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