Galileo ADP 4100 Setup guide

ADP 4100 Printer
Installation and O
p
erations Manual

© 2007 Unimark Products, LLC. a Microcom Corporation Company.
This documentation contains confidential information proprietary to Unimark, Inc. Use, disclosure,
reproduction, copying and transfer of this documentation and the copyrights and proprietary information
embodied herein is permitted only for purposes authorized in, and subject to the terms and conditions of, the
License Agreement provided by Unimark, Inc. Other Use, disclosure, reproduction, copy or transfer is
permitted only with the prior written permission of Unimark, Inc.
Galileo International, L.L.C. obtained written permission from Unimark to reproduce contents of the Unimark
XP Installation and Operator’s Manual 71U-1429-100 © 2007 Unimark Products, LLC. for the ADP 4100
printer. No part of this publication may be reproduced or transmitted without prior written permission of
Galileo International, L.L.C. or Unimark, Inc.
ADP 4100 Installation and Operators Manual
4/07

Table of Contents
FCC ...........................................................................................................................................................3
FCC Emission Interference....................................................................................................................3
Note........................................................................................................................................................3
ADP 4100 Printer..........................................................................................................................................4
Introduction................................................................................................................................................4
Operating Tips .......................................................................................................................................5
Warnings and Cautions..........................................................................................................................5
Box Contents .........................................................................................................................................6
Product Specifications ...........................................................................................................................7
Printing system...................................................................................................................................7
Magnetic encoding.............................................................................................................................7
Document handling ............................................................................................................................7
Interface .............................................................................................................................................7
Control Panel......................................................................................................................................7
Physical..............................................................................................................................................8
Environmental ....................................................................................................................................8
Installation .................................................................................................................................................8
Unpacking..............................................................................................................................................8
Bin Full Feature..................................................................................................................................9
Attaching the Ticket Catcher............................................................................................................10
Location and Setup ..........................................................................................................................10
Plugging in the Unit..........................................................................................................................12
Host Interface Specification.................................................................................................................13
Hardware Interface...........................................................................................................................13
Data Structure..................................................................................................................................13
Front Panel ..........................................................................................................................................14
Keypad Display/Layout ....................................................................................................................14
Basic Operator Level Menu .................................................................................................................15
Adjustments Menu...............................................................................................................................16
Basic Unit Operation and Setup..............................................................................................................17
Powering the Unit On and Off..............................................................................................................17
Loading Ticket Stock............................................................................................................................18
Operating Under a CRS or Airline Host...................................................................................................20
Clearing Stock Jams................................................................................................................................21
Cleaning ..................................................................................................................................................24
Using the Cleaning Card......................................................................................................................24
Periodic Inspection...............................................................................................................................25
Cleaning External Surfaces.................................................................................................................26
Cleaning Inside the Enclosure.............................................................................................................26
Cleaning the Encoder Drive and Idler Rollers......................................................................................27
Cleaning the Print Head and Platen ....................................................................................................29
Troubleshooting.......................................................................................................................................30
Basic Scenario Failure Analysis ..........................................................................................................30
Basic Alert Messages ..........................................................................................................................31
Thermal Print Head Replacement...........................................................................................................34
Customer/Technical Support...................................................................................................................36
Return Authorization/Customer Service..............................................................................................36
Technical Support....................................................................................................................................37
Warranty Statement.................................................................................................................................38
Alerts and LCD Messages.......................................................................................................................40
ADP 4100 Printer Installation and Operators Manual, April 2007 1

ADP 4100 Printer
SCOPE.................................................................................................................................................40
POWER UP SEQUENCE MESSAGES...........................................................................................40
FIRMWARE UPDATE MESSAGES.................................................................................................40
STOCK JAM MESSAGES ...............................................................................................................41
STOCK STATUS MESSAGES ........................................................................................................43
AEA ERROR MESSAGES...............................................................................................................44
NORMAL PROCESS MESSAGES..................................................................................................47
COMMUNICATION ERROR MESSAGES.......................................................................................47
2 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
FCC
FCC Emission Interference
This device complies with Part 15 of the FCC Rules. Operation is
subject to the following two conditions:
1. This device may not cause harmful interference,
and,
2. This device must accept any interference received, including
interference that may cause undesired operation.
Any changes or modifications not expressly approved by Unimark
could void the operator’s authority to operate the equipment under
these conditions and rules.
Note
This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be
required to correct the interference at their own cost.
ADP 4100 Printer Installation and Operators Manual, April 2007 3

