TransAct Ithaca 800 Series User manual

800 Series
Models 850, 860
PN: 85-03670
Rev C
Mar-03

Mar-03 Rev C Page
Confidential Information: Not for Distribution.
i
Change History
Rev A Initial Release
Rev B Page 36 added Item #14 (85-04169)
Rev C Updated disclaimer

Page ii Rev C Mar-03
Confidential Information: Not for Distribution.
Important:
Before installing any equipment be sure to consult the specifications in this manual. Failure to do so may
cause integration problems. Please confirm any specifications with TransAct’s Ithaca Facility’s Sales
Department. Portions of this manual may be changed without prior notice.
Note:
Losses that can be attributed to improper installation and working procedures are not the responsibility of
TransAct Technologies Inc. No part of this manual may be used to recreate any part of the 800 Series
Printer. If this manual contains any questionable information or mistakes please contact TransAct for
assistance.
Disclaimer
© 2003 TransAct Technologies, Inc. All rights reserved.
NOTICE TO ALL PERSONS RECEIVING THIS DOCUMENT:
The information in this document is subject to change without notice. No part of this
document may be reproduced, stored or transmitted in any form or by any means,
electronic or mechanical, for any purpose, without the express written permission of
TransAct Technologies, Inc. ("TransAct"). This document is the property of and contains
information that is both confidential and proprietary to TransAct. Recipient shall not
disclose any portion of this document to any third party.
TRANSACT DOES NOT ASSUME ANY LIABILITY FOR DAMAGES INCURRED,
DIRECTLY OR INDIRECTLY, FROM ANY ERRORS, OMISSIONS OR
DISCREPANCIES IN THE INFORMATION CONTAINED IN THIS DOCUMENT.
Some of the product names mentioned herein are used for identification purposes only
and may be trademarks and/or registered trademarks of their respective companies.
TransAct, PowerPocket, Magnetec, Insta-Load, POSjet, Ithaca, 50Plus and "Made to
Order. Built to Last" are registered trademarks and BANKjet is a trademark of TransAct
Technologies, Inc.
Copyright
© 2003 TransAct Technologies, Inc. All rights reserved.
Revision Level C
Mar-03
Printed in USA

Table of Contents Series 800 Maintenance Manual
Mar-03 Rev C Page
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iii
Table of Contents
Change History..............................................................................................................................................i
Important:.....................................................................................................................................................ii
Note:...............................................................................................................................................................ii
Disclaimer......................................................................................................................................................ii
Copyright.......................................................................................................................................................ii
Trademarks......................................................................................................Error! Bookmark not defined.
Table of Contents.........................................................................................................................................iii
Figures........................................................................................................................................................... v
Tables............................................................................................................................................................. v
SERIES 800 GENERAL INFORMATION 1
Who should read this guide?........................................................................................................................ 1
What is included in this guide?.................................................................................................................... 1
Warranty Options......................................................................................................................................... 1
Internet Support........................................................................................................................................... 1
www.transact-tech.com.............................................................................................................................. 1
Service Information...................................................................................................................................... 2
Ithaca Product Support Procedure............................................................................................................. 2
Contacting TransAct’s Ithaca Facility........................................................................................................ 3
SERIES 800 SPECIFICATIONS AND REQUIREMENTS 4
Series 800 Model Functionality Descriptions............................................................................................. 4
Standard Features ........................................................................................................................................ 4
Optional Features......................................................................................................................................... 5
Dimensions ................................................................................................................................................ 6
Interface..................................................................................................................................................... 6
Printer ........................................................................................................................................................ 6
Printer Environmental Conditions.............................................................................................................. 6
ESD............................................................................................................................................................ 6
Reliability................................................................................................................................................... 7
Power Requirements.................................................................................................................................. 7
Test Standards............................................................................................................................................ 7
Mechanism Characteristics ........................................................................................................................ 7
Printing Specifications.................................................................................................................................. 8
Ticket Specifications..................................................................................................................................... 8
Ticket Specifications (continued) .............................................................................................................. 9
Design Envelope: Ticket Clearance........................................................................................................... 9
Print Characteristics................................................................................................................................. 10
Black Dot Position and Presentation Scheme .......................................................................................... 10
Ticket Stack Orientation............................................................................................................................ 11
MOUNTING REQUIREMENTS 12
Chassis Mounting to Final Product.......................................................................................................... 12
Custom Bezel Specifications and Recommendations............................................................................... 13
SERIES 800 PRINTER SENSORS 14
Paper Low Sensor.................................................................................................................................... 14
Top-of-Form Sensor................................................................................................................................. 14

