THASOS 4182

SERVICE MANUAL

MICRELEC SA

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INTRODUCTION

Welcome to THASOS SERVICE MANUAL. This short manual is aimed at service technicians. It is assumed that the service technician is already familiar with the THASOS basic functions so that he can perform an operating test of the machine. The THASOS basic functions are described in the INTRODUCTORY USER MANUAL. All service technicians may refer to this manual for details on the machine operation. The aim of the present manual is to educate the service technician to be able to recognise all replaceable modules in the ECR and be able to diagnose which is the most likely module to cause a given malfunction. The aim of the service technician visiting a customer is to be able to fix a problem by quickly replacing on site one (or more in rare cases) of malfunctioning modules. Doing so, he will be able to deliver a working machine within minutes. The picture below presents all functional modules (or subassemblies) that make up the THASOS ECR. The picture was taken after a technician has unscrewed the sealed screw at the top (fiscal seal) and the four screws at the bottom that hold top and bottom case together. Right after that, the technician has moved the top case over and behind the bottom case and then moved the keyboard assembly at the front of the bottom case, placing it top side down to reveal all modules. For details on opening up the case for servicing the internal parts, please refer to the following chapter, OPENING UP THE CASE. For details on the function, debuging and probability of any given module to be malfunctioning please refer to the following chapter, MODULE LINE UP. For details on how to power up the ECR again after replacing a faulty module, please refer to the chapter named RESETING THE ECR.

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MAINBOARD MODULE : The heart of the system, the mainboard module, drives all other modules and runs the application fiscal software. The mainboard can be replaced on site, as any other module, with minimum effort.

THASOS 4182 FUNCTIONAL MODULES

PRINTERS MODULE The 2 thermal printers (receipt and journal) are both assembled on one PCB that connects both mechanisms to the mainboard using a single 20 pin flat wire PAPER WIND MODULE This module is an electric DC motor driven Mechanism to wind the journal paper

DISPLAY MODULE The display module consists of one customer LCD display and one operator LCD display. These are the only modules attached on the upper part of the case. Both LCDs connect to the MAINBOARD via one flat cable connector. BACK CONNECTORS MODULE: This is a PCB that carries the serial RS232 and drawer connectors (also the Ethernet connector if that option exists) POWER SUPPLY MODULE: this module consists of AC two pole on/off switch and a filter/switching power supply unit that takes 150-240VAC as input and delivers 12VDC / 50W output. FISCAL MEMORY MODULE: this is the fiscal PROM memory unit, normaly covered with resin that completely seals the module in the box provided in the case.

KEYBOARD MODULE: Here shown top side down, the keyboard module is a subassembly of 70 raised top keys that connects to mainboard using a standard 20pin IDC

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OPENING UP THE CASE

There are just 6 screws to remove to open up the case. For security reasons,though, you can not unscrew the top screw unless you break up the special fiscal seal that is covering up the top screw 1. Only a qualified technician should attempt this. Follow these steps: 1. Unscrew the top sealed screw as shown in picture. To be able to unscrew this you must first break the fiscal screw. Use the tip of a screwdriver or any other sharp object to remove the resin or any other seal material that is used.

CAUTION: Only qualified technicians shall break the fiscal seal. Qualified technicians carry with them approved sealing material to restore the fiscal seal after repair. 2. Unscrew the four bottom screws as shown in picture.

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MODULE LINE UP
Once the case is opened the technician can place the top cover, which carries the displays, at a distance behind the bottom case. The flat cable connecting the top displays with the mainboard is enough to displace the cover at a logical distance so all interior is easily accessible. Then the whole keyboard assembly can be raised from its seat and placed at the front of the bottom case as shown in the picture above without removing the flat wire from its mainboard connector. As you may see on the picture above, all eight functional modules are thus made available for inspection and change. Here is a short description of each one:

1. MAINBOARD MODULE
What does it do? The mainboard is the heart of the system, driving all other modules and storing all data and parameters. The mainboard contains the main CPU, the application software in firmware, all data and parameters in CMOS RAM which is backed up with a NiCd battery, and generally all necessary electronics to drive all peripherals. When to change it? The mainboard should be changed when there is power (you can easily measure it using a voltmeter on the power output of the PSU module) but the ECR is not responding to any operation or the operation is totally erratic. Also, the mainboard should be changed when you can operate the ECR but you get totally wrong printouts (like wrong numbers in totals, distorted graphics or upredictable printings). Obviously, the mainboard should be changed when everything else fails!

