Zebra® TTPM3™ Kiosk Ticket Printer/Encoder Service Manual P1011350-001
© 2009 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and Monotype Imaging fonts.
CONTENTS March, 09 1 INTRODUCTION .............................................................................................5 1.1 About this manual............................................................................................5 1.2 Updating ..........................................................................................................5 2 PRODUCT PRESENTATION .........................................................................6 2.1 Document printing ................
6 REPLACEMENT PARTS............................................................................. 39 6.2 Desktop version, final assembly................................................................... 40 6.3 Modules ........................................................................................................ 44 6.4 Input module................................................................................................. 48 6.5 Magnetic encoding module ...............................
1 INTRODUCTION 1.1 About this manual This manual describes the design and function of the TTPM3 Ticket Printer/Encoder, which creates credit-card-wide documents with magnetic encoding and thermal printing. The manual also contains maintenance instructions and replacement parts lists. 1.2 Updating This manual will be updated as, from time to time, printer functions and features may be added or amended. You will always find the latest edition on our web site (www.zebra.com).
2 PRODUCT PRESENTATION TTPM3 Ticket Printer/Encoder creates credit-card-wide tickets with magnetic encoding and thermal printing. 2.1 Document printing TTPM3 uses the direct thermal printing technique and can print the entire surface of the ticket with text, bar codes, or graphics, or any combination hereof. Text block position and orientation is software programmable as is the character size.
Control panel Power switch Input 2 (upper) Input 1 (lower) Ticket output Power inlet (24V) Interface connector Figure 1. Desktop printer Figure 2.
The figure below shows the main parts of the OEM-type printer/encoder unit with attached front load mechanism. Items in the figure, but not pointed to belong to the basic module. Front load module (optional) Printhead module Output module Magnetic stripe module Input module Control board assy Protective plate Basic module Cutter module SW95039A Figure 3.
3 FUNCTIONAL DESCRIPTION The TTPM3 connects to a host computer, for example a workstation or a PC, through the RS232 serial interface or optional Ethernet. The host controls the operation of the TTPM3 by means of software commands. A microprocessor on the control board interprets the commands and generates the necessary control and data signals. Besides the on-line mode, you can force the TTPM3 into a self-test mode producing a printed and encoded ticket containing information about firmware version. 3.
3.1.1 Document paths See Figure 4. The TTPM3 can handle the following document path combinations: Two software-selectable paths for fanfold or roll stock. One path for a fanfold or roll stock and one single-document path with override function. Lower document path used for automatic insertion of single cards from an optional card dispenser fitted at the back of the TTPM3. Upper document path is not used. The figure shows the TTPM3 design with two software- selectable paths for fanfold or roll stock.
3.1.3 Cutting module See Figure 4. The knife in the cutting module moves by means of a DC-motor (u) with a combined carrier and cam wheel (ae). The motor runs in one direction only during normal cutting operations. A micro-switch sensor (v) detects when the knife reaches its home position. If the mechanism cannot reach its home position, possibly due to a paper jam or similar, the motor will run in the opposite direction until the mechanism reaches its home position. WARNING! DANGER OF INJURY.
Printhead module assy Front load module Print platen Micro switches Eccentric cam wheel Actuator arm Adjustment plate Lock screw SW97093B Figure 6. Printhead lifting mechanism design (optional) 3.2.2 Function FEEDING THE DOCUMENT IN When the paper presence sensor detects a document, the printhead lifting mechanism lifts the printhead and the stepper motor starts turning. Printhead module assy Print platen SW97093A Figure 7.
The document is fed through the front load input/output module into the ordinary “output module” now also serving as an input device. A leaf spring ensures that the document is kept pressed against the running feed belts to get sufficient friction. Paper presence detector Feed roll Print head Leaf spring Document Stepper motor SW97096-R2 Figure 8. Document is fed through into the ordinary output module The document moves all the way into the upper rear document path.
