, then press any
key to clear message

Check stock in indicated bin(s) and verify it is
installed correctly

Verify stock in indicated bin(s) is actually pre­encoded SCN type

Load the appropriate PECTAB. Call the CRS or
Airline Host help desk for assistance. ERR6 will
be returned to the host CRS.

Call the CRS or Airline Host help desk for help.
ERR8 will be returned to the host CRS.

Call the CRS or Airline Host help desk for help.
ERR8 will be returned to the host CRS.

Call the CRS or Airline Host help desk for proper
stock setup based on the ticketing data stream
being utilized.

ERRS will be returned to the host CRS.

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ADP 4100 Printer

Alert Message Possible Cause Corrective Action

“TK: Missing Sep.”

“TK: Bad Elem ##”

“ERR7: Cpn Inserted”

“Online”

“Online”

“Online”

Unit detected an error in the ticketing
data stream. The Unit did not receive
a separator character in a location
that it expected.

Unit detected an error in the ticketing
data stream. ## indicates the
element number in the data where
the Unit detected the error.

Unit has received a ticketing data
stream while a coupon has been
inserted in the front revalidation slot.
The Unit cannot process tickets while
a coupon is inserted for revalidation.

Call the CRS or Airline Host help desk for help.
ERR3 will be returned to the host CRS.

Call the CRS or Airline Host help desk for help.
ERR3 will be returned to the host CRS.

Call the CRS or Airline Host help desk for help.
ERR7 will be returned to the host CRS.
Reset will eject coupon. ERR1 will be returned

to host CRS.

ADP 4100 Printer Installation and Operators Manual, April 2007 33

ADP 4100 Printer

Thermal Print Head Replacement

1. Power the Unit off. CAUTION: Print head is sensitive to ESD.

2. Unlock the door on the left side of the Unit and swing it open.

3. Remove the power cable from the rear of the print head.

4. Remove the interface cable from the rear of the print head. The
cable may have RTV applied to the cable, therefore take caution
when pulling the cable free from the print head.

5. Loosen the thumbscrew on the underside of the print head. Turn
the thumbscrew counter clockwise until it drops free from the print
head, but remains captive in the print head block.

6. Slide the print head assembly straight out from the transport
mechanism. Note how the guide on the print head assembly
matches the groove in the print head mounting block.

7. Slide the new print head assembly into the transport mechanism,
matching the print head assembly guide to the groove in the print
head mounting block.

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ADP 4100 Printer

8. Tighten the thumbscrew clockwise and secure the new print head
assembly. Torque thumbscrew to 10in-lbs.

9. Re-install the power and interface cables into the print head
assembly.

10. Power the Unit on. Take the Unit off-line by pressing the ONLINE
key.

11. Press the ENTER key and then either the UP or DOWN arrow
until the SERVICE MENU appears. Press the ENTER key.

12. Enter the service password (UP/DOWN arrows change the
individual character value and RIGHT/LEFT arrows move the
cursor side to side). Press the ENTER key.

13. Press the UP or DOWN arrow key until the MAINTENANCE menu
appears. Press the ENTER key.

14. Press the UP or DOWN arrow key until the NEW PRINTHEAD
option appears. Press the ENTER key. The Unit will read the
baseline resistance of the print head you just installed.

Once the baseline resistance has been read, press the ONLINE
key to put the Unit back into service.

ADP 4100 Printer Installation and Operators Manual, April 2007 35

ADP 4100 Printer

Customer/Technical Support

Return Authorization/Customer Service

To return a product to Unimark for repair or other assistance, please
be prepared with the following information before calling our Customer
Service department at [phone] (U.S. office) or [phone]­990 (International office):

y Customer name and telephone number
y Product model number or description
y Product serial number
y Description of failure
y Billing address
y Customer ship to address and method of shipping
y Repair option selection (Warranty, Flat Rate, Time and Materials

or Refurbishment)

Our Customer Service Specialist will be entering the information into
our system during your call to ensure quick and accurate handling of
your return. You will then be given a return authorization number.
Perform the following steps to complete the return process:

Prepare item for return to Unimark - Do NOT include accessories,
power cable or ancillary items unless directed otherwise by Customer
Service. DO NOT SHIP WITH TICKET STOCK INSTALLED!