ADP 4100 Printer
ADP 4100 Printer
Introduction
The XP is a state-of-the-art Airline Ticket and Boarding (ATB) pass
printer (hereafter referred to as the Unit), capable of high speed
printing and incorporating standard ATB features such as magnetic
data encoding and revalidation. The Unit has two RS-232
Asynchronous Serial Communication ports to interface to the host
system. The ports are configured as DTE requiring a null modem
cable connection to a DTE host system. Other interface options are
available or can be developed such as Ethernet, USB, or Modem.
The Unit is designed to set on the floor. There are multiple caster
options available, allowing the Unit to be easily moved around in
airport and travel agency environments.
The Unit transport mechanism accepts full size ATB coupons (8 and
7-3/8 inch stock). The Unit has three input bins. Bins A and B are
internal secured locations for ATB ticket stock. Both A and B bins can
hold up to 1000 ATB documents. Bin C is external which is typically
unsecured and used for mini ITIN stock. An optional Bin C shelf is
available as well as a Bin C box which can be secured. The
printed/encoded coupons are automatically presented at the exit bin
on the front of the Unit. The Unit has an internal reject bin for
coupons which cannot be properly encoded or are otherwise
damaged and unusable.
The Unit’s front control panel incorporates control/function keys,
indicator LEDs, and an alpha-numeric character display. The display
provides Unit status and activity information as well as providing
visible feedback when the operator or service provider is navigating
through the menu system.
The Unit uses an auto switching power supply which allows automatic
operation in both 110 and 220VAC environments.
4 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
Operating Tips
yRead and follow all warning instruction labels on the Unit itself.
yDo not operate your Unit near water or spill liquid of any kind into
it.
yDo not use a damaged power cord. Do not put anything on it or
place it in an area where it will be walked on. If the power cord
becomes damaged or frayed, replace it immediately.
yDo not insert anything into the ventilation slots or openings as this
can result in damage to the Unit.
yOnly trained technicians should attempt to service the Unit if in
need of repair.
Warnings and Cautions
The Unit is designed to operate safely and effectively under normal
circumstances with both enclosure doors closed. However, some of
the procedures presented in this manual, such as cleaning and
clearing ticket jams, must be completed while the left door of the
enclosure is open. When the left door of the Unit is open, the
operator is exposed to moving mechanisms and components.
WARNING
For your safety, a warning notice will appear before any procedure
involving moving components. Each warning notice will be prefaced
by the international safety alert symbol and warning label. The
warning text will explain the precautions to take involving the
procedure being followed.
CAUTION
You may damage some of the components in the Unit during
maintenance procedures if you do not take specific precautions.
When a component is subject to damage, a caution notice will appear
before the step. Each caution notice will explain the potential damage
and specify the appropriate precautions.
ADP 4100 Printer Installation and Operators Manual, April 2007 5

ADP 4100 Printer
Box Contents
Items Included (contents vary with customer configuration):
1. XP Unit
2. Keys
3. AC Power Cord
4. XP Manual or Product CD
5. Optional items such as ticket catchers, Bin C options, and
interface cables and adaptors/gender changers
6. Sample Test Stock
6 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
Product Specifications
Printing system
-Method: Direct Thermal
-Resolution: 203DPI
-Speed: Up to 50 documents per minute
-Font:Contains Andale from Agfa Monotype Corporation®
Magnetic encoding
-Stock type: ATB1 and ATB2 tickets with and without magnetic
stripe
-Encoding specification: Conforms to IATA specification
1722C, Attachment C
-Encoding format: Four tracks Read/Write verification (210
bpi)
-Pre-Encoding: Standard pre-read of magnetically encoded
SCN numbers
Document handling
-Types: ATB1 and ATB2, 8 and 7-3/8 inch stock
-Source: Two internal (Bins A and B); 7-3/8 and 8 inch stock.
One external (Bin C); 8 inch stock only
-Revalidation: One front input feed slot; 7-3/8 and 8 inch stock
-Reject: One internal reject bin
-Exit: One stock path exit point at the front below the
revalidation slot
Interface
-RS-232: Two Asynchronous Serial Communication ports (DB-
25F DTE standard)
-Ethernet: *Optional network interface (RJ-45) with TCP/IP and
Web Server functionality
-USB: *Optional Universal Serial Bus interface
-Modem:*Optional Modem Phone Line (RJ-11/RJ-12) interface
-RF: *Optional RF antenna mount
*Not part of the Standard XP configuration
**Other interface options can be developed as necessary
Control Panel
-Keys: Eight momentary push button keys (see “Front Panel”
section for details)
-LEDs: Four indicator LEDs (see “Front Panel” section for
details)
-Display: 2 row by 20 column (2x20) alpha numeric (see “Front
Panel” section for details)
ADP 4100 Printer Installation and Operators Manual, April 2007 7