How to change it?

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To remove the mainboard you follow two steps: Step 1: Remove all connecting wires marked with a green dot in the following picture. The green dots are numbered 1 to 7 for the total of the connectors existing on board. These are: DOT 1 is the power connector, oriented by the mating connector DOT 2 is the paper winding connector, oriented by the mating con DOT 3 is the printers connector, oriented by the mating con DOT 4 is the keyboard connector. Observe the orientation shown in picture since there is no oriented mating connector DOT 5 is the RS232 connector. Observe the orientation shown in picture since there is no oriented mating connector DOT 6 is the displays connector. Observe the orientation shown in picture since there is no oriented mating connector DOT 7 is the fiscal memory connector. Observe the orientation shown in picture since there is no oriented mating connector

Step 2: unscrew the four screws that are holding it at the bottom case as shown by the red arrows above. Repeat above steps in reverse order when placing a new (and tested) mainboard. To power up the new mainboard, follow the instructions on following chapter, RESETING THE ECR. How rare is it? Due to its complexity, you will encounter mainboard malfunctions more often than any other module malfunctions. This means that the mainboard module is suspect for malfunction in many cases where the cause is not obvious.

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2. KEYBOARD MODULE
What does it do? The keyboard module is the array of keys used to operate the machine. It has no electronics, only a PCB and 70 switches / keys connected to the mainboard via a flat cable wire. The keys are connected in a 9X9 scan matrix driven by a dedicated microcontroller on the mainboard. Their function is to close a circuit between scan and input lines when pressed. When to change it? Usually one or two keys present problems in operation due to wear from frequent use. The modular approach for the service of CRETA calls for replacing the whole keyboard module instead of the single malfunctioning key. This allows for easy on site repair, while the malfunctioning unit can then be repaired at the service lab later. How rare is it? Because of its mechanical nature, some keys may present problems after a long time of use or when liquids are spilled onto them. Their expected life is over a 1,000,000 contacts, so even if you use a key 1000 times per day, you can expect that key to last for more than three years.

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3. PRINTER MODULE
What does it do? The printer module is a complex one since it is an assembly of one base PCB and two thermal printer mechanisms. You can replace just one of the two printers or the whole assembly depending on the nature of the malfunction. The printer on the left is used to print out the journal and the printer on the right is used to print out the receipt. Both printers work in parallel and the two printouts are identical. Sometimes, because of the parallel driving, the malfunction of one mechanism affects the printout of the other. When to change it? If you notice a portion of the printout missing in one printer while the other one still prints accurately, then the first printer needs to be replaced. If you get continous paper out messages even though you have paper installed you may be facing a printer mechanism malfunction or a mainboard malfunction. Try to replace the printer mechanism first and if that does not change replace the mainboard. How to change it? The following picture shows the printer module:

First, observe the blue arrows. In journal printer, marked with the green dot 1, the blue arrows show the correct, operational position of the thermal head. The green plastic is at its lowest position. On the right, at the receipt printer marked with the green dot 2, the blue arrows show the head off position, that is the non-operational position of the green plastic thermal head.

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The service technician should always make sure that the heads are at on position before doing anything else. To replace just one mechanism unscrew the relative screws shown by the yellow arrows at the picture above. Then pull out the ribbon cable marked with the green dot in same picture. If you need to replace the whole assembly, then you must unscrew the screws marked with the red arrows in the picture. How rare is it? The FUJITSU thermal printers are extremely reliable. On an installed base of around 50,000 units we get about 1 or 2 units per month that need replacement. This may vary, though, depending on the quality of the thermal paper used, service time and conditions of operation. The thermal head has a life of approximately 50km of paper or 100million dot lines, whichever comes first. This is practice may mean that in cases of heavy printouts you may need to change the mechanism in about three years service time.