Packaging – Use original packaging materials or equivalent. If not
available, Unimark can provide at a small cost.

36 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer

1. Place the Unit inside an appropriately sized plastic bag.

2. Place the Unit onto the bottom piece of foam pad.

3. Wrap the narrow foam pad sleeve around the base of the Unit,
enclosing the wheels of the Unit and consequently the bottom
foam pad.

4. Place the top piece of foam padding onto the Unit.

5. Slide the wrapped Unit into the open side of the shipping
container.

6. Enter the RA # on the packing list and on the outside of the
container in at least two locations for easy identification at
Unimark.

7. Shipping label to include return address as well as “ship to”.

8. Notify your “carrier of choice” for pick-up and delivery to Unimark.

Technical Support

As a purchaser or Unimark authorized third party maintainer of
Unimark products, you have the added benefit of technical assistance
in the installation, diagnosis and use of Unimark products.

Just call our toll free number (800 451-2926) and allow the auto­attendant to guide you to our technical support line. A technical
support analyst will assist you.

To better serve you, please have the product in question on-line and
ready to test prior to calling technical support. In addition, have the
following information available:

y Model Number/description
y Serial Number
y Failure message/code/description

Unimark operates two service support centers. Select the office
closest to you from the Unimark Contacts web page
(www.unimark.com). The customer support telephone number and e­mail address are listed for your convenience.

ADP 4100 Printer Installation and Operators Manual, April 2007 37

ADP 4100 Printer

Warranty Statement

Printer

Unimark warrants to Purchaser that under normal use and service,
the products (with the exception of the thermal print head, platen
roller, and belts) purchased hereunder shall be free from defects in
material and workmanship for a period of one year (365 days) from
the date of shipment by Unimark.

Expendable and/or consumable items or parts such as lamps, fuses,
labels, and ribbons are not covered under this warranty. This warranty
does not cover equipment or parts which have been misused, altered,
neglected, handled carelessly, or used for purposes other than those
for which they were manufactured. This warranty also does not cover
loss, damages resulting from accident, or damages resulting from
unauthorized service.

Thermal Print Head / Platen and Stock Drive Rollers / Belts /
Magnetic Read and Write Heads

This warranty is limited to a period of one year, (365 days) for high
wear items such as the platen and stock drive rollers, belts, and
magnetic read and write heads. In addition, the thermal print head
warranty is limited to a period of one year (365 days) or 1,000,000
linear inches of use, whichever comes first. This warranty does not
cover any components which have been misused, altered, neglected,
handled carelessly, or damaged due to improper cleaning or
unauthorized repairs.

Warranty Service Procedures

If a defect should occur during the warranty period, the defective Unit
shall be returned, freight and insurance prepaid, in the original
shipping containers, to Unimark at: 9910 Widmer Road, Lenexa, KS

66215. A Return Authorization (RA) number must be issued before

the product can be returned. To open an RA, please call the Unimark
Customer Service Department at [phone]. Please print your
RA number on the outside of the box and on the shipping document.
Include a contact name, action desired, a detailed description of the
problem(s), and examples when possible with the defective Unit.
Unimark shall not be responsible for any loss or damages incurred in
shipping. Any warranty work to be performed by Unimark shall be
subject to Unimark’s confirmation that such product meets Unimark
warranty. In the event of a defect covered by its warranty, Unimark will
return via ground transportation, the repaired or replaced product to
the Purchaser at Unimark’s cost.

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ADP 4100 Printer

With respect to a defect in hardware covered by the warranty, the
warranty shall continue in effect until the end of the original warranty
period, or for ninety (90) days after the repair or replacement,
whichever is later.

General Warranty Provisions

Unimark makes no warranty as to the design, capability, capacity or
suitability of any of its hardware, supplies, or software.

Software is licensed on an “as is” basis without warranty. Except and
to the extent expressly provided in this warranty and in lieu of all other
warranties, there are no warranties, expressed or implied, including,
but not limited to, any warranties of merchantability or fitness for a
particular purpose.

