Arrow International PrecisionCounter 500 User manual

Service Manual
This service manual is only authorized for use by Arrow Distributors
Revision 1.12089

1. Overview of Parts and Procedures .................................................................. 4
2. Disassembly ................................................................................................................ 16
a. Remove the column .................................................................................... 16
b. Remove the ticket catcher assembly ........................................................ 17
c. Remove the metal film retainer and metal ticket guide .......................... 19
d. Remove the plastic body ............................................................................ 19
e. Remove the metal top wrap ....................................................................... 22
f. Remove the metal side wall ....................................................................... 23
g. Partial disassembly ..................................................................................... 26
3. Procedures ................................................................................................................... 28
1. Adjusting the metal ticket guide ............................................................... 28
2. Adjusting the ticket catcher assembly ..................................................... 30
3. Adjusting the mylar ticket deflector ......................................................... 31
4. Replacing the mylar ticket deflector ........................................................ 32
5. Replacing the ticket catcher sensor ......................................................... 33
6. Adjusting the ticket gate ............................................................................ 34
7. Replacing the square pushbutton switch ................................................. 36
8. Replacing the keypad ................................................................................. 37
9. Replacing the LCD assembly ..................................................................... 38
10. Adjusting the metal spring foot ................................................................. 40
11. Cleaning the ticket-count optical sensor ................................................. 41
12. Replacing a plastic gear ............................................................................ 42
13. Replacing a roller ........................................................................................ 43
14. Replacing the ticket-count optical sensor ............................................... 44
15. Replacing the motor belt ............................................................................ 46
16. Replacing the plastic pulley ...................................................................... 47
17. Replacing the motor ................................................................................... 48
18. Cleaning the rollers .................................................................................... 50
19. Diagnosing power issues ........................................................................... 51
Table of Contents

LEGAL NOTICE
This document is provided “AS IS” and Arrow International, Inc. and its affiliated companies
(collectively, “Arrow”) assume no responsibility for any typographical, technical, or other
inaccuracies in this document. In order to protect Arrow proprietary and confidential information
and/or trade secrets, this document may describe some aspects of Arrow technology in
generalized terms. Arrow reserves the right to periodically change information that is contained
in this document; however, Arrow makes no commitment to provide any such changes, updates,
enhancements, or other additions to this document to you in a timely manner or at all.
ARROW MAKES NO REPRESENTATIONS, WARRANTIES, CONDITIONS, OR COVENANTS,
EITHER EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION, ANY EXPRESS OR
IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGEMENT,
MERCHANTABILITY, DURABILITY OR TITLE) AS TO THE PERFORMANCE OF THE
PRECISIONCOUNTER 500 (THE “EQUIPMENT”) OR ANY RELATED EQUIPMENT OR SERVICE EXCEPT
FOR THE “PrecisionCounter 500™ Limited Warranty” SET FORTH IN THE OWNER’S MANUAL (a
copy of which is available upon request from Arrow).
IN CONNECTION WITH YOUR USE OF THIS DOCUMENTATION, NEITHER ARROW NOR ITS
RESPECTIVE DIRECTORS, OFFICERS, EMPLOYEES, OR CONSULTANTS SHALL BE LIABLE TO YOU
FOR ANY DAMAGES WHATSOEVER BE THEY DIRECT, ECONOMIC, COMMERCIAL, SPECIAL,
CONSEQUENTIAL, INCIDENTAL, EXEMPLARY, OR INDIRECT, EVEN IF ARROW HAS BEEN ADVISED
OF THE POSSIBILITY OF SUCH DAMAGES. IN NO EVENT WILL ARROW’S LIABILITY IN CONNECTION
WITH THE EQUIPMENT OR ANY RELATED SERVICE EXCEED THE SALES PRICE PAID FOR THE
EQUIPMENT.
Part number: 46731-MNL2
Revision 1.12089
March 2012
© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
This manual should not be reproduced in any manner without written consent from Arrow International, Inc.

#1 Overview of Parts* and ProceduresChapter
3434
Adjusting the ticket gate
2828
Adjusting the metal ticket guide
3838
Replacing the LCD assembly
3737
Replacing the keypad
3636
Replacing the square pushbutton switch
Square Pushbutton Switch
Keypad
LCD Assembly (display)
Plastic - Main Body
Metal - Ticket Guide
Ticket Gate & Metal Ticket Gate Edge
Column
* For replacements: contact the Arrow Technical Assistance Center, at 800.277.6214 and refer to the part name.
