Ithaca PcOS series 90plus User manual

MAINTENANCE
MANUAL
P
C
OS
SERIES 90PLUS
PN: 100-9067

WARNING: To prevent fire or shock hazard, do not expose this printer to rain
or moisture.

Disclaimer
Information in this publication is subject to change without notice. However, as product improvements become
available, Ithaca Peripherals will make every effort to provide updated information for the products described
in this publication.
Ithaca Peripherals cannot guarantee that changes in software and equipment made by other manufacturers, and
referred to in this publication, do not affect the applicability of the information in this publication.
Copyright
© 1996, 1998, 1999 Ithaca Peripherals. All Rights Reserved.
Revision C, June 1999
Printed in the United States of America.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, mechanical, photocopying, recording, or otherwise, without the prior written permission of Ithaca
Peripherals.
Trademarks
Ithaca and PcOS are registered trademarks of Ithaca Peripherals. Ithaca Peripherals is a Transact Technologies
Incorporated Company. IBM is a registered trademark of the International Business Machines Corporation.

Federal Communications Commission Radio Frequency Interference
Statement
The Series 90PLUS printer complies with the limits for a Class A computing device, in accordance with the
specifications in Part 15 of the FCC rules, which are designed to minimize radio frequency interference during
installation. However, there is no guarantee that radio or television interference will not occur in any particular
installation. If the equipment does cause interference to radio or television reception, which can be determined
by turning the equipment off and on while the radio or television is on, the user is encouraged to try to correct
the interference by one or more of the following measures:
♦Reorient the radio or television receiving antenna;
♦Relocate the printer with respect to the receiver; or
♦Plug the printer and receiver into different outlets.
If necessary, the user should consult their dealer or an experienced radio/television technician for additional
suggestions.
The user may find the following booklet prepared by the Federal Communications Commission helpful: How to
Identify and Resolve Radio/TV Interference Problems. This booklet is available from the United States
Government Printing Office, Washington, DC 20402. Ask for stock number 004-000-00345-4.
Canadian Department of Communications Radio Interference Statement
The Series 90PLUS printer does not exceed Class A limits for radio noise emissions from digital apparatus set
out in the Radio Interference Regulations of the Canadian Department of Communications.
UL, CSA, VDE, CE Statement
Ithaca Peripherals’ printers are UL and CSA listed, VDE certified, and carry the CE mark.

Table of Contents i
TABLE OF CONTENTS
PRODUCT INFORMATION 1
What is in this book? ................................................................................................ 1
Who should read this book?....................................................................... 1
What does it cover?.................................................................................... 1
Where can you find more information?...................................................... 1
Contacting Ithaca Peripherals..................................................................... 1
Warranty Information............................................................................................... 2
Options....................................................................................................... 2
Ordering Supplies..................................................................................................... 2
Paper........................................................................................................... 2
Ribbon Cassettes ........................................................................................ 3
Take-up Spool............................................................................................ 3
Print Head and Clamp ................................................................................ 3
Cables......................................................................................................... 3
Description of the Series 90PLUS Printer................................................................ 4
Series 90PLUS Models .............................................................................. 4
Standard Features....................................................................................... 6
Optional Features ....................................................................................... 6
Technical Specifications........................................................................................... 7
Printing Specifications................................................................................ 7
Print Characteristics ................................................................................... 7
Reliability................................................................................................... 8
Dimensions................................................................................................. 8
Weight........................................................................................................ 8
Power Requirements................................................................................... 8
Environmental Conditions.......................................................................... 8
Communication Interfaces and Cash Drawer Connectors......................................... 9
Serial Cable ................................................................................................ 9
Parallel Cable ........................................................................................... 10
Cash Drawer Pin Assignments.................................................................. 11
CLEANING AND ADJUSTMENTS 13
Cleaning the Printer................................................................................................ 13
Making Adjustments............................................................................................... 13
Diagnosing the Print Quality.................................................................... 13
Necessary Tools ....................................................................................... 14
Adjusting the Platen Gap.......................................................................... 15
Adjusting the Platen Parallel to the Print Head ........................................ 16