Purchaser shall be solely responsible for the selection, use, efficiency
and suitability of Unimark’s products.

Limitation of Liability

In no event shall Unimark be liable to the purchaser for any indirect,
special or consequential damages or lost profits arising out of or
relating to Unimark’s products, or the performance or a breach
thereof, even if Unimark has been advised of the possibility thereof.
Unimark’s liability, if any, to the purchaser or to the customer of the
purchaser hereunder shall in no event exceed the total amounts paid
to Unimark hereunder by the purchaser for a defective product.

In no event shall Unimark be liable to the purchaser for any damages
resulting from or related to any failure or delay of Unimark in the
delivery or installation of the computer hardware, supplies or software
or in the performance of any services.

Some states do not permit the exclusion of incidental or consequential
damages, and in those states the foregoing limitations may not apply.
The warranties herein give you specific legal rights, and you may
have other legal rights which vary from state to state.

ADP 4100 Printer Installation and Operators Manual, April 2007 39

ADP 4100 Printer

Alerts and LCD Messages

SCOPE

The following document details the XP LCD (Liquid Crystal Display) messages that may be encountered
during regular unit operation.

POWER UP SEQUENCE MESSAGES

RAM T e s t
Pattern 1

RAM T e s t P a s s e d

RAM T e s t
Pattern 2

C l e a r i n g S t o c k P a t h

FIRMWARE UPDATE MESSAGES

1. Set printer communication parameters to match host (PC) syst em.

2. Using the host application or a terminal emulator program load and send firmware or font/logo
library data files to the printer.

3. The printer will indicate file size remaining to be received, and then indicate “Programming” when
the file download is complete.

P D : x x x x R e m a i n i n g

4. Once the printer has finished programming it will either go back Online, or Reboot depending on the
type of data being programmed (firmware/code VS font/logo library). If the firmware application is
different enough from the current version, the unit will display a reset defaults message at the time
it reboots. Press ENTER key to continue.

O n l i n e

O n l i n e

R e a d y

O n l i n e

P r o g r a m m i n g

S e t u p L o s t , U s i n g
D e f a u l t s , P r e s s K e y

40 ADP 4100 Printer Installation and Operators Manual, April 2007

O n l i n e

R e a d y

ADP 4100 Printer

STOCK JAM MESSAGES

Jam at Exit: Stock did not pass through the exit sensor at the expect point or time in the print process.

Press RESET key to clear jam, and then the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Jam at Bin A: Stock did not pull from Bin A to the burst sensor at the expect point or time in the process.
Press RESET key to clear jam, and then the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Jam at Bin B: Stock did not pull from Bin B to the burst sensor at the expect point or time in the process.

O f f l i n e

O f f l i n e

J a m – E x i t
C l e a r , P r e s s R e s e t

J a m – B i n A
C l e a r , P r e s s R e s e t

Press RESET key to clear jam, and then the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Jam at Bin C: Stock did not pull from Bin C to the burst sensor at the expect point or time in the process.
Press RESET key to clear jam, and then the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Jam at Encoder: Stock did not pass through the encoder at the expect point or time in the print process.
Press RESET key to clear jam, and then the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

O f f l i n e

O f f l i n e

O f f l i n e

J a m – B i n B
C l e a r , P r e s s R e s e t

J a m – B i n C
C l e a r , P r e s s R e s e t

J a m – E n c o d e r
C l e a r , P r e s s R e s e t

ADP 4100 Printer Installation and Operators Manual, April 2007 41

ADP 4100 Printer

Jam at Print Head: Stock did not pass over the print head at the expect point or time in the print process.
Press RESET key to clear jam, and then the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Load Error at Bin A: Stock is detected at input, but the unit was unable to pull stock into the transport
mechanism from Bin A.

Removing stock completely from Bin A and reinserting should clear the error. Pressing the ONLINE key
should place the unit back in operation. Messages may vary slightly depending on the sequence of
events.