FEEDING THE DOCUMENT OUT Returning the document through the input/output module (can also be fed out through the rear document path) is the reverse of feeding the document in. Note that the document is guided out through the horizontal path (see arrow). Document SW97098 Figure 9.
Alternatively, the document can be fed out downward into a waste bin or similar. This is affected by a software command that actuates the solenoid that pushes the link upward and pivots the input module so that the document is guided downward and out. In/out feeder Document Link Deflection plate Solenoid SW97099-R1 Figure 10.
3.3 Control board See Figure 12. TTPM3 functional block diagram on page 19 and the logic diagram in Chapter 5. 3.3.1 Microprocessor system The main parts of the microprocessor system are 80C420 processor 2MB FlashPROM 128 K RAM Two programmable I/O ports 3.3.2 Memory The Flash stores system parameters, fonts and firmware. The RAM stores print data saved in a page memory area that can be further split into one area for fixed, recurring, information and one area for variable information.
3.3.5 Cutting The DC-motor first turns in one direction to perform the cutting. The cam wheel actuates the micro-switch sensor when the mechanism reaches its home position again. At this moment, the motor is forced to a quick stop as the drive circuit for turning the motor in the opposite direction is activated momentarily. 3.3.6 Communications interface The TTPM3 communicates with the host through the RS232 serial interface.
3.3.7 Power supply The power supply unit (PSU) is of the switched mode type and supplies +24V to the control board. A transistor on the control board switches ON the +24 V when motors, solenoids and printhead is to be used and keeps it off when the printer is idle. This is to prevent the drive circuits in the printhead from becoming damaged since their status is undefined before the +5 V is at correct level. NOTE! — At these high currents it is essential that the leads and connectors be in good condition.
A8—A15 RAM ADDR.
4 MAINTENANCE WARNING! DANGER OF INJURY! Depending on the position of the crank mechanism in the cutter module, the cutting knife may start moving when the printer is switched ON. KEEP HANDS AWAY! CAUTION! The power supply should be switched off before you disconnect or connect any other cable on the control board. The printer electronics might otherwise be damaged. CAUTION! The printhead and some components on the control board are sensitive to ESD (electrostatic discharges).
= Grease = Oil = Red laquer sealant = Apply on thread: Loctite 243 Threadlocker, medium strength, removable, and oil tolerant Figure 13.
4.2 Fault finding The TTPM3 informs the host of some error symptoms by means of status reports and error codes (if not disabled with parameter n6). The indicators on the control panel indicate errors requiring assistance of the operator. Both parameter settings and error codes are described in the TTPM3 Technical Manual Below follow some hints on other error symptoms and how to act upon them: SYMPTOM Varying space between lateral dot lines as a result of irregular paper feed.
SYMPTOM Only one self-test ticket can be done. When you press the print button again, only blank tickets are produced. ACTION Check the setting of parameter n7, "Clear memory after print". If it is ON, this is the correct behavior. If n7 is OFF, test the printer with another power supply unit. If the power supply fails to deliver enough current, the printer is reset when the black line at the end of the self-test ticket is printed. 4.
Cover Remove the four screws holding the printer mechanism to the bottom of the cover. Lift the printer-mechanism out of the cover. Print Module Open the printhead and clean the printhead resistor-line with alcohol. Check the plastic cogwheels for wear. Check for wear in bearings. Check that the plastic cogwheel fastening bolts do not jiggle (are secured with Loctite) Output Module Remove the output module. Check for damages on the feed roller and pressure rollers. Replace at signs of wear.
4.4 Parts removal and replacement Whenever modules are loosened, removed or replaced, a complete adjustment and verification cycle must be performed. NOTE 1! — This is essential for the reliability of the printer and should NEVER be overlooked! NOTE 2! — Only technicians having the appropriate knowledge and experience of the TTPM3 should carry out the adjustments. WARNING! DANGER OF INJURY.