A technician will provide you with the current part number or will place an order for that part
OVERVIEW OF PARTS AND PROCEDURES CHAPTER 1
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© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
ARROW INTERNATIONAL
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3131
Adjusting the mylar ticket deflector
3333
Replacing the ticket catcher sensor
Power Entry Module (the fuse is located in this component)
Wire Harness for the Ticket Catcher Optical Sensor
Ticket Catcher Optical Sensor
Ticket Catcher Assembly (hopper)
Mylar - Ticket Deflector
Metal - Film Retainer
Thumb Nut 6-32 - Knurled Brass
3030
Adjusting the ticket catcher assembly
3232
Replacing the mylar ticket deflector
3434
Adjusting the ticket gate
Metal - Mounting Bracket for the Ticket Catcher Assembly
Serial number of the ticket counter:
Have available when calling the Technical Assistance Center
OVERVIEW OF PARTS AND PROCEDURES CHAPTER 1
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© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
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4242
Replacing a plastic gear
Harness for the square pushbutton switch: 2 variants may exist in the field. Both variants uti-
lize 2 wires for sending the switch signal, and those 2 wires connect to SW1 and SW2 on the
Main PCB (it doesn’t matter which wire connects to which connector). The 1st variant consists
of just the 2 wires connecting to the pushbutton switch. The 2nd variant, utilizes a 5-prong
plug to connect to the pushbutton switch. This 5-prong plug, has 3 extra prongs for possible
expanded functionality in future models of the ticket counter
7-pin harness for the keypad - Connects to HDR2 on the main PCB (underneath the ticket coun-
ter). The header which connects to the keypad itself is not keyed. Prior to removal, it is recom-
mended that both the header and connector on the keypad be marked in some way to ensure
correct re-attachment: in the diagram, the header has a black mark indicating the location of
PIN 1 ... the keypad connector (not visible) has a similar marking
Power wires for the motor - they go underneath the ticket counter, across the main PCB, and
connect to the motor on the other side of the ticket counter (see p.10-11)
Motor Board PCB
Plastic Gear - 60 Tooth. It is mounted on the transfer shaft (which does not contain any rollers)
Plastic Gear - 96 Tooth. It is mounted on the shaft with the two visible rollers
The optical sensor responsible for counting tickets includes these 4 wires pre-attached (con-
sisting of 2 braids [red/black & orange/black]). The other ends of the wires are soldered to the
motor board PCB (which is visible on this page)
4141
Cleaning the ticket-count optical sensor
Plastic Gear - 35 Tooth. It is mounted on the motor shaft
5-pin harness for the motor board PCB - Connects to HDR1 on the main PCB (underneath the
ticket counter). This harness has a keyed header on both ends that snaps into place when
inserted correctly
4444
Replacing the ticket-count optical sensor
14-pin harness for the LCD assembly - Connects to HDR3 on the main PCB (underneath the
ticket counter). This harness has a keyed header on both ends that snaps into place when
inserted correctly
There is an interlocking mechanism between
the header on the harness and the header on
the PCB. This results in a very solid connec-
tion, but, it can also make it seem difficult to
disconnect the harness from the PCB
The following notes should be followed when
disconnecting the harness from the PCB
• make sure there is enough room to
comfortably grip the harness header
• grip the harness header from the left
and right plastic sides of the connector
(not from the wires) and pull the con-
nector straight backwards (red arrow)
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© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
ARROW INTERNATIONAL
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Arrow International cannot guarantee that the original trans-
former is present in a machine at the time of repair, or that the
wiring has not been tampered with. When working with power,
always verify the connections on both the transformer and the
power entry module. Also verify that the outlet used by the ticket
counter does not have its hot/neutral/ground pins reversed or
disconnected
4747
Replacing the plastic pulley
Motor - Column Drive
Gear - Plastic Pulley
O-ring Motor Belt
4848
Replacing the motor
4646
Replacing the motor belt
Transformer: current model # 4-49-5016 (see label on top of transformer)
Motor Bracket
5) Double spade (both brown)
• Jump to # 2
• ‘Line in’ from power entry module
4) Jump from #1 (blue)
3) (Empty)
2) Jump from #5 (brown)
1) Double spade (both blue)
• ‘Neutral’ from power entry
module
• Jump to #4
(10
(9
(8
(7
(6
(white) To AC1 or AC2 on main
PCB (doesn’t matter which since
rectification is performed on the
main PCB itself)
(black) Jump to # 7
(Empty)
