II User's Guide Manual Part No. 107187 Rev.
Safety and Agency Compliance This Class A device complies with part 15 of the FCC rules and Canadian ICES-003 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. NOTICE 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.
When connecting the printer to a host computer system, always use shielded interface cables. The use of non-shielded interface cables can violate the FCC emissions limits for a Class A computing device. Do not leave unterminated interface cables connected to the printer. WARNING Any alteration or modification to this equipment may cause non-compliance to: UL safety standard 1950 CSA safety standard C22.2 No.
WARNING The operator must disconnect the printer from the AC power supply before performing any corrective action procedure that requires reaching into the printer. The printhead gets hot during use. Wait until the printhead is cool before handling the printhead. Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.
ACHTUNG Vor der Durchführung korrektiver Maßnahmen, die ein Hineingreifen in den Drucker erforderlich machen, muß das Netzkabel für den Drucker abgezogen werden. Der Druckkopf heizt sich während des Betriebs auf. Vor dem Berühren des Druckkopfs warten, bis er abgekühlt ist.
ADVERTENCIA Antes de que el operario realice cualquier reparación interna de la impresora, deberá desconectarla del suministro de alimentación de CA. La cabeza de la impresora se calienta durante su uso. Antes de tocarla deberá esperar a que ésta se enfríe. Cualquier cambio o modificación que se realice en esta unidad sin la aprobación expresa en conformidad con la parte responsable, puede terminar los derechos del usuario para operar el equipo.
TABLE OF CONTENTS Safety and Agency Compliance ...................................................................... i SECTION 1 — INSTALLATION AND START UP...............................1 1.1 Introduction...............................................................................................1 1.2 Printer Specifications ...............................................................................2 1.3 Printer Parts....................................................................................
TABLE OF FIGURES Figure 1-1. External Printer Parts (Front View) .................................................5 Figure 1-2. External Printer Parts (Back View)..................................................6 Figure 1-3. Internal Printer Parts (Side View)....................................................7 Figure 1-4. Output and Reject Bins (Front View)...............................................8 Figure 1-5. Loading Coupons into BIN 2 (acceptable methods).......................10 Figure 1-6.
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Section 1 Installation and Start Up 1.1 Introduction The Journey II Desktop ATB printer combines rugged durability and high performance at a low cost, for ATB direct thermal ticketing applications at travel agencies and satellite ticket printing (STP) locations. Communication protocols and AEA emulation provide compatibility for existing applications without host system code modifications. Multiple PECTABS may be permanently stored in FLASH memory. A companion itinerary printer serial port is provided.
1.
DOCUMENT HANDLING • Burst Fan-fold Stock • Secure BIN 1 Stock Capacity of 500 Coupons • External BIN 2 Stock Capacity of 1,000 coupons • Secure Output Bin holds up to 200 Coupons, with Reject Bin that holds up to 50 coupons (secured) • Easy Access for Cleaning COMMUNICATIONS • COM 1 Port: RS-232C • COM 2 Port: RS-232C (or optional parallel) • Baud Rates: 1200, 2400, 4800, 9600, 14400, 19200, 38400, 57600 • Full Hardware and Software Handshaking • Optional DTR control on Pin 11 • Multipl
LANGUAGES • Standard Keypad Display Options include English, German, French, Italian, Spanish, and Portuguese. PROGRAMMING • AEA ’94 / ’95 • Minimum of 8 PECTABS in Non-Volatile Memory (NVM). • Re-programming via a standard 3.5” diskette or through flash memory POWER • Auto Voltage Select • 97V to 132V, 57Hz to 63Hz • 195V to 264V, 47Hz to 53Hz RELIABILITY • Duty Cycle: 70 Coupons per Day • MTBF: 25,000 hrs @ Rated Duty Cycle • MTTR: 15 Minutes PHYSICAL • Size: 27.5 in.(L) x 10.5 in.
1.3 Printer Parts The following illustrations highlight the major printer parts. Please become familiar with these parts before continuing with installation and setup. KEYPAD BIN 1 ACCESS DOOR DISPLAY DISKETTE DRIVE OUTPUT/REJECT BIN DOOR KEY LOCKS Figure 1-1.
BIN 1 ACCESS DOOR FAN COM 2 (OUTPUT) PORT BIN 2 INPUT SLOT BIN 2 INSTRUCTION LABEL COM 1 (INPUT) PORT COVER LOCK (on side) POWER CORD CONNECTION POWER SWITCH (on side) Figure 1-2.
ZONE 1 ACCESS DOOR AND LATCH PRINTHEAD BIN 1 ACCESS DOOR ZONE 3 ACCESS DOOR AND LATCH ZONE 2 ACCESS DOOR BIN 2 INPUT SLOT (on back) OUTPUT BIN DOOR REJECT BIN LEVER BIN 1 OUTPUT BIN STOCK LOAD KNOB A REJECT BIN (located inside the OUTPUT BIN) BIN 1 INPUT SLOT TRANSPORT KNOB B Figure 1-3.
REJECT BIN (drops down when lever is depressed) SECURITY LOCK FOR OUTPUT AND REJECT BINS REJECT BIN LEVER OUTPUT BIN OUTPUT BIN DOOR (shown open) Figure 1-4.
1.4 Quick Start-Up Procedure The following abbreviated installation and start-up procedures are provided for users already familiar with the Journey II Desktop product. If you are not familiar with this printer, follow all of the instructions in Chapter 1 for setting up the printer. 1. Unpack the printer using adequate assistance. Save the packing materials. 2. Choose a location for the printer with the following considerations: • A level surface capable of adequately supporting printer weight.
14. To load BIN 2, place a maximum of 1,000 coupons at the back of the printer, directly behind and aligned with the BIN 2 INPUT SLOT. Orient the coupons as shown on the BIN 2 label. 15. Insert the staple tab end or leading edge of the coupon squarely into the document slot (with the print surface facing up). The BIN 2 INPUT SLOT has a sensor that automatically detects and loads the document. (Both Bins should now be loaded with coupon stock.) 16. Place the printer Off line by pressing the ON LINE/MENU key.