ADP 4100 Printer
Physical
-Dimensions: 11-5/8” wide, 23-1/2” high (without casters), 21-
3/4” deep
-Weight: 50lbs (23 kg), Standard Configuration
-Shipping Container Dimensions: (See “Installation” section)
Environmental
-Operating Temperature:40 to 104°F (4 to 40°C)
-Storage Temperature:-4 to 140°F (-20 to 60°C)
-Relative Operating Humidity:5 to 95%, non-condensing,
without degraded performance
-Relative Storage Humidity:5 to 95%, non-condensing,
without damage to components
Installation
Unpacking
Inspect the shipping container for evidence of in-transit damage, such
as being dropped, crushed, or punctured. If damage is evident,
contact the carrier directly to specify the nature and extent of damage.
If the container is free of damage, remove the Unit from the shipping
container by opening the side panel marked “OPEN THIS END”. Pull
the Unit (secured with packing foam pieces) from the container and
remove the foam from the Unit.
The keys are in a package attached to the rear of the Unit.
Retain original shipping carton and foam for future use.
Accessories Kit
After the Unit has been removed from the shipping container, remove
the Accessories Kit from the Bin A/B location on the left side. The
Accessories Kit consists of the power cord, ticket catcher, Operator's
Manual or Product CD, and some sample stock for testing. The exact
contents of the kit are subject to change without notice.
8 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
Bin Full Feature
The Bin Full Bale allows the Unit to sense when the ticket catcher is
full (approximately 125 tickets). Under this condition a front control
panel alert is set and ticket printing is automatically halted. The alert
condition is cleared and printing is resumed as soon as the tickets are
removed. To enable the Bin Full feature, simply place your index
finger against the top left side of the bin full bale and push slightly to
the right while pulling out. This action moves the bin full bale from the
locked storage position to the operating position. The bin full bale
should move freely up and down.
ADP 4100 Printer Installation and Operators Manual, April 2007 9

ADP 4100 Printer
Attaching the Ticket Catcher
Remove the ticket catcher from the Accessories Kit. Hold the catcher
by the sides, between your thumb and fingers, with the open end of
the catcher facing up. Set the bottom of the catcher into the bottom of
the opening in the front of the Unit. Gently squeeze the sides of the
ticket catcher and push it into place. Let go of the ticket catcher and it
will remain in place.
Handle
The Unit can incorporate a handle located on the front just below the
user interface keypad. The handle is designed to assist the operator
when rolling the Unit out to load stock and for service and product
support. The handle is not to be used to lift Unit, which could result in
product damage.
Bin C Shelf
The Unit can incorporate a shelf to support stock for the Bin C input.
The shelf is located on the rear of the Unit. During shipment it is
stored in the locked upright location. During on-site installation, the
shelf can be pulled down from the top and let down to the horizontal
(down) location. A support chain will limit the downward swing of the
shelf.
Location and Setup
Choose a location that provides at least 1-inch of open space
between surfaces adjacent to the Unit’s sides, front, and top. This
space is required to allow for proper ventilation of the Unit. At least 3
inches of space is required behind the Unit for cabling and airflow.
Position the Unit so adequate space is provided on both the left and
right sides to open the doors. Alternately verify that the Unit can be
moved (or rolled) to an open area where the doors can be fully
opened. The left and right doors must be able to swing open 90º to
load ticket stock or to perform routine maintenance.
10 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
yDo not install the Unit where it will be exposed to direct sunlight.
Sunlight may affect the optical sensors resulting in stock loading
difficulties. Direct sunlight can also affect the readability of the
front panel display.
yThe Unit is intended for indoor use only. Place the Unit on a firm
solid surface. If placed on an unsteady surface, it may fall and
become damaged.
yTo protect the Unit from overheating, do not block openings on the
enclosure. Do not place the Unit on or near a heat source, such as
a radiator or heat register.
yThe Unit uses a grounded 3-prong power cable as a safety feature,
which will only connect to a grounded wall outlet. If the power cable
cannot be plugged into the outlet, contact an electrician to have the
outlet replaced. Do not use an adapter to defeat the grounding
feature.
ADP 4100 Printer Installation and Operators Manual, April 2007 11