4.4.3 Firmware The firmware is the software that controls the TTPM3. It is stored in a Flash PROM and can be updated from the host computer. How to do this is described in the Technical Manual. You can download firmware from www.zebra.com. 4.4.4 Cover REMOVAL 1. Turn the printer upside down. 2. Remove the four screws securing the printer/encoder unit to the bottom pat of the cover. 3. Lift the printer/encoder mechanism out of the Cover. REPLACEMENT Install the module in the reverse order.
4.4.5 Printhead module REMOVAL 1. Disconnect the printhead cable from the printhead. 2. Remove the two circlips from the shaft attaching the printhead support plate to the output module. 3. Pull the printhead engagement arm forwards to relieve the printhead and then pull out the shaft completely. REPLACEMENT If the output module has been removed as well, this one should be mounted on the basic module before you fit the printhead module. 1. Mount the printhead module in the reverse order. 2.
4.4.8 Magnetic stripe module REMOVAL 1. Remove the printer/encoder unit from the cabinet as described above. 2. Remove the input module as described above. 3. Disconnect the two cables from the control board connector J3. 4. Remove the four screws securing the magnetic stripe module. 5. Remove the magnetic stripe module. Save the two plastic spacers located under the magnetic stripe module. REPLACEMENT Mount the module in the reverse order.
4.4.10 Control board When you order a control board as replacement parts it is configured with firmware and parameter settings suitable for the factory. REMOVAL 1. Remove the printer/encoder unit from the cabinet as described above. 2. Disconnect all cables from the board, and mark them with a permanent marker pen to ease reconnection. 3. Remove the big hexagonal spacers (nuts) and remove the board. REPLACEMENT 1. Fit the board in the reverse order. 2.
4.4.11 Front load module REMOVAL SW98076 Figure 14. Removing the frontload module assembly 1. 2. 3. 4. 30 Disconnect the frontload cable connectors J11 and J20 from the control board (Remember to mark the houses with No,). Remove one screw on each side of the front load module assembly (see bottom arrow). Lift the printhead. Hook the frontload module off from the print platen bearings.
5 ADJUSTMENTS Whenever modules are loosened, removed or replaced, a complete adjustment and verification cycle must be performed. NOTE 1! — This is essential for the reliability of the printer and should NEVER be overlooked! NOTE 2! — Only technicians having the appropriate knowledge and experience of the TTPM3 should carry out the adjustments. The TTPM3 Ticket Printer/Encoder is designed for the ticket width 53.98 ±0.2 mm according to the ISO 7810 standards.
5.2 Ticket path adjustment Stop screw Gauge 54.3mm Ticket path width adjustment Cutout of printer seen from front Drive roller Adjustable guide Fixed guide Stop screw Correct! Remove guide and measure ~54.2-54.4 mm Press lightly and tighten stop screw Stop screw WRONG! Too narrow! Less than 54.2 mm If you press hard and tighten stop screw Guide bend sideways Figure 16.
5.2.1 Rear 1. Loosen 1.5-mm Allen-screws G and H keeping the rear ticket guide plate in position. Widen the ticket path by pushing the loose guide plate toward the right hand side of the TTPM3. Figure 17. Adjusting the rear ticket path 2. Insert the gauge through the rear lower ticket entrance, and feed the gauge all the way up to the cutter. CAUTION! — The gauge must not be inserted through the rear upper ticket entrance since this may damage the gauge.
5.2.2 Front TTPM3 without front load option 1. Loosen 1.5-mm hexagonal (Allen) screws J and K keeping the front ticket guide plate in position. Widen the ticket path by pushing the loose guide plate toward the right hand side of the TTPM3. 2. Insert the gauge under plastic leaf spring L and feed the gauge up to the front of feed rollers M. Do not insert the gauge between the rollers. 3. Verify that the gauge, in all its length, is in touch with the fixed guide plate on the lefthand side. 4.