1.5 Unpack the Printer Remove the following from the shipping carton: Always use adequate lifting assistance when removing the printer from the box. U.S.
The printer weighs 55 pounds (25 kg) and should not be moved without adequate assistance. To move the printer, grip the underside of the metal base. Printer Size: • • • Depth: 27.5 inches (698 mm) Width: 10.5 inches (267 mm) Height: 14.8 inches (376 mm) Additional space and location considerations are as follows. Location: 1.
VORSICHT DIE ANSAUGÖFFNUNG VORN UND DIE ABLUFTÖFFNUNG HINTEN NICHT BLOCKIEREN, UM EIN ÜBERHITZEN DES DRUCKERS ZU VERMEIDEN. ATTENZIONE NON OSTRUIRE LA PRESA D’ARIA ANTERIORE O L’APERTURA DI SFOGO POSTERIORE PER EVITARE L’ACCUMULO DI CALORE ALL’INTERNO DELLA STAMPANTE. PRECAUCIÓN PARA EVITAR LA ACUMULACIÓN DE CALOR EN LA IMPRESORA, NO OBSTRUIR LA VÁLVULA DE ADMISIÓN DELANTERA O LA VÁLVULA DE ESCAPE TRASERA.
Avoid the following: • Direct sunlight or excessively illuminated areas. • Direct placement in front of air conditioning or heating vents. • Extreme high or low temperatures. • Exposure to excessive dirt or dust. • Exposure to vibration or mechanical shock. • Excessive humidity or condensation. TOP CLEARANCE OF 15 INCHES (380 mm) LEFT SIDE CLEARANCE OF 3 INCHES (80 mm) 3 INCHES TO 9 INCHES (80 TO 230 mm) REQUIRED FOR REAR CLEARANCE, DEPENDING ON COUPON STOCK PLACEMENT. Figure 1-6.
1.7 Connect the Host and Itinerary RS-232 Cables Two RS-232 serial interfaces are provided on the Journey II Desktop unit. COM 1 (INPUT) — the bottom connector — is used to connect to the host or modem in STP environments. COM 2 (OUTPUT) — the top connector — is provided to connect an itinerary printer in STP environments. CAUTION BEFORE CONNECTING THE CABLE, MAKE CERTAIN BOTH THE HOST COMPUTER AND THE PRINTER ARE POWERED OFF. THE USE OF CABLES LONGER THAN 15 FEET (4.
Connecting COM1 (Input) 1. 2. 3. Connect your host or modem RS-232 cable to the port labeled COM1 (INPUT) — bottom connector — on the back of the printer. Secure the connector with interface cable screws. To automatically set the communication features, select the correct Profile for your environment with the keypad. If changes are needed, refer to the section on Features and Profiles.
Refer to the documentation for your computer to determine the type of shielded interface cable needed and any unique pin-out configuration that may be required.
1.8 Install the Power Cord The printer’s power supply is a universal input supply capable of operating with any standard domestic and international AC power system. For user safety and correct printer operation, the printer must be connected to a properly grounded three-pin receptacle as specified by local codes and ordinances. Installing the power cord: 1. Set the POWER SWITCH located on the left side of the printer to OFF (0 position). CAUTION CONNECT THIS EQUIPMENT TO A GROUNDED POWER RECEPTACLE ONLY.
PRECAUCIÓN ESTE EQUIPO DEBERÁ SER CONECTADO ÚNICAMENTE A UN SUMINISTRO DE ALIMENTACIÓN PUESTO A TIERRA. NO CORTAR EL CONECTADOR A TIERRA DEL ENCHUFE . SI LA IMPRESORA NO ES DEBIDAMENTE CONECTADA A TIERRA PUEDE PROVOCAR UNA DESCARGA ELÉCTRICA PELIGROSA. ATTENZIONE COLLEGARE QUESTO APPARECCHIO SOLAMENTE A UNA PRESA DOTATA DI MESSA A TERRA. NON TAGLIARE IL POLO DI MESSA A TERRA DELLA SPINA. LA MANCATA MESSA A TERRA DI QUESTA STAMPANTE PUÒ RISULTARE NEL RISCHIO DI SCOSSA ELETTRICA. 2.
POWER SUPPLY CORD SELECTION Use the following information to choose the proper power cord for your unit. COUNTRY/VOLTAGE PLUG DESC. RECEPTACLE DESC. U.S.A./115V NEMA 5-15P IEC CEE-22 female 18 AWG minimum U.S.A.
1.9 Loading and Removing Coupons The Journey II Desktop supports magnetic and non-magnetic ATB direct thermal, fan-folded continuous stock. Following are guidelines for the recommended coupon types and sizes for use with this printer. Coupon Types: The Journey II accepts both 7 3/8 and 8 inch (187.3 mm or 203.20 mm), magnetic and non-magnetic ATB stock. Only high quality stock conforming to IATA 722e, ATA 20.201 specifications or equivalent should be used.
11. Press the RESET/CLEAN key to recover from a stock empty error message when instructed by the LCD. Failure to fully close and lock the BIN 1 ACCESS DOOR may result in the printer reporting a cover open condition. To Load Stock (BIN 2): 1. Leave the printer powered on. 2. Place a maximum of 1,000 coupons at the back of the printer, directly behind and aligned with the BIN 2 INPUT SLOT. Orient the coupons as shown on the BIN 2 label (with the side to be printed facing up). 3.
1.10 Printer Self-Test This test is used to verify printer operation. Coupon stock must be loaded in the printer to run a self-test. To start the test: 1. Verify coupons are properly loaded. (if required, refer to the procedures for loading coupons.) 2. Power up printer by moving the POWER SWITCH to the ON (1) position. 3. Wait for the power up self test to complete. The top line of the keypad display should show ‘On line:’ when ready. 4.
Section 2 Keypad Operation 2.1 Keypad Configuration The Journey II Desktop user interface consists of a 12-button keypad; a 2 line by 24 character wide, back-lit, Liquid Crystal Display (LCD); and one green Light Emitting Diode (LED) indicator. The user interface is used to display the current status of the printer, configure the printer, recover from error conditions, perform cleaning functions, and update the printer’s internal software.
