Te c hnical Manual
Revision D: 04.18.08
FSP 42/44/46 Flight Strip Printer
BOCA SYSTEMS, INC.
©
2008 Boca Systems, Inc. All rights reserved.
Under the copyright laws, this manual may not be copied, in whole or in part, without
the written consent of BOCA.
Every effort has been made to ensure that the information in this manual is accurate.
BOCA is not responsible for printing or clerical errors and reserves the right to change
specifications without notice.
Table of Contents Page
1.0 Introduction 1
2.0 Unpacking the Printer 2
3.0 A tour of your printer 3
4.0 Installation 7
4.1 Loading Flight Strips 7
5.0 Standard Configuration 9
5.2 Control Panel Indicators 18
6.0. Interface Pinouts 19
7.0 Thermal Paper - Theory and Specification 20
8.0 Maintenance and Adjustments 21
8.1 Paper Guide and Print Head assembly 21
8.1.5 Optical Devices 21
8.1.5.5 Ticket Load Switch 22
8.1.6 Thermal Print Head 23
8.1.7 Rubber Drive Roller 23
8.2 Cutter Assembly 25
8.3 Logic Board 25
8.4 General Cleaning 25
9.0 Spare Parts List 26
10.0 Troubleshooting Guide 27
5.1 This Section has been removed 15
Table of Figures and Appendices Page
Figure 1 Packaging 2
Figure 2a Control Panel and LCD 3
Figure 2b Flight Strip Printer(FSP) 3
Figure 2c Cabinet Lock Mechanism 3
Figure 3a FSP side view 4
Figure 3b FSP, cover open 5
Figure 4 FSP, rear view 6
Figure 5 Adjustable paper path 7
Figure 6 Adjustable paper path instructions 7
Figure 7 Flight Strip Loading 8
Figure 8 Optical Device 22
Figure 8a Ticket Load Switch 22
Figure 9a-c Print head removal, cleaning and adjustment 24
FCC NOTICE
NOTE: The 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 his own expense.
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.
NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded
cables must be used with the unit to insure compliance.
i
WARRANTY INFORMATION
PRINTERS - BOCA warrants each printer to be free of defects for a period of one year
from the date of shipment when subject to normal use and service. This warranty covers all parts and labor except for the print head which is warranted for 90 days. All
warranty labor is to be performed at the BOCA facility. Equipment damaged by misuse
or negligence including damage to print heads caused by defective ticket stock is
excluded from this warranty.
Any defective equipment meeting these conditions should be returned to BOCA for
repair (freight prepaid) in its original box and packing material. A short note describing
the failure should be enclosed with the printer.
Equipment damaged in shipping should be reported immediately both to BOCA and to
the shipper.
ii
1.0 Introduction
The BOCA Flight Strip Printer, (FSP) is a direct thermal ticket printer with an integrated
cutting mechanism designed for air traffic control environments. This manual will
provide the user with general information regarding printer set-up, configuration and
troubleshooting. Please review your programming guide for additional details.
1
2.0 Unpacking the Printer
The printer is shipped in a ruggedized container. Please save packing material for
future use. Remove the printer (see figure 1) and accessories from the box and
inspect for obvious damage. If damage is noticed, please report it immediately to
BOCA.
Tel: (561) 206-0100 Fax: (561) 998-9609 boca@bocasystems.com
The following items should be in the box:
a) Flight Strip Printer
b) Hopper (Optional)
c) AC power cord
2
Figure 1 - Packaging
3.0 A Tour of Your Printer
Figure 2b - Flight Strip Printer (FSP)
3
Output Slot
(Hopper Mounting
Holes)
Figure 2a - Control Panel
and LCD
Figure 2c - Cabinet Lock Mechanism
Figure 3a - FSP , Side View
4
A. Cutter Assembly
B. Optical Detector
C. Timing Belt
D. Drive Pulley (2)
E. Transformer
F. Print Head Release Lever
A
B
C
D
E
F
NOTE:
THE CUTTER ASSEMBLY MAY VARY
DEPENDING ON THE DATE OF
MANUFACTURE OF THE PRINTER.
THE SC2 CUTTER IS SHOWN.
5
Figure 3b - FSP , Cover Open
A. Print Head Release Lever
B. Logic Board
C. LCD Control Board
A
B
C
NOTE:
LOGIC BOARD CONFIGURATIONS MAY
VARY DEPENDING ON THE DATE OF
MANUFACTURE OF THE PRINTER.
THE FGL42 LOGIC BOARD IS SHOWN.