Table of Content
ii
ASSEMBLY/DISASSEMBLY 17
Precautions for Disassembly................................................................................... 17
Necessary Tools ....................................................................................... 17
Disconnecting the Power Cord ............................................................................... 18
Disconnecting the Communication Cable............................................................... 19
Disconnecting the Serial Cable................................................................. 19
Disconnecting the Parallel Cable.............................................................. 20
Disconnecting the Cash Drawer Cables.................................................... 20
Removing the Ribbon Cassette............................................................................... 21
Installing the Ribbon Cassette.................................................................. 21
Print Head............................................................................................................... 23
Removing the Used Print Head................................................................ 23
Installing the New Print Head................................................................... 25
Removing the Covers.............................................................................................. 26
Take-up Motor Assembly Kit................................................................................. 28
Mechanical Base Assembly.................................................................................... 30
Knife Disassembly.................................................................................................. 32
25-pin Parallel Interface Cable............................................................................... 34
9-pin Serial Interface Cable.................................................................................... 35
Cash Drawer Harnesses .......................................................................................... 36
Power Supply Assembly......................................................................................... 37
Power Switch and AC Inlet Assembly.................................................................... 38
Controller Board Assembly.................................................................................... 39
Keypad PC Board................................................................................................... 40
Carrier/Cam Plate ................................................................................................... 41
Cam Plate................................................................................................................ 44
Carrier Assembly.................................................................................................... 47
Removing the Print Mechanism Assembly............................................................. 49
Print Mechanism Assembly.................................................................................... 50
Carriage Assembly.................................................................................................. 51
Carriage Motor ....................................................................................................... 52
Line Feed Motor..................................................................................................... 53
TROUBLESHOOTING 55
Determining the Problem........................................................................................ 55
LED Indicators ....................................................................................................... 71
Printer Fault Indicators........................................................................................... 72
Checking Connections and Resistance.................................................................... 74

Table of Contents iii
Print Head................................................................................................. 74
Space Motor Assembly............................................................................. 75
Line Feed Motor (Slip)............................................................................. 75
Line Feed Motor (Receipt)....................................................................... 76
APPENDIX A: THEORY OF OPERATION 77
Electrical Operation................................................................................................ 78
Circuit Operation...................................................................................... 78
Microprocessor and Peripheral Circuits ................................................................. 79
Microprocessor (U1: 80C154) ................................................................. 79
Program ROM (U4).................................................................................. 79
Program RAM (U2).................................................................................. 79
RAM (U5)................................................................................................ 79
LSI (M7U042-026) .................................................................................. 79
Initialization............................................................................................................ 80
Interface Control..................................................................................................... 80
Parallel Interface ...................................................................................... 80
Serial Interface ......................................................................................... 80
Print Head Drive Circuit......................................................................................... 81
Carriage Drive ........................................................................................................ 81
Space Motor Control................................................................................ 81
Slit Encoder.............................................................................................. 82
Line Feed................................................................................................................ 82
Alarm Circuits ........................................................................................................ 83
Drive Circuit Fault Alarm Circuit............................................................. 83
Head Overheat Alarm Circuit................................................................... 83
Power Supply.......................................................................................................... 83
AC Input................................................................................................................. 83
Mechanical Operation............................................................................................. 84
Print Head Mechanism and Operation...................................................... 84
Space Mechanism and Operation ............................................................. 84
Ribbon Feed Mechanism and Operation .................................................. 85
Paper Feed Mechanism and Operation..................................................... 86
Paper-low Detection Mechanism and Operation...................................... 86
APPENDIX B: PARTS LISTS 87
Packing Materials/Publications............................................................................... 88
Printer Assembly..................................................................................................... 90
Paper Cover Assembly............................................................................................ 92
Paper Cover Assembly with Lock........................................................................... 93
Right Cover Assembly (90-7464)........................................................................... 94
Right Cover Assembly with Lock (90-7470).......................................................... 95
Base Cabinet and Take-up Motor........................................................................... 96

Table of Content
iv
Take-up Motor Assembly (90-7462) ...................................................................... 97
Mechanical/Electrical Base Assembly.................................................................... 98
Mechanical/Electrical Base Assembly (continued)................................................. 99
Mechanism Base Assembly - Models 91PLUS and 92PLUS............................... 100
Mechanism Base Assembly - Models 93PLUS and 94PLUS............................... 102
Mechanism Base Assembly - Models 93PLUS and 94PLUS (continued)............ 103
Knife Assembly .................................................................................................... 105
Cam Plate Assembly............................................................................................. 107
Carrier Assembly (Standard) ................................................................................ 108
Carrier Assembly (3” Paper Option).................................................................... 109
Print Mechanism Assembly.................................................................................. 110
Carriage Assembly................................................................................................ 111
Carriage Motor Assembly..................................................................................... 112
Electronic Base Assembly .................................................................................... 113
APPENDIX C: SCHEMATICS 115