O f f l i n e

J a m – P r i n t
C l e a r , P r e s s R e s e t

B i n ( s ) A E m p t y
P l e a s e L o a d S t o c k

Load Error at Bin B: Stock is detected at input, but the unit was unable to pull stock into the transport
mechanism from Bin B.

Removing stock completely from Bin B and reinserting should clear the error. Pressing the ONLINE key
should place the unit back in operation. Messages may vary slightly depending on the sequence of
events.

B i n ( s ) B E m p t y
P l e a s e L o a d S t o c k

Load Error at Bin C: Stock is detected at input, but the unit was unable to pull stock into the transport
mechanism from Bin C.

Removing stock completely from Bin C and reinserting should clear the error. Pressing the ONLINE key
should place the unit back in operation. Messages may vary slightly depending on the sequence of
events.

B i n ( s ) C E m p t y
P l e a s e L o a d S t o c k

B i n A L o a d E r r o r
R e m o v e & R e l o a d

B i n B L o a d E r r o r
R e m o v e & R e l o a d

B i n C L o a d E r r o r
R e m o v e & R e l o a d

Jam at Burster: Stock was not properly separated at the perforation by the burster module.
Manually back the stock out of the unit using the Encode and Bin path knurl knobs. Press RESET key

and reload stock, then press the ONLINE key to place the unit back in operation.

O f f l i n e

P r e s s E n t e r f o r M e n

42 ADP 4100 Printer Installation and Operators Manual, April 2007

J a m – B u r s t F a i l
C l e a r , P r e s s R e s e t

ADP 4100 Printer

STOCK STATUS MESSAGES

Bin A Empty (While processing Tickets): Stock ran out in Bin A while processing tickets.

Manually load more stock into Bin A and press the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Bin B Empty (While processing Tickets): Stock ran out in Bin B while processing tickets.
Manually load more stock into Bin B and press the ONLINE key to place the unit back in operation.

P r e s s E n t e r f o r M e n

Bin C Empty (While processing Tickets): Stock ran out in Bin C while processing tickets.
Manually load more stock into Bin C and press the ONLINE key to place the unit back in operation.

O f f l i n e

O f f l i n e

B i n ( s ) A E m p t y
P l e a s e L o a d S t o c k

B i n ( s ) B E m p t y
P l e a s e L o a d S t o c k

P r e s s E n t e r f o r M e n

Bin A Empty (Stock manually removed typically): Stock removed from Bin A.
Manually load more stock into Bin A; unit already in the Online state and ready for operation.

Bin B Empty (Stock manually removed typically): Stock removed from Bin B.
Manually load more stock into Bin B; unit already in the Online state and ready for operation.

Bin C Empty (Stock manually removed typically): Stock removed from Bin C.
Manually load more stock into Bin C; unit already in the Online state and ready for operation.

O f f l i n e

O n l i n e

R e a d y

O n l i n e

R e a d y

O n l i n e

R e a d y

B i n ( s ) C E m p t y
P l e a s e L o a d S t o c k

B i n ( s ) A E m p t y
P l e a s e L o a d S t o c k

B i n ( s ) B E m p t y
P l e a s e L o a d S t o c k

B i n ( s ) C E m p t y
P l e a s e L o a d S t o c k

ADP 4100 Printer Installation and Operators Manual, April 2007 43

ADP 4100 Printer

Bin A, B, & C Empty (Stock manually removed typically): Stock removed from Bins A, B, & C.
Manually load more stock into Bins A, B & C; unit already in the Online state and ready for operation.

Reject Bin Full: Reject coupon counter has been exceeded since last reset. Remove coupons from
reject bin.

Pressing RESET and then the ONLINE key will clear the message and place the unit back in operation.

P r e s s E n t e r f o r M e n

Exit Bin Full: Exit bin has filled and tripped the stock level sensor.
Manually remove coupons to continue print process; press ONLINE key if necessary.

P r e s s E n t e r f o r M e n

O n l i n e

R e a d y

O f f l i n e

O f f l i n e

B i n ( s ) A , B , C E m p t y
P l e a s e L o a d S t o c k

R e j e c t B i n F u l l
E m p t y , P r e s s A n y K

E x i t B i n F u l l
R e m o v e C o u p o n s

AEA ERROR MESSAGES

Illogical Command: Unit received an illogical command, or a non-AEA (non-supported) command.