2.2 Placing the Printer On and Off line The printer alternates between On line and Off line modes each time the ON LINE/MENU key is pressed. The On or Off line status of the printer is displayed on the top line of the keypad display. While the printer is On line, the LED is on and all keys (other than the ON LINE/MENU key) are inactive. During data transmission, the LED blinks — corresponding to the transaction data blocks received. This status is used during normal printer operation.
2.3 Using the Reset/Clean Key The RESET/CLEAN key is used for resetting error conditions and cleaning internal surfaces (see Fig. 2-3). Conditions for using this key are described below. Resetting Error Conditions Press the RESET/CLEAN key to reset any condition that the printer indicates as an error. Do not press the ON LINE/MENU key before resetting the error condition (the error does not clear in the Off line mode).
2.4 Updating the Printer Software A 3.5 inch front mounted floppy disk drive is used for internal printer software upgrades (firmware upgrades). The data format used is DOS compatible. To update the firmware: 1. 2. 3. 4. Insert the software upgrade disk. Press the ON LINE/MENU key to place the printer Off line. Press the SOFTWARE LOAD key. The following message appears: S o f P r t e s w a r s e L o a d E N T E R t F r o o m B e g i D i s k n 5.
2.5 Ready/Receive LED The printer is equipped with one green LED that indicates the printer status as listed in the following table. Ready/Receive LED On Off Rapid Blinking Slow Blinking Printer Status The printer is On line and ready to receive data. The printer is Off line. The printer is powered Off. Data is being received on the interface. An error has occurred. Refer to the LCD for information. READY/RECEIVE LED Figure 2-4.
2.6 LCD Display The printer signals various messages through the LCD display.
2.7 Key Functions ONLINE/MENU Pressing this key alternates the printer between On line and Off line (Menu mode, where all other keys become active). FEATURE çè These keys are used to select a specific feature. Press the FEATURE ç key to move the display up the features list. Press the FEATURE è key to move the display down the features list. SETTINGS é ê These keys are used to change the value of a specific feature. Press the SETTINGS é key to increase the value of a feature.
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Section 3 Loading Coupon Stock 3.1 Recommended Types and Sizes The Journey II Desktop supports magnetic and non-magnetic ATB direct thermal, fan-folded, continuous stock. Following are guidelines for recommended coupon types and sizes for use with the printer. Coupon Types: Two sizes: 7 3/8 or 8 inch (187.33 or 203.20mm) magnetic and non-magnetic ATB stock. Only high quality stock conforming to IATA 722e, ATA 20.201 specifications or equivalent should be used.
3.2 Coupon Path The fanfold coupons are separated at the burster station for BIN 1, and by the cutter station for BIN 2. If the printer has magnetics and stock control number (SCN) enabled, the coupon is then fed through the magnetic station for the SCN read, magnetic encode and verify. Coupons are then printed, exit the print station, and are stacked in sequential order in the OUTPUT BIN. BURSTER STATION COUPON PATH CUTTER STATION Top View (With Access Door removed) BIN 2 INPUT SLOT Figure 3-1.
3.3 Loading and Removing Coupons To Load Stock (BIN 1): 1. Unlock the BIN 1 ACCESS DOOR lock located on the right side of the printer. 2. Remove the key in the unlocked position so the locking latch remains in the unlocked position. 3. Raise the BIN 1 ACCESS DOOR fully until it rests on the top left side of the printer as shown below. BIN 1 ACCESS DOOR STOCK LOAD KNOB A BIN 1 INPUT SLOT BIN 1 Figure 3-2. Loading Coupons 4. Open a box of approved coupon stock so that the leading edge staple tab is exposed.
6. Place the stock in BIN 1 in the orientation shown on the BIN 1 instruction label. Gently square the coupon stack against the inside wall of the input bin. 7. Insert the staple tab (with the side to be printed facing up) into the BIN 1 INPUT SLOT (located at the top left corner of the input bin) until it is snug against the input rollers. 8. Turn the green STOCK LOAD KNOB A one-quarter (1/4) turn counter-clockwise to fully engage the staple tab in the load rollers.
9. Close the BIN 1 ACCESS DOOR fully, lock the cover, and remove the key. 10. If the printer is powered off, power on the printer. If the printer is already powered on, press the RESET/CLEAN key to recover from a stock empty error message. Failure to fully close and lock the BIN 1 ACCESS DOOR may result in the printer reporting a cover open condition. Move the key to the unlock position, press the cover firmly to fully close the cover, then lock. RESET KEY Figure 3-4.
To Load Stock (BIN 2): 1. Leave the printer powered on. 2. Place a maximum of 1,000 coupons at the back of the printer, directly behind the BIN 2 INPUT SLOT. Orient the coupons as shown on the BIN 2 label (with the side to be printed facing up). 3. Insert the staple tab end or leading edge of the coupon squarely into the document slot. The BIN 2 INPUT SLOT has a sensor that automatically detects the document. The rollers activate and pull the document to the correct “parked” position. 4.
Removing Coupons After coupons are passed through the printer, the coupons are routed to the OUTPUT BIN. The OUTPUT BIN DOOR can be unlocked with the same keys that unlock the BIN 1 ACCESS DOOR. Coupons are placed in one of two locations: • OUTPUT BIN (maximum capacity of 200 coupons) • REJECT BIN (maximum capacity of 50 coupons). The REJECT BIN is inside the OUTPUT BIN, dropping down from the top area of the OUTPUT BIN.
REJECT BIN (drops down when lever is depressed) SECURITY LOCK FOR OUTPUT AND REJECT BINS REJECT BIN LEVER OUTPUT BIN OUTPUT BIN DOOR (shown open) Figure 3-6.
Section 4 Maintenance and Troubleshooting 4.1 Scheduled Maintenance and Cleaning This chapter provides scheduled maintenance and troubleshooting procedures that can be performed by the operator. A qualified service technician should perform any troubleshooting or maintenance procedures beyond the level presented in this section. WARNING MAKE CERTAIN THE PRINTER IS DISCONNECTED FROM THE AC POWER SUPPLY BEFORE REACHING INTO THE UNIT TO PERFORM ANY CLEANING OR MAINTENANCE TASKS.