Product Information 1
PRODUCT INFORMATION
WHAT IS IN THIS BOOK?
WHO SHOULD READ THIS BOOK?
This book is a maintenance guide intended for trained, service technicians.
WHAT DOES IT COVER?
This book only covers the Series 90PLUS printer, not the entire point-of-sale system, but it will tell
you all you need to know about properly maintaining and servicing the printer. You will learn how to
clean and adjust the printer, troubleshoot problems, and disassemble the printer.
This book also provides some general and technical information about the printer, so you will learn
what the features are, how reliable it is, and what its printing capabilities are.
WHERE CAN YOU FIND MORE INFORMATION?
A Programmer’s Guide is available if you need to know how to program a point-of-sale terminal or a
PC to work with the printer. It describes the commands the printer recognizes to perform its functions.
An Operator’s Guide is also available and is intended for new and experienced operators. It covers
setting up and using the Series 90PLUS printer with any point-of-sale system. For information about
ordering these books, refer to the next section.
CONTACTING ITHACA PERIPHERALS
Contact your dealer first for general information about the Series 90PLUS printer and how it works
with your system. If you need more specific information about the printer, you may contact Ithaca
Peripherals directly. The Sales and Technical Support Departments will be able to help you with most
of your questions.
To order supplies or send a printer in for service, the Technical Support Department can help. Also,
contact the Technical Support Department to receive information about your warranty, technical
advice, or additional information about the Series 90PLUS printer. To order supplies or receive
information about other products by Ithaca Peripherals, contact the Sales Department.
You may reach both the Sales and Technical Support Departments at the following address and phone
or fax numbers:
Ithaca Peripherals
20 Bomax Drive
Ithaca, NY 14850

Series 90PLUS Maintenance Manual
2
Main phone [phone]
Main fax [phone]
Sales fax [phone]
Technical support fax [phone]
Technical support E-mail [e-mail]
Web site http://www.ithper.com
WARRANTY INFORMATION
OPTIONS
All Ithaca Peripherals PcOS Series 90PLUS printers come with a standard 24-month warranty
covering both parts and labor. An optional warranty, covering both parts and labor for an additional 12
months, may be purchased separately.
For more information concerning the warranty options, please contact your dealer or the Sales
Department at Ithaca Peripherals. See “Contacting Ithaca Peripherals” on page 1.
ORDERING SUPPLIES
You may order supplies by calling Ithaca Peripherals or by faxing the order form that was shipped in the
box with the printer. If you would like more forms, call Ithaca Peripherals at [phone], and ask for
the Sales Department. If you already have forms, fax the order to [phone].
You may order the following supplies:
♦Paper,
♦Ribbon cassettes,
♦Take-up spool,
♦Print head and clamp, and
♦Cables.
PAPER
Paper Type Dimensions Stock Number
Receipt paper Single-ply 3.25 inches (width)
3.5 inches (diameter)
240 feet (length)
100-2203
Receipt-journal
paper Double-ply 3.25 inches (width) 3.5 inches (diameter)
125 feet (length)
100-2206
Receipt-journal
paper Triple-ply 3.25 inches (width) 3.5 inches (diameter)
85 feet (length)
100-2207

Product Information 3
RIBBON CASSETTES
Color Supplier Stock Number
Black Ithaca Peripherals 100-7565
Purple Ithaca Peripherals 100-7859
Note: The warranty may be voided if other than genuine Ithaca Peripherals ribbons are used.
TAKE-UP SPOOL
Take-up Spool Stock Number
Journal take-up spool 90-6415
PRINT HEAD AND CLAMP
Print Head and Clamp Stock Number
Print head 90-7337
Print head clamp 06-0571
CABLES
Cables Stock Number
110V power cable 06-0561
230V power cable 06-0806
Parallel-communication cable 253-9800007
Serial-communication cable
PC, 9-pin female to 9-pin female
PC, 9-pin female to 25-pin female 10-2020 10-2021