ADP 4100 Printer
Plugging in the Unit
The Unit has the following physical connections:
1. POWER: An IEC 320 power connection accepting 110/220VAC
(50/60Hz).
2. COMM 1 and COMM 2: RS-232 interface connections. These
connections are DB-25 female pin connectors and are configured
as DTE. A null modem cable quickly interfaces the Unit to a
standard connection on a typical PC-based host system.
Optional Connections
3. Ethernet: An optional RJ-45 connection is available for Ethernet-
based connections providing TCP/IP and Web Server
connectivity.
4. USB: An optional Universal Serial Bus connection is available for
USB connectivity.
5. Modem: An optional RJ-11/RJ-12 connection is available for
modem (phone line) based connections.
6. RF: An optional antenna mount is available for RF based
connectivity.
12 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
Host Interface Specification
Hardware Interface
The Unit has two RS-232 Asynchronous Serial Communications ports
to interface to the Host system. The physical connection is provided
using two DB-25 female pin connectors marked COMM 1 and COMM
2. The ports are configured as DTE connections and can be used to
connect to an associated DTE host using a null modem cable. The
pinout below provides the basic cabling requirements to connect the
Unit to a PC-type host system (table shown assumes the host system
uses a DTE DB-9 connector).
Host (DTE) PC/AT or equivalent Signal Flow XP (COMM 1 and 2)
Pin #, DB-9 Signal Name Signal Name Pin #, DB-25F
1 CD N/A
2 RxD ⇐TxD 2
3 TxD ⇒RxD 3
4 DTR ⇒DSR 6
5 Signal GND N/A Signal GND 7
6 DSR ⇐DTR 20
7 RTS ⇒CTS 5
8 CTS ⇐RTS 4,11
9 RING ⇒
The connection from pin 11 to RTS enables the Unit to function with
existing customer cabling. This connection can be removed if
necessary.
The Unit may also have optional hardware interfaces including
Ethernet, USB, and Modem. Custom firmware interfaces can be
written for these and the existing serial interface.
Data Structure
The Unit uses an asynchronous serial data transmission method.
Data is sent based on any combination of the following:
Baud Data Length Parity Stop Bit
1200 - 115,200 7, 8 None, Even, Odd, Mark,
Space 1, 2
ADP 4100 Printer Installation and Operators Manual, April 2007 13

ADP 4100 Printer
Front Panel
Keypad Display/Layout
You will find the following elements in this display.
1. ONLINE - Indicates that the Unit is in the online state. The
ONLINE LED also flashes when the Unit is receiving and
transmitting data.
2. STOCK: Indicates that the Unit is out of stock.
3. ALERT - Notifies the operator of a condition that needs immediate
attention.
4. POWER - Indicates that the Unit is powered.
5. The front control panel character display: Provides the operator
with information about the Unit’s state. The display is also used to
navigate the Unit’s menu system, allowing the operator to change
settings and address conditions to which the Unit has alerted the
operator.
6. ONLINE - Used to change the Unit state from ONLINE (ready to
receive data from the host and print) to OFFLINE (standby state).
7. ⇐⇒⇑⇓ - Arrow keys are used to navigate through the menu
system. The up and down arrow are also used to change the
display contrast/intensity while the Unit is in the ONLINE state.
8. ENTER - Used to access the Unit’s menu system. Pressing this
key moves the operator up one menu level or selects a particular
setting.
9. RESET - Used to clear alert messages and conditions.
10. EXIT -Pressing this key moves the operator back one menu level
or cancels a particular operation.
¡¢£¤
¥
¦§¨
©ª
14 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
Basic Operator Level Menu
Menu structure may change depending on the specific customer
firmware version.
Print Configuration
Print Sample Test Pattern
Online/Offline (1) Print Tests Print Head Profile (4)
Adjustments (2) Cleaning Card (5)
Service Menu (3)
1. Press the ONLINE key to take the Unit off-line, and then press the
ENTER key to access the menu system.
2. See Adjustments sub menu tree for further details.
3. Service menu is password protected. See Service sub menu
trees for further details.
4. Print head profile checks element resistance and then prints
results. Profile algorithm takes approximately 20 sec.
5. See Operator's Manual "Cleaning" Section for complete process
details.
ADP 4100 Printer Installation and Operators Manual, April 2007 15