Printer Cleaning NOTE: Under normal conditions, the printer will operate for extended periods of time without the need for cleaning. However, if certain coupon stocks or operating conditions have an adverse effect on document quality, the following cleaning procedures should be performed. Cleaning the Coupon Path NOTE: Perform this cleaning first before cleaning the rollers or print head. 1. 2. 3. 4. Turn the printer off and open the BIN 1 ACCESS DOOR.
Cleaning the Rollers NOTE: Perform the previous Cleaning the Coupon Path instructions before cleaning rollers. 1. 2. 3. 4. 5. 6. 7. 8. After vacuuming the coupon path, leave the BIN 1 ACCESS DOOR open and unload any existing coupons from the STOCK LOAD KNOB A rollers by turning the knob clockwise. Unload the coupons from the BIN 2 INPUT SLOT (gently pull the coupon back and out of the slot.).
Cleaning the Thermal Printhead NOTE: Perform only when necessary to remove ink, paper and dust deposits on the print head. 1. 2. 3. 4. Turn the printer off. Open the BIN 1 ACCESS DOOR and the ZONE 2 ACCESS DOOR. Remove the ATB Printhead Cleaning Card from its protective pouch and hold the cleaning card “felt” side up (“plastic” side down). Insert the cleaning card about ½ inch (12 mm) between the black roller and the metal print head.
4.2 Error Messages The following messages represent the most commonly encountered errors by Journey II Desktop users. A more detailed list of error messages is found in the Appendices. Stock Out Bin 1 When the printer runs out of coupon stock in BIN 1, the following message appears in the display: O f f l P r e s s i n e : S t R E S E T o c k t o O u t B i C o n t i n 1 n u e To recover from this condition: 1. Unlock and open the BIN1 ACCESS DOOR and load coupon stock into the printer.
Stock Out Bin 2 When the printer runs out of coupon stock in BIN 2, the following message appears in the display: O f f l P r e s s i n e : S t R E S E T o c k t o O u t B i C o n t i n 2 n u e To recover from this condition: 1. 2. Insert a coupon into the BIN 2 INPUT SLOT, according to the instruction label shown on the rear of the printer below the input slot. Press the RESET/CLEAN key. INSERT COUPON HERE FOR BIN 2 AS SHOWN ON THE LABEL, INSERT STAPLE END FIRST. Figure 4-5.
Jam Zone 1 If the printer has a coupon jam in ZONE 1, the following message appears in the display: O n l P r e s s i n e : J a m R E S E T Z o n e t o C o n t 1 i n u e To recover from this condition: 1. Unlock and open the BIN 1 ACCESS DOOR. 2. Slide the green ZONE 1 DOOR LATCH back to open the ZONE 1 ACCESS DOOR. After unlatching, the ZONE 1 door lifts automatically. 3. Clear the jammed coupon from ZONE 1. 4.
Jam Zone 2 If the printer has a coupon jam in ZONE 2, the following message appears in the display: O n l P r e s s i n e : J a m R E S E T Z o n e t o C o n t 2 i n u e To recover from this condition: 1. Unlock and open the BIN 1 ACCESS DOOR. 2. Open the ZONE 2 ACCESS DOOR (and the OUTPUT BIN locked door if necessary). 3. Clear the coupon from ZONE 2 (and the OUTPUT BIN and REJECT BIN if necessary). 4. Close the ZONE 2 ACCESS DOOR (and the OUTPUT BIN DOOR if necessary).
Jam Zone 3 If the printer has a coupon jam in ZONE 3, the following message appears in the display: O n l P r e s s i n e : J a m R E S E T Z o n e t o C o n t 3 i n u e To recover from this condition: 1. 2. 3. 4. 5. 6. Unlock and open the BIN 1 ACCESS DOOR. Slide the green ZONE 3 door latch to open the ZONE 3 ACCESS DOOR (also open the ZONE 2, ZONE 1, and OUTPUT BIN locked door if necessary, depending on the position of the jam).
Cover Open When the printer detects an open access cover, the following message appears in the display: O n C l l o s i e n e : C o v C o v e r e r O p e n t C o n t o i n u e To recover from this condition: 1. Close and lock the BIN 1 ACCESS DOOR. NOTE: FAILURE TO FULLY LOCK THE BIN 1 ACCESS DOOR WILL RESULT IN COVER OPEN WARNINGS.
Mag Verify Error If the printer is equipped with magnetics and has a magnetic verification problem, the following message appears in the display: O n l i P r e s s n e : M a g R E S E T V e r t o i f y C o n t E r i r n u e To recover from this condition: 1. Unlock and open the BIN 1 ACCESS DOOR. Check the coupon stock in both bins for damage (and make sure that you are using approved coupons with a magnetic stripe). 2. Verify that the coupon stock is loaded in the proper orientation.
Output Bin Full When the OUTPUT BIN becomes full (at approximately 200 coupons), the following message appears in the display: O f f l P r e s s i n e : O u t R E S E T p u t t o B i n C o n t F u l i l n u e To recover from this condition: 1. Unlock and open the OUTPUT BIN DOOR. 2. Remove all the coupons from the output bin. 3. Close and lock the OUTPUT BIN DOOR and press the RESET/CLEAN key. REJECT BIN (located inside the OUTPUT BIN) OUTPUT BIN DOOR OUTPUT BIN Figure 4-9.
Reject Bin Full When the REJECT BIN becomes full (at approximately 50 coupons), the following message appears in the display: O f f l P r e s s i n e : R e j R E S E T e c t t o B i n C o n t F u l i l n u e To recover from this condition: 1. 2. 3. 4. 5. Unlock and open the OUTPUT BIN DOOR. Press and hold the Reject Bin Lever in the lowered position. Remove all the coupons from the reject bin. Release the Reject Bin Lever. Close and lock the OUTPUT BIN DOOR and press the RESET/CLEAN key.
