Gtech Accutherm Service Manual

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.

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 digits 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

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you believe your manual is out of date, contact GTECH Learning Technology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 [e-mail]

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 [e-mail] and it will be forwarded.

RH-ii GTECH Technical Training and Support Services

Table of Contents

Revision History

Chapter 1

Introduction

Overview of Accutherm Ultra....................................1-2

Mechanical Specifications..........................................1-3

Environmental Specifications ....................................1-4

Electrical Specification ..............................................1-4

Standard Printer Features ...........................................1-5

Mechanism.................................................................1-7

Print Head ................................................................1-7

Paper Motion............................................................1-8

Cutter .......................................................................1-8

Sensors.....................................................................1-8

Power Supply...........................................................1-8

Control Electronics.....................................................1-9

Overview..................................................................1-9

Processor and Memory ............................................1-9

Print Head Interface...............................................1-10

Motor Controllers ..................................................1-10

Sensor Interface .....................................................1-11

Power Supply Circuitry .........................................1-11

Communications Interface.....................................1-12

Chapter 2

Installation

Introduction................................................................2-1

Installation Instructions..............................................2-2

Loading Paper ............................................................2-6

Chapter 3

Configuration

Chapter 4

Operation

Chapter 5

Diagnostics

Printer Self Test..........................................................5-2

Self-Test Mode.........................................................5-3

Normal Operation Errors .........................................5-4

Extended Diagnostics.................................................5-6

Chapter 6

Download

AccuTherm® Ultra Firmware Install Procedure........6-2

Chapter 7

Disassembly

Warranty Information.................................................7-1

Required Tools...........................................................7-2

Disconnect the Power Cable ......................................7-2

Disconnect the USB Communications Cable.............7-3

Remove the Cover Assembly.....................................7-4

Remove the Power Supply from the Base

Assembly...................................................................7-7

Remove the Printer Mechanism Assembly from

the Base Assembly....................................................7-8

Remove the Main Controller PCB Assembly

from the Printer Mechanism Assembly ....................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..............................................................7-14

Remove Stacker Guide Assembly from the

Printer Mechanism Assembly.................................7-18

Remove Platen from the Knife/Stacker Assembly...7-20
Remove Fixed Blade from the Knife/Stacker

Assembly.................................................................7-21

Chapter 8

Troubleshooting

Introduction to Troubleshooting.................................8-1

Troubleshooting Steps for FST’s ...............................8-2

Troubleshooting Steps for RLT’s...............................8-5

Loading Paper ............................................................8-9

Clearing a Paper Jam................................................8-11

Chapter 9

Preventive Maintenance

General Cleaning........................................................9-1

Cleaning the Print Head .............................................9-2

Cleaning the Top-of-Form/ Paper Low Sensor..........9-3

Cleaning the Jam Detection Sensor............................9-4

Cleaning the Platen.....................................................9-4

Service Manual for the Accutherm Ultra Printer TOC-iii

Appendix A

Handling Precautions

ESD HANDLING .....................................................A-ii

What is ESD?..........................................................A-ii

Becoming “Static Safe” ..........................................A-ii

ESD-Induced Failure Modes..................................A-iii

Typical Symptoms of ESD Damage......................A-iii

Common False Assumptions Concerning ESD.....A-iii

ESD Precautions Checklist....................................A-iv

GTECH Manufacturing Specification ..................A-vii

PACKAGING ........................................................A-viii

General Packaging Procedures ............................A-viii

Appendix B

Diagrams

Appendix C

Spare Parts and Tools

In-Warranty Service.................................................C-iii

Post-Warranty Service..............................................C-iv

Ordering Spare Parts from Assembly Drawings......C-vi

Printer Assembly.....................................................C-vii

Assembly-Base (16-2054-01E)................................C-ix

Assembly-Paper Bucket (16-2056-01E) ................... C-x

Assembly - Mid-Frame (16-2055-01E)....................C-xi

Assembly-Paper Cover............................................C-xii

Assembly-Lower Mechanism ................................C-xiii

Assembly-Knife/Slacker (15-3737-01E)................C-xvi

Assembly-Paper Path (15-3746-01E).....................C-xix

Tools List.................................................................C-xx

TOC-iv GTECH Technical Training and Support Services

Appendix D

Product Safety & Approvals

Safety Instructions......................................................D-i

Radio Interference.....................................................D-ii

FCC.........................................................................D-ii

Industry Canada......................................................D-ii

European Union......................................................D-ii

Telecom....................................................................D-iii

FCC........................................................................D-iii

Industry Canada.....................................................D-iv

Replaceable Batteries................................................D-v

Wireless Device Option ............................................D-v

Appendix E

Acronyms & Abbreviations

Service Manual for the Accutherm Ultra Printer TOC-v

Introduction

The Accutherm® Ultra Printer is a stand-alone thermal printer designed for use
with GTECH Lottery Terminals for printing lottery receipts.

1

Service Manual for the Accutherm Ultra Printer 1-1

Overview of Accutherm Ultra

• 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 > 75 tickets

• User Flash Memory

• 1M bytes User Graphics Memory

• 128K bytes User Data Memory

• Font/System Flash Memory:

• 2M bytes for Fonts and System files.

• Manual configuration mode

•

Self test diagnostics

• 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

1-2 GTECH Technical Training and Support Services

Mechanical Specifications

6.5 “ (165.1 mm)

13.26” (336.8 mm)

8.81” (223.77 mm)

• Height: 8.81" (223.77 mm)

• Width: 6.5" (165.1 mm)

• Depth: 13.26" (336.80 mm)

Introduction

Service Manual for the Accutherm Ultra Printer 1-3

• Weight: Approximately 4.9 lbs, 2.22 kg.