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Ticket Taken Sensor ................................................................................................................................ 14
Head-Up Switch....................................................................................................................................... 14
Void and Reprint (Model 860 only)......................................................................................................... 14
Open/Close Position Sensor/Audible Alarm............................................................................................ 15
Printer Status LED................................................................................................................................... 16
ELECTRICAL CONNECTIONS 17
Serial Communications Interface PCB..................................................................................................... 17
Default Communication Settings ............................................................................................................. 18
Bezel Lamp Connector............................................................................................................................... 18
Printer Block Diagram............................................................................................................................... 19
OPERATIONAL PROCEDURES 20
Loading Tickets into Feeding Mechanism............................................................................................... 20
Removing Loaded Tickets ....................................................................................................................... 21
Cleaning the Print Head........................................................................................................................... 23
CHAPTER 7: ASSEMBLY/DISASSEMBLY 24
Precautions for Disassembly...................................................................................................................... 24
Necessary Tools....................................................................................................................................... 24
Model 850 OEM Variations Notice......................................................................................................... 24
Racking/Unracking the Printer Mechanism Assembly............................................................................. 25
Removing the Ticket Tray from the Main Printer Assembly................................................................... 26
Remove PCB Cover Plate from Printer Mechanism Assembly................................................................ 27
Remove Print Mechanism from Printer Mechanism Assembly................................................................ 28
Remove Controller PCB Assembly from Printer Mechanism Assembly................................................. 29
Remove Interface PCB Assembly from Outer Slide Chassis................................................................... 30
CHAPTER 8: PARTS LISTS 31

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Figures
Figure 1 800 Series Printer Component Overview............................................................................................................. 4
Figure 2 Series 800 Printer: Dimensions ........................................................................................................................... 6
Figure 3 Design Envelope: Ticket Clearance..................................................................................................................... 9
Figure 4 Location of Black Dot/Top of Form Indicator on Back of Ticket.......................................................................... 10
Figure 5 Ticket Stack Orientation .................................................................................................................................... 11
Figure 6 Outer Chassis Mounting to Final Product........................................................................................................... 12
Figure 7 Custom Bezel Mounting and Hardware Requirements....................................................................................... 13
Figure 8 Sensor Breakdown and Locations ..................................................................................................................... 14
Figure 9 Open/Close Position/Audible Alarm................................................................................................................... 15
Figure 10 Serial Communication PCB Location and Connector Info................................................................................ 17
Figure 11 Bezel Lamp Connector Location and Connector Information........................................................................... 18
Figure 12 Series 800 Electrical Operations Diagram ....................................................................................................... 19
Figure 13 Ticket Loading and Ticket Feed Mechanism.................................................................................................... 20
Figure 14 Actuator latch and platen/cover assembly........................................................................................................ 21
Figure 15 Feed Switch and LED indicator Location ......................................................................................................... 22
Figure 16 Cleaning the Printhead .................................................................................................................................... 23
Figure 17 Racking/Unpacking the Printer Mechanism Assembly..................................................................................... 25
Tables
Table 1 Font Statistics..................................................................................................................................................... 10
Table 2 Printer Status LED Indication Descriptions ......................................................................................................... 16
Table 3 Serial Communication PCB Pin-Outs.................................................................................................................. 17
Table 4 Bezel Power Connector Pin-Outs........................................................................................................................ 18