4. PAPER WIND MODULE

What does it do? The paper wind module is an electromechanical assembly at the back of the journal printer that serves to roll the journal paper. It consists of an electric DC motor, driven by the mainboard, an elastic belt and gear to exert a tension at the journal paper roll. When to change it? You may need to replace the DC motor if you notice you dont get any movement of the motor even if you have disengaged the belt. You may also need to replace the elastic belt if it is worn out. How often is it? The DC motor is not stressed at all and you will very rarely meet any problems. The elastic belt is also very long life, but eventualy you may need to replace it.

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5. DISPLAYS MODULE
What does it do? The displays module is the only one of the modules that is assembled at the top case of the ECR. It is a complex module consisting of both the operator display unit and the customer display unit. Both units are driven in parallel, so you must see exactly the same text on both screens. When to change it? If one of the screens fails to show a correct text or doesnt show anything at all while the other one is displaying correctly, you know you must replace the faulty one. If both screens fail to show anything at all then you may have a problem not with the display module itself but with the mainboard. How rare is it? The LCD screens rarely present problems, but one must keep in mind that those screens are sensitive to extreme heat or cold and permanent damage may result if exposed to such conditions.

6. BACK CONNECTORS MODULE

What does it do? This is the plastic cover at the back of the ECR carrying the two RS232 ports and the drawer connector. If the optional ethernet board is installed, then the back panel carries also a UTP standard ethernet connector. When to change it? When you have a problem with RS232 or drawer operation and can not be remedied by replacing the mainboard. How rare is it? Since only electromechanical components (connectors) are present on this module, malfuntions due to this module are extremely rare.

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7. POWER SUPPLY MODULE

What does it do? The power supply unit (PSU) together with the necessary AC cables and mains on/off switch comprise the power supply module. This module provides all power to the ECR and any malfuntion in this module results in total failure to operate. When to change it? Power Supply failures are the easiest to diagnose: you turn on the ECR and nothing happens. You open the case and, using a voltmeter, you measure the voltage across the black and red wires coming out of the PSU. If your reading is 0V or fluctuating then you have a problem with PSU. In some cases, though, the problem is not with the PSU at all. The PSU has a built-in short circuit protection that prevents the power supply from starting up if there is a short circuit present. So in some rare cases you may have a short circuit on the mainboard or the printers and this is causing the PSU to stop from starting up. To distinguish between those two situations, remove the black/red cable from the PSU and then measure the voltage across the connector, prefferably with an ohmic load in place. If you get close to 12VDC under load, then the PSU is likely to be ok and you should look for a short circuit somewhere. How often is it? This module is the second most probable to malfuntion module besides the mainboard for two reasons: one, because it is the second most complex electronic module in the ECR and second, because it must handle all mains surges and interference which, in extreme cases, may damage its circuitry.

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8. FISCAL MEMORY MODULE

What does it do? Fiscal memory module is the most critical component in a fiscal cash register as it is this that keeps all tax totals. The fiscal memory module is kept always separately from the mainboard and is always glued at the bottom case with a resin. Normally you have no access to this module and, once an error in fiscal memory is detected, the ECR will stop operating automaticaly, displaying a message like FISCAL MEMORY ERROR. When to change it? Actually in fiscal countries the fiscal memory is never changed. If a permanent failure is detected, then a special procedure defined by the local tax authorities must be followed. The service technician is adviced to perform first a full system reset (as described in next chapter) and see if this remedies the problem. If not, then he must try out changing the mainboard, in case the fiscal error is caused by mainboard malfunction and is not located in the fiscal module. If everything fails, then the fiscal module is in error. How rare is it? Fiscal memory errors are extremely rare. Because this is the most important component in terms of fiscal law, special care has been taken to protect as much as possible the fiscal memory. For the THASOS model the statistical data show the occurrence of about 1 such error per 10,000 units per year.

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RESETING THE ECR

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