4.3 Printer Diagnostics The following printer diagnostics are available to aid in troubleshooting printer malfunctions. They are accessed while in the Menu Mode (Off line). NOTE: LOAD SAMPLE COUPONS BEFORE PERFORMING PRINTER DIAGNOSTICS. Print Current Settings Used to verify that all feature settings are correct and to list the features of a particular profile. To perform this function: 1. Press the ONLINE/MENU key to take the printer Off line. 2.
Software Revision # Used to identify the current firmware revision level. To perform this function: 1. Press the ONLINE/MENU key to take the printer Off line. 2. Press the FEATURE ç key until the following is displayed: S o f t w a r e R e v . Example: 107023 (######) 03 (xx) # # # # # # x x Firmware base number Firmware revision This information is also printed as part of the "Print Current Settings" feature.
Print # Test Coupons Print # Test Coupons is a preprogrammed print routine that is used to verify proper operation. When the Print # Test Coupons feature is selected, a test pattern prints. To perform this function: 1. Press the ONLINE/MENU key to take the printer Off line. 2. Press the FEATURE ç key until the following is displayed: P r i n t # T e s t C o u p o n s 3. Press the SETTINGS é ê keys to select the number (#) of test coupons to print. 4. Press the ENTER key.
4.4 Troubleshooting NOTE Please read this section before continuing symptom analysis. The diagnostic tests are used to aid in isolating possible printer malfunctions. These tests assist the operator in determining printer/host problems. Additional information for printer error recovery is described under the Appendices. For host to printer communication problems, it is suggested that the operator read the Connect the Host and Itinerary RS-232 Cables Section.
4.5 Troubleshooting Table Symptom No Host Communication or Communication Problems No Power/Blank Display Print Quality Burst Errors Cover Open Error Corrective Action Verify that printer is On line. Verify cable is connected and secured to COM1. Verify baud rate, serial type (RS-232), parity, data bits, DTR, handshaking. Verify properly selected profile. Reset profile and re-configure the printer. Check interface cable (pin outs), cable connections, or try a new cable.
Symptom Mag. Verify Errors Corrective Action Verify that unit has magnetic capability and the mag feature is enabled. Verify the coupon has a mag stripe, or the mag stripe is not damaged. Verify that coupon stock is properly loaded (magnetic stripe down and towards the inside wall of the printer). Use the Mag. Calibration Feature to recalibrate printer magnetics. SCN Read Errors Verify that unit has magnetic capability and that SCN is enabled. Verify that the coupon is SCN encoded.
Appendix A — User Level Keypad Display Messages Common Messages On line: Description and Corrective Action This is the normal On line message. Name of Profile represents the last profile loaded via the profile load keys. This is the normal Off line message. Name of Profile represents the last profile loaded via the profile load keys.
Profile Load Messages Description and Corrective Action Ready To Load Profile x This message indicates the user has Press ENTER to Load Press RESET to Cancel pressed one of the four PROFILE keys. To load the selected profile: • Press the ENTER key. To cancel this procedure: • Press the RESET key. This message indicates the user has canceled the profile load procedure. The message indicates that all feature settings are being reconfigured according to the newly selected profile.
Erasing Flash Memory erasing flash memory in preparation for new software. This message indicates the completion status of the software load operation from the floppy disk. This message indicates the printer is waiting for the new software to be downloaded to the printer via the COM1 port. This message indicates the printer is receiving new software via the COM1 port. This message indicates the new software load operation is complete and the new software is being checked for validity.
Software Download Messages Drive Controller Error Press RESET to Continue Description and Corrective Action This message indicates an error occurred on the Floppy Disk Drive Controller. This error can occur when: • A PCB component fails. Disk Not Present Press RESET to Continue or Press RESET, To Restore Old Software To correct this problem: 1. Press the RESET key to terminate the software download. 2. Call Service organization for help. This message indicates the printer could not access the diskette.
Software Download Messages Config File Not Found Press RESET to Continue Description and Corrective Action This message indicates the printer could not find a valid configuration file during an attempt to load new software from disk. This error can occur when: • The program disk does not contain a valid configuration file. • The configuration file JOURNEY.CFG is corrupted. To correct this problem: 1. Press the RESET key to terminate the software download. 2.
Software Download Messages Disk Read Error Press RESET to Continue or Press RESET, To Restore Old Software Description and Corrective Action This message indicates the printer detected an error while reading data from the diskette. This error can occur when: • The floppy disk is bad. • The floppy disk drive power or data cable fails or is not connected properly. Communication Error Press RESET, To Restore Old Software To correct this error: 1. Press the RESET key to terminate the software download. 2.
Software Download Messages Invalid S-Record Data Press RESET, To Restore Old Software Description and Corrective Action This message indicates the program file contained invalid data. OS Checksum Error Press RESET, To Restore Old Software To correct this problem: 1. Press the RESET key to restore the original software. 2. Obtain/create a valid Journey II program file. This message indicates the new software did not pass a checksum validation test.
Software Download Messages Flash Write Error Press RESET, To Restore Old Software Description and Corrective Action This message indicates a failure occurred when trying to write the new software into flash memory. This error can occur when: • A flash component on the PCB fails. To correct this problem: 1. Press the RESET key to restore the original software. 2. Call Service organization for help. This message indicates the user has pressed the RESET key to recover from a software load error.
General Printer - Error Messages On line: COM1: Error Description and Corrective Action This message indicates a communication error occurred between the printer and the host. Press RESET to Continue This error can occur when: • The COM1: baud rate, data bits, and parity configuration is not specified properly. • COM1: cable is not attached or configured correctly. To correct this problem: 1. Press the RESET key to continue. 2.
it continues without issuing any error conditions. 5. If the printer is unable to recover after exhausting the specified number of retry attempts, it will go Off line and display this error message. This error can occur when: • Coupon stock does not meet IATA specifications. • The coupon is loaded incorrectly. • The coupon stock does not have a magnetic stripe on the back of the coupon. • The magnetic stripe is damaged. • The printer is not writing or reading the magnetic stripe correctly.