ADP 4100 Printer
Adjustments Menu
Menu structure may change depending on the specific customer
firmware version.
Left Margin (dots) Enter Value (-50 to +50)
Top Margin (dots) Enter Value (-50 to +50)
Contrast
Enter Value (01 to +10)
Bin A:xx B:xx C:xx
Contrast Front Feed Enter Value (01 to 10)
5 Inches Per Second
6 Inches Per Second
Adjustments Print Speed
7 Inches Per Second
8 Inches Per Second
Burst Position Adjust
Enter Value (-30 to +30)
Bin A:xx B:xx C:xx
Print Sample
16 ADP 4100 Printer Installation and Operators Manual, April 2007

ADP 4100 Printer
The following elements are part of this menu:
yLeft Margin shifts the entire printed image left and right (staple
stub direction).
yTop Margin shifts the entire printed image to the top and bottom
edges.
yContrast sets print darkness (individual settings for each bin).
yContrast Front Feed is the setting for the reval slot input.
yPrint speed selects the ticket stock speed through the print head
path area.
yBurst position adjustment (individual settings for each bin).
Basic Unit Operation and Setup
This Unit has been configured at the factory to meet each customer's
requirements. Use the following procedures to power on the Unit and
load ticket stock. If any difficulties are experienced with any of these
procedures, please refer to the “Troubleshooting” section for help.
CAUTION!
To prevent damage, immediately toggle the power switch to the O
(OFF) position if the Unit does not indicate RAM TEST status on the
display within 2-3 seconds after power is applied.
If the display does not show ONLINE status within 30 seconds, refer
to the “Troubleshooting” section for help.
Powering the Unit On and Off
yTo power-up the Unit, locate the power switch below the front
control panel on the front of the Unit and toggle it to the I (ON)
position. As soon as the Unit is powered on, it will begin
performing an internal self-test procedure that may take up to 10
seconds.
yTo power-down the Unit, simply toggle the power switch to the O
(OFF) position.
ADP 4100 Printer Installation and Operators Manual, April 2007 17

ADP 4100 Printer
Loading Ticket Stock
CAUTION
Take caution when opening the left side door. Refer to “Installation”
section for details on how the left side door opens and the space
required.
WARNING
To prevent personal injury, do not wear loose clothing or jewelry and
do not stick fingers into transport mechanism when loading ticket
stock. The transport mechanism contains moving parts.
To load ticket stock, follow these steps:
Note: Read the entire procedure before loading ticket stock.
1. Verify the power switch is in the I (ON) position.
2. Unlock the door on the left side of the Unit and swing it open.
3. Rotate the ticket stock box until the arrows on the side of the box
point up.
4. Remove the box top (see the figure on the next page for an
example of ticket stock loading).
Note: The example shown on the next page is a standard ARC
box design. Ticket stock box nomenclature varies from stock
supplier and controlling agencies. Check with the ticket stock
supplier for details.
5. Place the box(s) into the selected bin locations with the printable
side of the first ticket facing down, and the magnetic stripe (if
applicable) on the back of the ticket against the inner wall.
Note: The printable side of direct thermal stock has a heat
sensitive coating. Although it is obvious which side of ATB ticket
stock is the printable side, it may not be as easy to determine on
blank itinerary stock.
6. To determine which side of the direct thermal stock is the printable
side, rub your fingernail or a hard object across the surface of the
ticket. The printable side will show a dark mark and the non-
printable side will not.
18 ADP 4100 Printer Installation and Operators Manual, April 2007