Series 90PLUS Maintenance Manual
4
DESCRIPTION OF THE SERIES 90PLUS PRINTER
The PcOS (personal computer, point-of-sale) Series 90PLUS printer is a stand-alone, 40-column, high-
speed impact printer. The Series 90PLUS printer performs a variety of functions in a point-of-sale
environment and is available in the following models:
♦Model 91PLUS: Receipt only
♦Model 92PLUS: Receipt and Journal
♦Model 93PLUS: Receipt, Journal, and Slip/Validation
♦Model 94PLUS: Receipt and Slip/Validation
SERIES 90PLUS MODELS
Each of the four models in the Series 90PLUS line of printers has its own unique set of features.
PcOS Model 91PLUS Receipt Printer
The Model 91PLUS is a receipt printer used for applications requiring high-speed printing of
receipts and single-line validation.
♦300 characters per second bidirectional printing
♦42-column printing at 15 characters per inch

Product Information 5
PcOS Model 92PLUS Receipt and Journal Printer
The Model 92PLUS is a receipt and journal printer used for applications requiring a transaction
audit trail (journal) in addition to high-speed printing of receipts and single-line validation.
♦300 characters per second bidirectional printing
♦42-column printing at 15 characters per inch
♦Journal take-up
PcOS Model 93PLUS Receipt, Journal, and Slip/Validation Printer
The Model 93PLUS is a receipt, journal, and slip/validation printer used for applications
requiring up to 17 lines of print on inserted forms such as checks (in validation mode) or charge
slips, guest checks, or personal checks (in slip mode). In addition, it provides the same high-speed
journal and receipt printing as the Model 92PLUS.
♦300 characters per second bidirectional printing
♦42-column printing at 15 characters per inch
♦Journal take-up
♦Form insertion sensor
♦17-line validation
♦Front slip insertion
PcOS Model 94PLUS Receipt and Slip/Validation Printer
The Model 94PLUS is a receipt and slip/validation printer used for applications requiring up to
17 lines of print on inserted forms such as checks (in validation mode) or charge slips, guest
checks, or personal checks (in slip mode). It does not include the journal take-up assembly.
♦300 characters per second bidirectional printing
♦42-column printing at 15 characters per inch
♦Form insertion sensor
♦17-line validation
♦Front slip insertion

Series 90PLUS Maintenance Manual
6
STANDARD FEATURES
The following features and items are standard on all Series 90PLUS printers:
♦Centronics parallel interface with 2K buffer
♦Internal international power supply (95 to 265 VAC)
♦Operating controls and lights
Power ON/OFF switch and indicator
Paper feed button
Forms release button
Resume button
Alarm and form LED’s
♦Paper-low sensor
♦Operator controlled self-test
♦Cash drawer connector (RJ12) and driver (24V, 1.5 amp pulse for approximately 150 ms;
drawer open/closed status reporting)
♦Nine-pin stored energy print head
♦Short line-seeking logic
♦Characters and graphics
Lowercase characters with descenders
300 characters per second bidirectional printing
42-column printing at 15 characters per inch
Emphasized and enhanced print
IBM compatible all-points-addressable (APA) graphics
♦Software controlled vertical spacing
♦Snap-on ribbon cassette
♦Steel receipt tear-off bar
OPTIONAL FEATURES
The optional features either replace a standard feature or enhance the operation of the printer. All
optional features are installed at the factory and must be selected when the printer is ordered.
♦RS-232C serial communication interface
♦RS-422 serial communication interface
♦Journal cover lock
♦Custom colors and logo

Product Information 7
TECHNICAL SPECIFICATIONS
PRINTING SPECIFICATIONS
♦Printing method impact dot matrix
♦Head wire arrangement 9 pins in line
♦Print wire diameter 0.012 inch (0.34 mm)
♦Print wire pitch 0.013 inch (0.35 mm)
♦Print directions bidirectional, logic-seeking
♦Print zone 2.80 inches (71.12 mm)
PRINT CHARACTERISTICS
The Series 90PLUS printer prints characters in a variety of pitches as shown in the following table.
Each pitch can also be printed in a variety of styles affecting the appearance of the characters and the
speed of the printer.
For information about programming the printer to print a particular pitch or style, please refer to the
Programmer’s Guide. You can order the Programmer’s Guide from Ithaca Peripherals. See
“Contacting Ithaca Peripherals” on page 1.
Pitch (in characters per inch) Maximum Characters per
Line Characters per Second
8 22 250
10 28 270
12 32 300
15 42 300
17.1 (condensed) 48 300
20 (super-condensed) 56 300
24 (super-condensed) 66 300
4 (double-wide) 11 150
6 (double-wide) 16 150
7.5 (double-wide) 21 150
8.5 (condensed, double-wide) 24 150
10 (condensed, double-wide) 28 150
12 (super-condensed, double-wide) 33 150