5.3 Magnetic head pressure rollers adjustment Rotate freely without ticket Hard to turn with ticket Move roller up&down to adjust d d ea ea H H ite ad Wr Re Figure 19. Adjusting the magnetic head pressure rollers to properly encode tickets of a specific thickness. REMEMBER! The grove on the roller shaft must face upwards! 5.3.1 Checking 1. Insert the ticket under the pressure rollers positioned above the magnetic heads. The ticket must be the type of ticket that is to be used in the TTPM3. 2.
5.4 Solenoids Solenoids create a linear movement that the TTPM uses to engage and disengage ticket feed. A solenoid consists of a coil with a hole in it, and a plunger. When voltage is applied to the coil, the plunger is pulled into the hole by the magnetic field generated. Solenoids are strongest when the plunger is close to its bottom position. So to get the most pullforce on the ticket material, the solenoid adjustment must be checked after the printer has been disassembled / reassembled. 5.4.
5.4.3 Adjusting output solenoid No ticket should be inserted! 1) Loosen the two screws holding the solenoid coil 2) Press and hold down the plunger 3) Move the coil towards the plunger using the screwdriver, and tighten the screw. Adjust Verify Pull / push to check that ticket is held by roller Press down on plunger Press down on plunger Lift with screwdriver and tighten 5.4.
5.5 Printers with front load 0.5 mm Eccentric cam wheel FRONT 0.5 mm FRONT Actuator arm Lock screw Adjustment plate SW99011 1. 2. 3. 4. 5. 6. 7. 8. 9. 38 Check with a feeler gauge that the distance between the actuator arm and the micro switch housing (the frame around the knob) is 0.5mm. Turn the cam wheel to make sure that it is the minimum distance that you measure. Adjust the switches if necessary. Loosen the lock screw.
6 REPLACEMENT PARTS This chapter lists the replacement parts available for the TTPM3. The number of replacement parts is restricted due to the division of the product into easily replaceable modules. Desktop version, final assembly ............................................................................. 40 Modules ................................................................................................................. 44 Input module ............................................................
6.
COVER Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 ? ? SP X X March 2009 X X X X X X X X X X X Part No.
TTPM3 - Service Manual March 2009
COVER Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 ? ? SP X X March 2009 X X X X X X X X X X X Part No. 02349-000 02382-000 02712-000 09100-168 09100-222 09100-224 09100-287 104047 104358 104433 104472 104573 104575 104576 104577 104578 104611 ??? 104985 105044 104434 104610 104698 Designation Foot, SJ 5514 Label TTPM3 tr.
6.
Quantity MODULES Pos. 3 4 5 6 7 8 13 9 10 11 12 14 15 15 16 17 18 19 20 21 22 23 SP X X X X X X X X X X X X X X March 2009 Part No. 01695-000 01721-000 02276-000 02309-000 02435-000 09022-310 101057 09045-108 09100-220 09100-222 100970 102111 ??? 104051 104179 104203 104277 104471 104568 104643 10819-001 10820-003 Designation Printhead Module Assy Screw MRT 8.8 M2.5x8 Washer BRB 2.7x8x0.
Modules, continued… 46 TTPM3 - Service Manual March 2009
MODULES Pos. 3 4 5 6 7 8 13 9 10 11 12 14 15 15 16 17 18 19 20 21 22 23 SP X March 2009 X X X X X X X X X X X X Quantity Part No. 01695-000 01721-000 02276-000 02309-000 02435-000 09022-310 101057 09045-108 09100-220 09100-222 100970 102111 ??? 104051 104179 104203 104277 104471 104568 104643 10819-001 10820-003 Designation Printhead Module Assy Screw MRT 8.8 M2.5x8 Washer BRB 2.7x8x0.
6.
INPUT MODULE Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 SP X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X March 2009 Part No.