Usually no error message is displayed, so normally the display will remain “Online/Ready”. However, if
an error message is displayed it will be in the form of “Online/ERR: cc” where cc represents the
unrecognized command.

Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving
any valid AEA command.

O n l i n e

Error in Ticket Print message: Unit detected an error in the ticket print message.
Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving

any valid AEA command.

R e a d y

O n l i n e

OR

E R R 2 : c c

Where ## = the Ticket Print message element where
the error was detected

O n l i n e

TK: B a d E l e m # #

44 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer

Print/Encode Error: Unit has detected an error during the print and/or encode process.
Usually no error message is displayed (except for jams), so normally the display will remain

“Online/Ready”. However, if an error message is displayed it will be in the form of “Online/Print / Encode
Error.

Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving
any valid AEA command.

O n l i n e

Missing PECTAB: Ticket print message is referencing a PECTAB not currently in memory.
Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving

any valid AEA command.

R e a d y

O n l i n e

M i s s i n g P e c t a b # # #

OR

P r i n t / E n c o d e E r r o r

Where #### = the PECTAB name being referenced
by the ticket data stream

O n l i n e

Check-In or Revalidation in progress: Unit could not process the incoming command (like PECTAB
load) because it is currently performing a Check-In or Revalidation process.

Consult CRS (Host Provider) for dealing with this condition.

O n l i n e

E R R 7 : C p n I n s e r t e d

Error in PECTAB load: Unit detected a format error in the PECTAB load.
Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving

any valid AEA command.

O n l i n e

P T : # # # # E l e m e n t : c c

PECTAB exceeds memory: There is not enough memory available in the unit to load the incoming data
such as a PECTAB, Logo, or Template.

Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving
any valid AEA command.

Where #### = the name of the PECTAB and
cc = the PECTAB element where the error was
detected

O n l i n e

Where #### = the name of the PECTAB

P T : # # # # N o M e m o r y

ADP 4100 Printer Installation and Operators Manual, April 2007 45

ADP 4100 Printer

LOGO exceeds memory: There is not enough memory available in the unit to load the incoming data
such as a PECTAB, Logo, or Template.

Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving
any valid AEA command.

O n l i n e

L T : # # N o M e m o r y

TEMPLATE exceeds memory: There is not enough memory available in the unit to load the incoming
data such as a PECTAB, Logo, or Template.

Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving
any valid AEA command.

O n l i n e

T T : # # N o M e m o r y

Incorrect stock type selected: Ticket print message is requesting a stock type not currently configured
for the selected Bin.

Press the ONLINE key twice to manually clear the message; or message will be cleared upon receiving
any valid AEA command.

O n l i n e

M i s s i n g S t o c k T y p e

Where ## = the LOGO ID

Where ## = the TEMPLATE ID

Where # = the Stock Type selected in the Ticket
print message

46 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer

NORMAL PROCESS MESSAGES

PECTAB LOADING: Typical message sequence when a PECTAB is loaded into memory.

P e c t a b # # # # S a v e d

LOGO LOADING: Typical message sequence when a LOGO is loaded into memory.

L o g o # # S a v e d

TEMPLATE LOADING: Typical message sequence when a TEMPLATE is loaded into memory.

T e m p l a t e # # S a v e d

O n l i n e

O n l i n e

O n l i n e

O n l i n e

R e a d y

O n l i n e

R e a d y

O n l i n e

R e a d y

COMMUNICATION ERROR MESSAGES

COMM ERROR: Typical message sequence when the unit detects that the incoming data does not match

its communication parameters such as baud rate, parity, or data/stop bit size.

C o m m u n i c a t i o n s E r r o

O n l i n e

O n l i n e

R e a d y

ADP 4100 Printer Installation and Operators Manual, April 2007 47

ADP 4100 Printer

48 ADP 4100 Printer Installation and Operators Manual, April 2007