(black) Jump from # 9
(white) To AC1 or AC2 on main
PCB (doesn’t matter which since
rectification is performed on the
main PCB itself)
Power wires for the motor - connect to other side of machine (see p.7)
Ground
Line-in
Neutral
115 VAC in ... 18 VAC out
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© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
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The optical sensor responsible for counting tickets includes 4 wires pre-attached (consisting of
2 braids [red/black & orange/black]). The other ends of the wires are soldered to the motor
board PCB (see p. 8-9)
4141
Cleaning the ticket-count optical sensor
4444
Replacing the ticket-count optical sensor
Roller Core (for 1” rollers)
1” Roller
2” Roller
Shaft Drive (Transfer): 6” long
Shaft Drive (Motor): 7” long
Shaft Collar
Clip Bearing
5050
Cleaning the rollers
4343
Replacing a roller
Foot Mounting Bracket
4040
Adjusting the metal spring foot
Metal Spring Foot
Roller Core (for 2” rollers)
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© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
ARROW INTERNATIONAL
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Ticket counter is positioned upside down,
exposing the main PCB underneath
Transformer side
CAUTION: When performing repairs & maintenance on the
PrecisionCounter 500, various jagged metal edges may be ex-
posed. These can cause personal injury or damage to property
if not properly accounted for
HDR1 - 5-pin - motor board PCB
HDR4 - 3-pin - ticket catcher optical sensor
HDR2 - 7-pin - keypad
HDR3 - 14-pin - LCD assembly
AC1 & AC2 - AC inputs
from transformer ...
order doesn’t matter
P1 - potentiometer (variable resis-
tor controls motor speed - factory
set for motor to receive 14.2 VDC)
VR3 - 5 VDC voltage
regulator for LCD
assembly
VR1 - voltage regula-
tor for motor: 14.2 VDC if
potentiometer is set correctly
SW1 & SW2 - pushbutton switch ... order doesn’t matter
VR2 - 5 VDC voltage
regulator for processor
Motor board PCB
Ticket catcher optical sensor
Keypad
LCD assembly
Pushbutton switch ... order doesn’t matter
AC inputs from transformer
... order doesn’t matter
Potentiometer
5 VDC voltage regula-
tor for LCD assembly
Voltage regulator for motor 5 VDC voltage regu-
lator for processor
Red & Black wires from
motor to motor board PCB
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© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
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Chapter #2 Disassembly
This chapter documents the common steps needed to begin all internal repairs of the PrecisionCounter 500.
Most procedures outlined in Chapter 3 will refer to this disassembly process and will state which steps
should have been completed before the procedure can begin
CAUTION: To prevent the risk of electrocution, unplug the
unit prior to performing maintenance. Failure to disconnect
power could result in injury and/or death, and possible dam-
age to the PrecisionCounter 500
Estimated Time 15 minutes
Difficulty 3 of 5
Possibility of damage 3 of 5
All procedure estimates assume a technician of average
skill who has only performed this process 1 or 2 times, and is
moving at a relatively cautious speed
Tools Required:
• #1 Phillips screwdriver (capable of
comfortably handling size 6 screws)
Figure 2.1
Use a cloth or paper towel to cover the gaps
Figure 2.3
With the column removed
Figure 2.4
Notice the angle of the thumb nuts
Figure 2.2
Remove these 4 screws
Remove the column
1) (Optional, but recommended) - use a cloth or paper
towel to cover the gaps through which a screw might
fall into the inner chamber of the machine
2) Remove the 4 screws which hold the column to
the main body of the ticket counter. The screws may
not be magnetic: do not rely on a magnetic-tip driver
to prevent a screw from falling. The order does not
matter but the last screw will have a lot of torque on
it from the weight of the column. Make sure to sup-
port the column with your hand as you remove the
last screw
Remove the ticket catcher assembly
4) If possible, take note of the angle at which the as-
sembly is currently attached to the main body (each
owner will customize this for his/her needs and the
results may vary)
3) Remove the cloth/paper towel and set aside the
column with its 4 screws
Figure 2.5
Remove the two thumb nuts
5) Remove the two thumb nuts which hold the as-
sembly to the main body. Gently lift the assembly to
alleviate any torque on the thumb nuts: it can help a
great deal
The ticket counter will then be easier to handle and can even be positioned upside down
A
B
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DISASSEMBLY CHAPTER 2
16
© 2012 Arrow International, Inc.
9900 Clinton Rd. Cleveland, OH 44144 • Toll Free: 800.321.0757
Technical Assistance Center (8 AM - 12AM EST): 800.277.6214
This service manual is only authorized for use by Arrow Distributors
ARROW INTERNATIONAL
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