General Information Series 800 Maintenance Manual
Mar-03 Rev C Page
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1
Series 800 General Information
Who should read this guide?
This document is intended for trained service technicians.
What is included in this guide?
This Maintenance Manual covers the proper maintenance procedures for servicing the Series 800 printer.
This manual provides an overview of the Series 800 printer specifications, mounting requirements, a
description of the printer sensors, overview of the electrical connections, operational procedures,
assembly/disassembly procedures, and listing of available spare parts.
Warranty Options
All 800 Series Printers come with a standard 24-month standard warranty covering both parts and labor that
starts upon shipment from the factory. An optional extended warranty, covering both parts and labor for an
additional 12 months, may be purchased separately. For more information concerning the warranty options,
please contact the Sales Department at TransAct’s Ithaca facility. You are responsible for insuring any
product returned for service, and you assume the risk of loss during shipment to Ithaca C.O.D. packages are
not accepted and warranty repairs are subject to the terms and conditions as stated on the Ithaca warranty
policy (packed with each new printer).
Internet Support
www.transact-tech.com
TransAct Technologies Incorporated maintains an Internet web site with content devoted to supporting our
products. At our Support Services section for our Ithaca brand products you can find documentation for the
800 Series printer including a current copy of the OEM Integration Manual. Our on-line suppport also
includes an option to obtain assistance from a technical support specialist by filling out a e-mail assistance
request form.Your e-mail will be received by one of our support specialists and they will contact you via a
phone call. The 800 Series printer support pages offer the latest information.

Series 800 Maintenance Manual General Information
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Service Information
TransAct Technologies Incorporated has a full service organization to meet your printer service and repair
requirements. If your printer needs service, please contact your service provider first. If any problems still
persist, you can directly contact the Ithaca facility’s Technical Support Department at [phone] or
(877) 7ithaca for a return authorization. International customers should contact your distributor for services.
TransAct offers the following service programs to meet your needs.
•Extended Warranty
•Depot Repair
•Maintenance Contract
•Internet Support
Ithaca Product Support Procedure
Monday through Friday, 8A.M. to 5 P.M. (excluding holidays)
To obtain technical support, call TransAct's Ithaca Facility at [phone] and ask for Technical
Support. When you call, please have the following information at hand:
•The Model Number and Serial Number of the printer
•A list of any other peripheral devices attached to the same port as the printer
•What application software, operating system, and network (if any) you are using
•What happened and what you were doing when the problem occurred
•How you tried to solve the problem
•Return Materials Authorization and Return Policies
If the technical support person determines that the printer should be serviced at our facility, and you want to
return the printer for repair, a Returned Materials Authorization (RMA) number must be issued before
returning the printer. Repairs are warranted for 90 days from the date of repair or for the balance of the
original warranty period, which ever is greater. Please prepare the printer being returned for repair as
follows:
•Pack the printer to be returned in the original packing material.
•Packing material may be purchased from TransAct's Ithaca Facility.
•Do not return any accessories unless asked to do so by a support technician.
•Write the RMA number clearly on the outside of the box.

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Contacting TransAct’s Ithaca Facility
Contact TransAct’s Ithaca facility for general information about integrating 800 Series printers with your
system. The Sales and Technical Support Departments will be able to help you with most of your questions.
Call the Technical Support Department to receive technical support; order documentation; receive
additional information about the 800 Series; or send in a printer for service. To order supplies; receive
information about other Ithaca products; or obtain information about your warranty, contact the Sales
Department. To receive information on International distribution, look on our web site at www.transact-
tech.com
You may reach both the Sales and Technical Support Departments at the following address and telephone
or fax numbers:
TransAct Technologies Incorporated
Ithaca Facility
20 Bomax Drive
Ithaca, NY 14850 USA
Telephone (877) 7ithaca or [phone]
Main fax [phone]
Sales fax [phone]
Technical Support fax [phone]
Web site http://www.transact-tech.com