When an SCN read verification error occurs: 1. The printer will attempt to re-read the SCN on the magnetic stripe the number of times specified by the Mag. Verify Count feature. 2. If unsuccessful, the printer will erase the data on the magnetic stripe, print VOID on the coupon, and place the coupon in the REJECT BIN. 3. The printer will then pick a new coupon and retry the procedure in steps 1 and 2 the number of times specified by the Coupon Retry Count feature. 4.
1. Verify the coupon stock meets IATA specifications and is SCN stock. 2. Verify the coupon stock has a magnetic stripe and is properly loaded. (Staple tab must be loaded first with magnetic stripe facing down and towards the inside of the machine.) 3. Close all ACCESS DOORS and press the RESET key to continue. 4. If problem persists, change to a different coupon stock. 5. Perform the cleaning procedures and vacuum out all media dust. 6. Clean the rollers, using the RESET/CLEAN procedure.
General Printer - Error Messages On line: Jam Zone 1 Description and Corrective Action This message indicates the coupon was not transported properly through the ZONE 1 area of the printer. This condition is detected by the Pre-Magnetic and Post-Magnetic Sensors, which are used to monitor the movement of coupons through the ZONE 1 area. Press RESET to Continue This error can occur when: • A coupon gets jammed in the ZONE 1 area. • The ZONE 1 ACCESS DOOR is not properly closed and latched.
General Printer - Error Messages On line: Jam Zone 2 Description and Corrective Action This message indicates the coupon was not transported properly through the ZONE 2 area of the printer. This condition is detected by the Exit Sensor, which is used to monitor the movement of coupons through the ZONE 2 area. Press RESET to Continue This error can occur when: • A coupon gets jammed in the ZONE 2 area. • The ZONE 2 ACCESS DOOR is not properly closed and snapped in place.
General Printer - Error Messages On line: Jam Zone 3 Description and Corrective Action This message indicates the coupon was not transported properly through the ZONE 3 area of the printer. This condition is detected by the Load and Burst Sensors, which are used to monitor the movement of coupons through the ZONE 3 area. Press RESET to Continue This error can occur when: • A coupon gets jammed in the ZONE 3 area. • The ZONE 3 ACCESS DOOR is not properly closed and latched.
General Printer - Error Messages On line: Head Error Description and Corrective Action This message indicates the thermal print head engagement mechanism is not functioning properly. This condition is detected by the Thermal Print Head Position Sensor, which is used to monitor the position of the print head during the printing. Press RESET to Continue This error can occur when: • A coupon is jammed in the thermal print head area.
General Printer - Error Messages On line: Stock Out Bin 1 Description and Corrective Action This message indicates no stock is loaded in BIN 1. This condition is detected by the Pre-Magnetic Sensor, which is used to detect the presence of a coupon when printing from BIN 1. Press RESET to Continue This error can occur when: • The printer is out of stock in BIN 1. • The printer is not sensing the presence of coupon stock correctly. • The ZONE 1 ACCESS DOOR is not closed or latched correctly.
General Printer - Error Messages On line: Stock Out Bin 2 Description and Corrective Action This message indicates no stock is loaded in BIN 2. This condition is detected by the Load Sensor, which is used to detect the presence of a coupon when printing from BIN 2. Press RESET to Continue This error can occur when: • The printer is out of stock in BIN 2. • The printer is not sensing the presence of coupon stock correctly. • The ZONE 3 ACCESS DOOR is not closed or latched correctly.
General Printer - Error Messages On line: Burst Err Zone1 Description and Corrective Action This message indicates the printer was unable to successfully separate a coupon from the main stack. This condition is detected by the Pre-Magnetic Sensor, which is used to detect the successful bursting of coupons from BIN 1. Press RESET to Continue This error can occur when: • An incorrect coupon length is specified in Setup Menu.
General Printer - Error Messages On line:Cover Open Description and Corrective Action This message indicates the BIN 1 ACCESS DOOR is open. This condition is detected by the Cover Switch, which is used to detect the position of the BIN 1 ACCESS DOOR. Close Cover to Continue This error can occur when: • The BIN 1 ACCESS DOOR is open. • The BIN 1 ACCESS DOOR latch is not in the locked position. • The switch under the BIN 1 ACCESS DOOR is not being depressed properly. To correct this error: 1.
General Printer - Error Messages Off line:Output Bin Full Description and Corrective Action This message indicates the OUTPUT BIN is full. This condition is detected by the Output Bin Full Sensor, which is used to detect when the OUTPUT BIN is holding approximately 200 coupons. Press RESET to Continue This error can occur when: • The OUTPUT BIN is full. • The printer is not sensing coupons in the OUTPUT BIN correctly. To correct this error: 1. Unlock and open the OUTPUT BIN DOOR. 2.
General Printer - Error Messages Off line:Reject Bin Full Description and Corrective Action This message indicates the REJECT BIN is full. This condition is detected by the Reject Bin Full Sensor, which is used to detect when the REJECT BIN is holding approximately 50 coupons. Press RESET to Continue This error can occur when: • The REJECT BIN is full. • The printer is not sensing coupons in the REJECT BIN correctly. To correct this error: 1. Unlock and open the OUTPUT BIN DOOR. 2.
AEA Data – Error Messages On line: Invalid Command Description and Corrective Action This message indicates the printer received an invalid AEA command from the host. The second line of the display identifies the AEA error category (ERR2) followed by the invalid command. ERR2… This error is displayed for informational purposes only. The printer remains fully functional and does not require any user intervention. Subsequent AEA errors will replace the existing display message.
AEA Data – Error Messages On line: Invalid PECTABS Description and Corrective Action This message indicates the printer received either invalid AEA PECTAB data (ERR8) or a reference to an invalid AEA PECTAB (ERR6) from the host. The second line of the display identifies the AEA error category (ERR6 or ERR8) followed by the invalid PECTAB information. ERR6… This error is displayed for informational purposes only. The printer remains fully functional and does not require any user intervention.
AEA Data – Error Messages On line: Memory Error Description and Corrective Action This message indicates the printer was unable to store AEA data in flash memory. The second line of the display identifies the AEA error category (ERR9). ERR9… This error is displayed for informational purposes only. The printer remains fully functional and does not require any user intervention. Subsequent AEA errors will replace the existing display message.