Series 90PLUS Maintenance Manual
8
RELIABILITY
♦Mean time between failure 30,000 hours (Model 91PLUS)
(except print head)
♦Print head life 200 million characters
♦Mean time to repair 15 minutes
DIMENSIONS
♦Width 7.30 inches (185.42 mm)
♦Length 12.25 inches (311.15 mm)
♦Height 6.00 inches (152.40 mm)
WEIGHT
♦Approximate weight 10 pounds
♦Approximate shipping weight 13 pounds
POWER REQUIREMENTS
The Model 90PLUS printer is designed to be AC self-powered in domestic and international markets.
The printer is equipped with a universal, input power supply that is designed to operate worldwide
without modification.
Supply
Voltage
Rating (VAC)
Supply
Voltage
Range (VAC)
Frequency
(Hz) Rated Power (watts) Current Idle (amps) Current Printing (amps)
100 - 240 90 - 264 47 - 63 45 0.08 @ 120VAC
0.04 @ 240VAC
0.9 @ 120VAC
0.4 @ 240VAC
ENVIRONMENTAL CONDITIONS
The printer will run its best when stored and operated in an environment that meets the following
temperature and humidity conditions:
♦Operating temperature 0° to 50°C (32° to 122°F)
♦Storage temperature -10° to +60°C (-14° to +140°F)
♦Operating relative humidity 10% to 90% (noncondensing)
♦Storage relative humidity 5% to 90%

Product Information 9
COMMUNICATION INTERFACES AND CASH
DRAWER CONNECTORS
SERIAL CABLE
Cable Requirements
The PcOS Series 90PLUS printer requires an RS-232C shielded cable, no more than 50 feet long.
The cable must be UL and CSA approved.
RS-232C Communication
The RS-232C interface uses the following protocol and communication characteristics:
♦Up to 19.2K baud
♦Up to 6K buffer
♦Ready/Busy or XON/XOFF protocol
♦Communications diagnostic mode
Pin Assignments for 9-pin Printer Connector
Pin Name Description
1 DCD Data carrier detect
2 RX Receive data
3 TX Transmit data
4 DTR Data terminal ready
5 GND Signal ground
6 DSR Data set ready
7 RTS Request to send
8 CTS Clear to send
9 SSD Secondary data
Serial Cable Configurations
The following cable configurations are for different host requirements.
Serial PC to Series 90PLUS (null modem)
Use the Ithaca Peripherals cable, part number 10-2020, for PcOS Series 90PLUS printers
connected to PC’s or PS/2’s with 9-pin serial ports.

Series 90PLUS Maintenance Manual
10
DTR
DSR
DCD
TXD
RXD
GND
RTS
CTS
4
6
1
3
2
5
7
8
DTR
DSR
DCD
TXD
RXD
GND
RTS
CTS
4
6
1
3
2
5
7
8
Nine-pin
Female
PC
Nine-pin
Female
Printer
PN 10-2020
Serial AT to Series 90PLUS (Null Modem)
Use the Ithaca Peripherals cable, part number 10-2021, for PcOS Series 90PLUS printers
connected to PC’s or PS/2’s with 25-pin serial ports.
DTR
DSR
DCD
TXD
RXD
GND
RTS
CTS
20
6
8
2
3
7
4
5
DTR
DSR
DCD
TXD
RXD
GND
RTS
CTS
4
6
1
3
2
5
7
8
Twenty-five-pin
Female
PC
Nine-pin
Female
Printer
PN 10-2021
PARALLEL CABLE
Cable Requirements
The PcOS Series 90PLUS printer requires a 25-pin male D-shell connector at the printer. To
connect the printer to most PC’s, use Ithaca Peripherals part number 253-9800007, 25-pin male to
25-pin male parallel interconnect cable.