6.5 Magnetic encoding module Mag. Stripe Module Assy, Tr 1-3, LC/HC Pos. 1 2 3 4 5 6 7 8 SP X X X X 6.6 Part No. 09018-217 09100-220 102858 103005 103006 103651 104045 10628-001 Designation Screw SK6SS M3x3 Screw MRX-H M3x6 Mag. Amplification Board, 3 Track, TTPM3 Write Head 3 Tr Assy Read Head 3 Tr Assy Magnetic head guide 3 Track Label, magnetic module 3 Track HiCo Mag-module cable assy 50 OEM Std FL 2 2 3 3 1 1 1 1 1 1 1 1 1 1 1 1 Desktop Std FL 2 2 3 3 1 1 1 1 1 1 1 1 1 1 1 1 Pcs. Pcs. Pcs.
6.7 Printhead module assembly 01695-000 Printhead Module Assy Pos. 1 2 3 4 5 6 7 8 SP X X X X March 2009 Part No. 01256-000 01694-900 02254-000 02307-001 09022-309 09100-189 09100-222 10634-000 Quantity Designation Printhead label Pressure Plate Assy Spacer, Cylindrical Thermal Print Head (Sparepart) Nut M6M M2,5 Screw MRX-H M2,5x4 Screw MRX-H M3x8 Print Head Cable Assy TTPM3 - Service Manual OEM Std FL 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 Desktop Std FL 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 Pcs. Pcs. Pcs.
6.
Output Module Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32 33 SP X X X X X X X X X X X X X X X X X X X X X X X X X X X X March 2009 Part No.
6.
Cutter Module Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SP X X X X X X X X X Part No. 00549-060 00555-000 00555-001 00556-000 00557-000 00559-000 02253-000 09023-118 09100-188 09100-193 09100-195 09100-218 100479 104493 104494 104569 Quantity Designation Cutter Support (Fixed Cutter Blade) Hub 5mm Hub 6.5mm Pressure Plate Compression Spring 0.4x5x11.2 Distance washer, 4x8x0.5 Spacer, Cutter Washer BRB 2.7x6x0.5 Screw MRX-H M2.5x3 Screw MRX-H M2.5x8 Screw MRX-H M2.
Front load module Sensor cable under this shaft = 100891 Oil ATF Dexron II 56 TTPM3 - Service Manual March 2009
Front Load Module Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 SP X X X X X X X X X X X X X X X X March 2009 Part No.
6.10 Basic Module = 104237 Vaseline Bajol = 100905 Loctite 243 threadlock = 100890 Grease HASCO Z260 Basic Module Pos. 1 2 3 4 5 6 7 8 9 10 11 58 SP X X X X X X X X X Part No. 00359-000 00375-000 00628-000 00629-000 01780-000 02217-000 02230-000 02233-000 02234-000 02235-000 02240-000 Designation Washer BRB 3.
Basic Module Pos. 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 69 SP X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X March 2009 Part No.
8 About This Document Contacts Contacts Technical Support via the Internet is available 24 hours per day, 365 days per year. Web Site: www.zebra.com E-mail Back Technical Library: E-mail address: emb@zebra.com Subject line: Emaillist Self Service Knowledge Base: www.zebra.com/knowledgebase Online Case Registration: www.zebra.com/techrequest Which Department Do You Need? Regional Headquarters The Americas Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, IL 60061-3109 U.S.A.
Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A T: +1 847 793 2600 Toll-free +1 800 423 0422 F: +1 847 913 8766 Zebra Technologies Europe Limited Dukes Meadow Millboard Road Bourne End Buckinghamshire, SL8 5XF, UK T: +44 (0)1628 556000 F: +44 (0)1628 556001 Zebra Technologies Asia Pacific, LLC 120 Robinson Road #06-01 Parakou Building Singapore 068913 T: +65 6858 0722 F: +65 6885 0838 http://www.zebra.com © 2009 ZIH Corp.