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Appendix B — Service Level Keypad Display Messages Printer Calibration - Error Messages Off line: Calibration Err Press RESET to Continue Description and Corrective Action This message indicates an error occurred during the magnetic calibration procedure. This error can occur when: • Coupon stock does not meet IATA specifications. • The coupon is loaded incorrectly. • The coupon stock does not have a magnetic stripe on the back of the coupon. • The magnetic stripe is damaged.
3. Close all ACCESS DOORS and press the RESET key to continue. 4. If problem persists, change to a different coupon stock. 5. Perform the cleaning procedures and vacuum out all media dust and debris. 6. Clean the rollers, using the RESET/CLEAN procedure. 7. If this error continues, power the unit off and check internal cable connections.
Printer Calibration - Error Messages Off line: Error: LD SNS Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the ZONE 3 Load Sensor (LD SNS), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Load Sensor. • The Load Sensor cable fails or is not connected properly. • The Load Sensor fails. • A component fails on the Bin 2 Controller PCB. To correct this error: 1.
Printer Calibration - Error Messages Off line: Error: BRST SNS Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the ZONE 3 Burst Sensor (BRST SNS), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Burst Sensor. • The Burst Sensor cable fails or is not connected properly. • The Burst sensor fails. • A component fails on the Bin 2 Controller PCB. To correct this error: 1.
Printer Calibration - Error Messages Off line: Error: PRE-MAG Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the ZONE 1 Pre-Magnetic Sensor (PRE-MAG), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Pre-Magnetic Sensor. • The Pre-Magnetic Sensor cable fails or is not connected properly. • The Pre-Magnetic Sensor fails. • A component fails on the Main Controller PCB. To correct this error: 1.
Printer Calibration - Error Messages Off line: Error: POST-MAG Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the ZONE 1 Post-Magnetic Sensor (POST-MAG), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Post-Magnetic Sensor. • The Post-Magnetic Sensor cable fails or is not connected properly. • The Post-Magnetic Sensor fails. • A component fails on the Main Controller PCB.
Printer Calibration - Error Messages Off line: Error: TPH-POS Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the Thermal Print Head Position Sensor (TPH-POS), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Thermal Print Head Sensor. • The Thermal Print Head Sensor or Thermal Print Head Solenoid cable fails or is not connected properly.
Printer Calibration - Error Messages Off line: Error: EXIT Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the ZONE 2 Exit Sensor (EXIT), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Exit Sensor. • The Exit Sensor cable fails or is not connected properly. • The Exit Sensor fails. • A component fails on the Main Controller PCB. To correct this error: 1.
Printer Calibration - Error Messages Off line: Error: R-POS Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the Reject Bin Position Sensor (R-POS), during the sensor calibration procedure. This error can occur when: • Media dust or debris obstructs the Reject Bin Position Sensor. • The Reject Bin Position Sensor or Reject Bin Position Motor cable fails or is not connected properly. • The Reject Bin Position Sensor or Reject Bin Position Motor fails.
Printer Calibration - Error Messages Off line: Error: R-FULL Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the Reject Bin Full Sensor (R-FULL), during the sensor calibration procedure. This error can occur when: • A calibration stack of 50 coupons was not placed in the Reject Bin prior to running the sensor calibration test. • Media dust or debris obstructs the Reject Bin Full Sensor.
Printer Calibration - Error Messages Off line: Error: O-FULL Press RESET to Continue Description and Corrective Action This message indicates an error occurred, in the Output Bin Full Sensor (O-FULL), during the sensor calibration procedure. This error can occur when: • A calibration stack of 190 coupons was not placed in the Output Bin prior to running the sensor calibration test. • Media dust or debris obstructs the Output Bin Full Sensor.
Flash Memory Test Mode Messages Test Access Denied Press RESET to Continue Description of Message This message indicates the service technician tried to run this test from software residing in flash memory. This test can only be run from software residing in a Test ROM Module. This error can occur when: • The Flash Memory Test is run from software residing in Flash Memory. To correct this error: 1. Press the RESET key to continue. 2. Power the unit off. 3.
Flash Memory Test Mode Messages Test Complete Press RESET to Continue Description of Message This message indicates the printer successfully completed the Flash Memory Test. As a result of this test, the contents of the Test ROM Module are copied into flash memory. This includes both new boot and system software. All other non-volatile storage is initialized to factory default conditions. To operate the printer from flash memory: 1. Press the RESET key to continue. 2. Power the unit off. 3.
Flash Memory Test Mode Messages Flash Erase Error Press RESET to Continue Description of Message This message indicates the printer detected an error when erasing flash memory. This error can occur when: • A flash memory component fails. To correct this error: 1. Press the RESET key to terminate the test. 2. Power the unit off. 3. Unlock and open the BIN 1 ACCESS DOOR and remove entire cover set. 4. Replace failed component or entire Main Controller PCB. 7.
Disk Drive Test Mode Messages Testing Disk Drive < Please Wait > Description of Message This message indicates the printer is in the process of testing the Floppy Disk Drive. This message indicates the printer is in the process of formatting the diskette contained in the Floppy Disk Drive. This message indicates the completion status of saving the printer’s system software to the diskette. This message indicates the printer could not access the diskette.
Disk Drive Test Mode Messages Format Failure Description of Message This message indicates the printer detected an error while formatting the diskette. Press RESET to Continue This error can occur when: • The floppy disk is bad. • The floppy disk drive power or data cable fails or is not connected properly. To correct this error: 1. Press the RESET key to terminate the test. 2. Insert a good diskette into the Floppy Disk Drive. 3.
Disk Drive Test Mode Messages Disk Read Error Description of Message This message indicates the printer detected an error while reading data from the diskette. Press RESET to Continue This error can occur when: • The floppy disk is bad. • The floppy disk drive power or data cable fails or is not connected properly. To correct this error: 1. Press the RESET key to terminate the test. 2. Insert a good diskette into the Floppy Disk Drive. 3.
Disk Drive Test Mode Messages Not enough disk space Description of Message This message indicates there is not enough room on the diskette to save the program file. Press RESET to Continue This error can occur when: • The size or the program file exceeds the free space available on the floppy diskette. To correct this error: 1. Press the RESET key to terminate the test. 2. Insert a good diskette into the Floppy Disk Drive.