• Inter

• Printer Type: Fixed 80 mm.linear therma

face Type: USB

l head.

Environmental Specifications

• Operating Temperature Range:5°C ~ 50°C (41°F ~ 122°F)

• Shipping/Storage Temperat ure Range:-10°C ~ 50°C (14°F ~ 122°F)

• Operating Humidity Range:10% ~ 90% @ 40°C (104°F) non­condensing only

• Shipp

ing/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 is equipped with a universal input power supply that is
designed to operate worldwide without modification.

Supply
Supply Voltage
Rating (VAC)

100-240 90-264 47-63 20 watts

Voltage Range

(VAC)

Frequency
(Hz) Power Consumption

1-4 GTECH Technical Training and Support Services

Standard Printer Features

Standard features of the Accutherm® Ultra printer include:

• High-speed (10 inches per second) thermal receipt printing

• Black dot - Top of Form and Paper Low Sensing capabilities

• Jam Detection

• Multiple barcode printing capabilities

•2 of 5

• EAN-8

• EAN-13

•UPC-A

•3 of 9

•UPC-E

•Codabar

Introduction

• Code 128

• Code 93

• PDF417 2D Stacked

•Data Matrix

• RSS GS1

• Print-Line Width of 640 dots @ 8 dots/mm centered on 3.25 in (82.5 mm)
Paper

•

Up to a 7.5 in (190 mm) Diameter Paper Roll

• Long-life auto ticket cutter

• Standard variable length stacking module capable of handling from 2.75 to
10 inch (70 to 254 mm) length tickets

• Ticket stacking capability (greater than 75 tickets)

• Modular printer design for easy servicing

• Internal Auto-Ranging (90-264 VAC) Power Supply

• Power and Error LED Indicator

• User Flash Memory

• 1M bytes User Graphics Memory

• Font/System Flash Memory:

Service Manual for the Accutherm Ultra Printer 1-5

• 128K bytes User Data Memory

• 2M bytes for Fonts and System files.

• Manual configuration mode

• Self test diagnostics

• Loadable Enhanced Diagnostics

• USB interface built into main controller PCB

1-6 GTECH Technical Training and Support Services

Mechanism

Top C ov e r

Paper Feed

Motor

Dual Step Motor

Driver

Allegro A 3988

(1000ma)

Step Motor Driver

Allegro A3 983

(400ma)

Knife Motor

Stack er Moto r

MCF5353
Processor

(BGA)

RAM

4Mb x 1 6

(BGA)

FLA SH

2Mb x 16

(BGA)

FPGA
(BGA)

Print
Head

Power Supply
and So ft Start

Address/Data Bus

+

Clock

Oscillator

Cover

EEPROM

RS2 32
Driver

+24 VDC

from

internal

power

brick

+3.3V
+1.5V

Paper

Cut

Home

TOF JAM

On board

sensors

(Interruptive)

Off board sensors

(reflective)

TOF Cur r e n t

Adjust

F
P
G

A

I
/

O

+

Print Head

Buffer

Print Head

Voltage Contro l

LED

Test

Switch

Feed

Switch

On Board

Operator
Inte rface

LED LED

USB

Protection

Beeper

USB

Clock

Debug Header

Program Header

Not

Populated

+1.5V

This section explains the Accutherm Ultra’s theory of operations.

Introduction

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”). 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).

Figure 1-1. Printer Block Diagram

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 b lade 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 activate
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 . Th e 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

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 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:

Introduction

• Status LEDs

• USB Communications

• Print Head Data and Timing

• Print Head Temperature and Voltage monitoring

• Programming the FPGA

The remaining printer functions are

• Stacker motor control

• Cutter motor control

• Paper feed motor control

• Thermal print head loading and protection

controlled though the FPGA including:

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. 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 . S tepper 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 ¼ 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 micro­stepping motor driver with translator. The driv er i s 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

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:

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.

Introduction

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 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 Schmitt 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
converter circuit

Processor I/O,USB
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
regulator resident in the MCF5253

1.5 VDC Derived from 3.3V using a TI
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.

Processor core

FPGA core

1-12 GTECH Technical Training and Support Services

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.

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

Accutherm® Ultra
Printer

The following steps describe the procedure for installing the Accutherm Ultra
printer:

1. Remove the printer and cables from its pac

kaging.

Figure 2-1. Remove Accutherm Ultra from Packaging

2-2 GTECH Technical Training and Support Services

Installation

Strain Relief

2. Move the Strain Relief lever (Figure 2-2) to the left and then plug the power
cord into the power connector, located at t

he rear of the printer.

Figure 2-2. Plug Power Cord into P

rinter

Service Manual for the Accutherm Ultra Printer 2-3

3. Plug the printer’s USB data cable into the Main Controller PCB, located on

Main Controller PCB USB
connection

Note how the USB cable routes
through the plastic guides on the
bottom of the printer.

the bottom of the Accutherm Ultra (Figure 2-3).

Figure 2-3. Plug USB Cable into Printer

2-4 GTECH Technical Training and Support Services

Installation

USB

USB

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 GT1 100 connections.

Figure 2-4. GT1200 USB Connection

5. Install a paper roll into the printer (see page 2-6 for paper loading
instructions).

6. Complete all required connections for

7. Apply power to both pieces of equipment.

Service Manual for the Accutherm Ultra Printer 2-5

Figure 2-5. GT1100 USB Connections

the terminal.

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
position.

2. T ear of f the first layer of the paper roll. Place the paper roll into the printer , so
that the paper unwinds from the bottom (front).

the paper cover to the open

3. Leave a few inches of paper outside of the printer.

2-6 GTECH Technical Training and Support Services