Series 800 Maintenance Manual Specifications and Requirements
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Series 800 Specifications and Requirements
Figure 1800 Series Printer Component Overview
1. Printer Mechanism
2. Printer Mechanism Assembly
3. Printer Ticket Bucket (200, 400, 600)
4. Outer Slide Chassis
Series 800 Model Functionality Descriptions
There is a specific functional difference between the Model 850 and the Model 860 printers. As an
option, the Model 860 incorporates a void and reprint sensor that verifies the integrity of the barcode.
The Model 860 can automatically determine if the ticket’s barcode is, or is not readable.
Standard Features
The following features are common to the 800 Series Printers:
•Perforated fan folded tickets in a stack of 200 tickets.
•Barcode and total ticket cash-out capabilities.
•Horizontal ticket exit.
•Ticket separation performed by customer.
•Modular printer mechanism, ticket tray and sliding unit for easy maintenance.
2
1
4
3

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•Modular Interface PCB.
•Audible Buzzer
Optional Features
•400 and 600 count ticket trays.
•Void and Reprint (Model 860 only)

Series 800 Maintenance Manual Specifications and Requirements
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(Dimensions reflect use of 200 unit ticket bucket unless otherwise noted)
Dimensions
Figure 2Series 800 Printer: Dimensions
Stationery Module Size: H: 2.66" (67.6mm) W: 4.46" (113.3 mm) D: 11.25" (285.75 mm)
The Series 800 is a stationery module, and is designed to work with either of the three interchangable Ticket
Buckets. Please be sure to specify the desired box size when making your selections.
200 ticket setup: H: 2.610" (66.29 mm) W: 4.46" (113.3 mm) D: 11.25" (285.75 mm)
400 ticket setup: H: 4.0" (101.60 mm) W: 4.46" (113.3 mm) D: 11.25" (285.75 mm)
600 ticket setup: H: 5.5" (139.70 mm) W: 4.46" (113.3 mm) D: 11.25" (285.75 mm)
Weight 5.3 lbs.
Interface
Type Bi-Directional, serial RS-232 using transmit, receive, and ground.
Protocol Ready/Busy or XON/XOFF, 9600 baud, 8 data bits, no parity,
1 start bit, 1 stop bit.
Printer
Printer Type: Fixed 2.25" linear thermal head.
Printer Environmental Conditions
Operating Temperature Range: 0º ~ 40ºC (32º ~ 77ºF)
Shipping/Storage Temperature Range: –10º ~ 50ºC (14º ~ 122ºF)
Operating Humidity Range: 10% ~ 90% Noncondensing only
Shipping/Storage Humidity Range: 5% ~ 90% Noncondensing only
ESD
Ground maintained between printer and product chassis.
40 KV sustained air discharge (door closed).
8 KV sustained current injection (door closed).
15 KV protection for exposed electronics (open, loading position).

Specifications and Requirements Series 800 Maintenance Manual
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45°
Reliability
Printer Life: 20 million print lines.
Mean time between failures: 45,000 hrs. @ 25% duty cycle.
Printer electronics: 250,000 hrs.
Printhead Life: 50Km min.
Flex ribbon (sliding module): 1,500 cycles min.
Power Requirements
24 Vdc ± 5%.
2.2 Amps max. @ 24 Vdc @ 25% print ratio.
Test Standards
FCC 47CFR, Part 15, Class A.
EN 55022, Class A.
ESD IEC 1000-4-2, 6kv direct discharge and 8kv air discharge.
Radiated RF IEC 1000-4-3, 3 v/m from 27 MHz to 1 GHz.
Fast transit (burst) IEC 1000-4-4, 2kv powerline, 1kv I/O lines (level 3, Industrial environment).
Accoustic Noise: Sound pressure level: 60 decibels max.
(measured in 10 positions @ operator level with distance of 1 meter).
Mechanism Characteristics
Drawer Slide Force: 2 lbs. max.
Opening Distance: 200mm (8") (approximate )
Drawer Holding Force: 4 lbs. (out of detents)
Mechanism Operating Angle: Horizontal to 45º inclination (ticket exit slot up).