Disk Drive Test Mode Messages Drive Controller Error Description of Message This message indicates an error occurred on the Floppy Disk Drive Controller. Press RESET to Continue This error can occur when: • A PCB component fails. To correct this problem: 1. Press the RESET key to terminate the test. 2. Power the unit off. 3. Unlock and open the BIN 1 ACCESS DOOR and remove entire cover set. 4. Replace failed component or entire Main Controller PCB. 5.
Appendix C — Features and Profiles C.1 Features This chapter describes and explains the various user programmable features of the printer. Using the keypad, the printer is easily configured to operate in a variety of host environments. Placing the printer Off line allows the Setup (Menu) mode to be accessed using the FEATURE and SETTINGS keys. After the value of a feature is changed, you must press ENTER to activate and save the new value. FEATURE KEYS ENTER KEY SETTINGS KEYS PROFILE KEYS Figure C-1.
C.2 Changing Features in a Profile Feature settings in a profile may be changed through the keypad by following the steps below. Selecting and loading a profile (even the profile in current use) returns all features to the factory default settings! Changing Features: 1. Press the ON LINE/MENU key to take the printer Off line. 2. Press the PROFILE key to select the profile being changed. 3. Press the ENTER key to load the selected profile. FEATURE KEYS ENTER KEY PROFILE KEYS SETTINGS KEYS Figure C-2.
C.3 User Programmable Features Feature Nationality Values English French German Italian Español Portuguese ASCII Mode Enabled Disabled Auto LF Enabled Disabled Enabled Disabled Auto CR COM1:Baud Rate COM1: Parity COM1: Data bits 1200 2400 4800 9600 14400 19200 38400 57600 None Even Odd 7 8 Description This feature selects the nationality displayed on the keypad display (LCD) and the Print Current Settings test coupon.
Feature COM2: Baud Rate COM2: Parity COM2: Data bits COM2: Handshaking BIN 1: Top Print Position BIN 1: Left Print Position BIN 1: Print Darkness Values 1200 2400 4800 9600 14400 19200 38400 57600 None Even Odd 7 8 None DTR XON/XOFF 0 . . . 20 0 . . . 245 +50 . 0 . -50 Description This feature sets the baud rate of data going out of the COM2 (itinerary printer port) serial interface. This feature sets the parity of data going out of the COM2 (itinerary printer port) serial interface.
Feature BIN 1: Horizontal Pitch Adjustment BIN 1: Mag. Values +60 . -60 Enabled Disabled BIN 1: SCN Enabled Disabled BIN 1: SCN Read Order Ascending Descending BIN 1: Stock Type 1 . 9 BIN 1: Document Length BIN 2: Top Print Position BIN 2: Left Print Position 7.375” (187.3mm) 8.0” (203.2mm) 0 . . . 20 0 . . . 245 Description This feature is used to horizontally expand and compress the printed output for BIN 1.
Feature BIN 2: Print Darkness Values +50 . 0 . -50 BIN 2: Horizontal Pitch Adjustment +60 . -60 BIN 2: Mag. Enabled Disabled BIN 2: SCN Enabled Disabled BIN 2: SCN Read Order Ascending Descending BIN 2: Stock Type 1 . 9 Default Bin 1 2 Mag Verify Count: 0 . . . 10 Description This feature adjusts the print darkness to compensate for coupons of varying thermal sensitivity, for BIN 2. Larger values increase the darkness of the printed image.
Feature Coupon Retry Count ## Coupon Print Order Values 0 . . . 10 FIFO LIFO Software Rev. 107652 ## Print Current Settings N/A Print # Peckman Coupons 1 . . . 10 Print # Test Coupons 1 . . . 10 BIN 1 BIN 2 Alt. In/Out Alt. Input Test Bin: N/A Description This feature specifies how many coupons in succession with magnetic verify errors will be allowed before a magnetic error is reported. This feature specifies the order in which AEA tickets are printed.
1. 2. 3. 4. Press the ON LINE/MENU key to place the printer Off line. Press the FEATURE ç key until the ‘Software Rev.’ feature is displayed. Press the ENTER key. Press the FEATURE è key to display the following features. CAUTION: Only qualified users/service technicians should select this menu.
Clear Format Record N/A This feature is used to clear all formats that may be stored in the printer’s RAM and FLASH memory. Emulation # Name of AEA Emulation This feature is used to select the active AEA emulation mode. Ignore Mag Errors Disabled Enabled 1 . . . 99 Used to ignore magnetic errors. Primarily used during testing. This feature determines how many hours the printer will perform a built in burn-in test.
Feature Flash Memory Test Values N/A Display Time and Date N/A Strike Wd Small Char # 1-4 Strike Wd Large Char # 1-4 Software Load 57K baud N/A Description This feature is used to test the FLASH memory. This test can only be accessed when diagnostic ROMs are plugged into the control board. If your printer is equipped with a realtime clock, this feature displays the current time and date.
C.4 Profiles Profiles are user definable sets of default parameters that can be used to setup the printer for predetermined functions. All profiles are defaulted to the factory settings. Default Profile Settings The four default profiles are custom-tailored for each CRS by the factory. As a result, default settings are not shown in this manual. Customer-specific defaults are provided to each customer in a supplement to this manual. Each default profile can be modified as shown in this section of the manual.
C.5 Changing Profiles Profiles may be changed through the keypad by following the steps below. To Change a Profile: 1. Press the ON LINE/MENU key to take the printer Off line. 2. Press the PROFILE key to select the profile being changed. 3. Press the ENTER key to load the selected profile. Selecting and loading a new profile (even the profile in current use) always returns all feature settings to the factory defaults for that profile.
C.6 Configuring the Printer Using Profile Keys Profiles can have different feature settings to match different user needs. This allows quick reconfiguration. Selecting a profile always returns the printer to the original factory settings for that profile. Any changes to a preconfigured profile must be made each time after a new profile is selected. To select a profile: 1. Press the ONLINE/MENU key to place the printer Off line. 2.