Series 800 Maintenance Manual Specifications and Requirements
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Printing Specifications
Print Method: Thermal Sensitive Line Dot System.
Ticket Handling: Straight. Entire path is accessible.
Print Speed: 125 mm/sec. (5" per sec.) max. (in text mode)
Paper advance speed: 125 mm/sec. (5" per sec.) min.
Resolution: 203dpi x 203dpi and 136dpi x 203dpi.
Dot Pitch-Horizontal: 0.125 mm (8 dots/mm)
Dot Pitch-Verticle: 0.125 mm (8 dots/mm)
Line Feed Pitch: 3.2 mm (.125")
Characters per line: 30 min.
No. of Elements: 500 dots in-line
Print Width: 62.5 mm (2.46")
Data Buffer: 8K
Memory: 256K EPROM & 128K RAM
Ticket Specifications
Dimension: (same size as US dollars)
Ticket Width: 65 ± .75mm (2.56"± .03")
Ticket Length: 156 ± 1mm (6.14" ± .04") between perforations
Ticket Thickness: 4.5 mils (114 microns)(.0045 inches)
Ticket Weight: 27# (102 g/m 2) Ave.
Reading Code: Interleaved. 2 of 5
Minimum Bar Width: 0.5 mm min./0.6 max.
W : N Ratio: 3 : 1
Letter Quantity: 6 min./18 max.
PCS Value: 0.6 min.
Printing Ink: BLACK: (visible light absorbtion: 600 ~ 700 nm)
Optical Reflection Level: White thick bar: 3.0V min. Black thick bar: 2.0V max.
Amplitude Level: 0.5V (white and black bar).
Waveform Distortion: 0.3V max.
Transmission Level: Level 1: 1.3V max. Level 2: 0.5V min.

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Ticket Specifications (continued)
The 800 Series printer requires the following tickets for proper printing:
Ticket Type: Kanzaki TO-381N or approved equivalent
Thermal sensitive layer facing down.
Thermal sensitive side to be coated for wear characteristics.
Quantities Available: Fan-folded stacks of 200, 400 and 600 tickets.
Design Envelope: Ticket Clearance
A minimum paper clearance distance of .75" is required above the printer’s ticket buckets. The minimum
clearance for all ticket buckets will vary, but should fall within the .75" minimum clearance measurement.
Figure 3Design Envelope: Ticket Clearance

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Print Characteristics
The statistics for the internal fonts the 800 Series Printer supports appear below. Height and width are
expressed in terms of dots.
Height Width Horizontal cpi Vertical cpi
24 12 16.9 8.4
32 16 12.7 6.4
32 20 10.2 6.4
56 28 7.3 3.6
Table 1Font Statistics
Black Dot Position and Presentation Scheme
All graphics preprinted on the ticket must be in thermal paper compatible ink.
Black Dot Position
The back of the ticket is used for the Black Dot/Top of Form indicator. For the printer to sense when a
ticket has been indexed to the printing position, a Black Dot/Top of Form sensor is needed. It must be
printed in black, thermal paper compatible, infrared readable ink. The 10.16mm area in line with the Black
Dot/Top of Form indicator and the ticket edge (keep-out zone) must remain clear, as the Ticket Out Sensor
will read that area while the ticket is printed and presented. The remaining area on the back of the ticket
may be used for rules and disclaimer.
Figure 4Location of Black Dot/Top of Form Indicator on Back of Ticket

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Ticket Stack Orientation
To ensure the ticket is loaded correctly into the printer, the ticket stack must be properly loaded in the ticket
box. The stack must be oriented so that the Black Dot/Top of Form mark of the tickets is on the leading
edge of the ticket, not near the perforation of the next ticket. If the top ticket on the stack has the back
facing upward, the perforation attaching the next ticket will be toward the front of the Ticket Supply Box
with the Black Dot/Top of Form indicator in the rear right corner. If the print area is facing upward, the
perforation attaching the next ticket will be toward the rear of the Ticket Supply Box. For instructions on
inserting the first ticket into the printer, see “Loading Tickets into Feeding Mechanism” on page 20.
Figure 5Ticket Stack Orientation

Series 800 Maintenance Manual Mounting Requirements
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Mounting Requirements
Chassis Mounting to Final Product
Bottom: 4x M4x 0.7 press nuts
4x .180" thru holes
Figure 6Outer Chassis Mounting to Final Product