Figure 4 - FSP , Rear View
6
A. AC Power Connector
B. Fuse Holder (2amp,SB)
C. Input Slot
D. Interface Connector (Serial)
E . Locking Mechanism
F. ON/OFF Switch
NOTE:
CONFIGURATION MAY VARY
DEPENDING ON THE DATE OF
MANUFACTURE OF THE
PRINTER FGL42 LOGIC BOARD
CONFIGURATION SHOWN.
A
B
D
E
C
F
4.0 Installation
The FSP is designed to be mounted on a counter top or shelf.
However, prior to site
and installation, the printer should be powered up
and run in the self test
ay the printer flat on a counter. Please confirm that the
line voltage agrees with
the voltage listed on the label affixed to the side of the unit
(see figure 4). Attach the
AC cord and serial/remote interface cables into the proper
connectors as shown in
Turn power on (figure 2) and you will hear the cutter
motor cycle. The LCD
will display PAPER OUT.
4.1 Loading Flight Strips
Prior to loading strips, open cabinet lock mechanism (figure 2c) by inserting screwdriv-
er and making one half turn. This printer is designed with an adjustable paper path feature. Flight strips measuring between 1.0 inches and 1.328 inches in width can be
accomodated.
7
Figure 6 - Adjustable paper path instructions
1. Feed stock into the paper path.
2. Loosen thumb screws on slider.
3. Move slider towards the stock until they touch.
4. Back slider away from the stock a little (
1
/32”)
5. Tighten thumb screws
CAUTION:
Do not adjust slider tight against ticket
stock. This will cause a feed problem.
Flight Strips will move from side to side if
the slider is adjusted too far away from
the flight strips. This will cause a feed
problem.
Thumb Screws
Figure 5 - Adjustable paper path
preparation
mode. L
figure 4.
F
EED DIRECTION
Figure 7 - Flight Strip loading
You may now install the printer in its permanent location. Adequate room should be
provided behind the printer for the smooth feeding of stock.
Begin loading flight strips through the entrance slot (
figure 7) with a smooth motion
until the printer automatically positions the flight strip.
NOTE: Flight Strips should be loaded with the black mark facing down in the feed
direction shown below (figure 7).
After the flight strip is automatically positioned (the READY LED will be illuminated),
press the TEST button located on the control panel (figure 2a) to print a test ticket.
Verify that the printer works properly with your system by issuing a ticket through your
computer system.
8
THERMAL
ACTIVE SURFACE
NOTE:
THE PICTURE OF THE
ARROW ON THE BOTTOM
OF THE FLIGHT STRIPS
IS AN OPTIONAL GRAPHIC.
5.0 Standard Configuration
The FSP is factory configured for specific customer requirements
using an enhanced
FGL package. Printing resolution is 300 dots per inch.
For complete informa
on
the FGL Programming Language, please see the programming guide.
FGL printers
allow the user to adjust various printer options through the control panel.
To access and use the FACTORY MENU, follow these steps:
1. Flight strip stock should be loaded into the printer. The LCD window displays
the firmware level installed in the printer.
2. Press both MENU and CHOICES switches simultaneously for about three seconds.
The LCD window displays FACTORY MENU! .
3. To scroll through the menu topic, use MENU stopping on the topic you wish to
change.
4. Press CHOICES to scroll through choices in the selected topic. NOTE: The
printer displays a blinking cursor for the values presently stored in the printer.
5. Once you have found the new value you want, press TEST. The LCD window
displays EXIT AND SAVE?. If you wish to save the new value, press TEST
again.
6. If you do not wish to save the new value, press MENU. The LCD window
displays JUST EXIT?. Press TEST to exit the FACTORY MENU without
saving new values or press MENU to enter back into the FACTORY MENU.
9
TEST
CHOICES
MENU
CHECK
PAPER
PAPER
JAM
DATA
READY
Enters new value / Also
saves new values.
Selects proper menu topic
(baud rate, cut count, etc.)
Scrolls through choices in
individual menu topics
.
tion
The chart below lists the present menu topics. These topics are subject to change.
TEST TICKET TYPE?
The FSP allows one of four different test tickets to be printed when the
printer’s test
button is pressed. In addition, this selection also determines other preset
associated with the test ticket format selected.
PRINT HEAD TYPE?
Here are the following choices.
BAUD RATE?
Controls the serial interface baud rate, parity bit, data bits and stop bits.
Here are the following choices:
10
1200,N,8,1
1200,E,7,1
1200,O,7,1
2400,N,8,1
2400,E,7,1
2400,O,7,1
4800,N,8,1
4800,E,7,1
4800,O,7,1
9600,N,8,1
9600,E,7,1
9600,O,7,1
19200,N,8,1
19200,E,7,1
19200,O,7,1
28800,N,8,1
28800,E,7,1
38400,N,8,1
38400,E,7,1
57600,N,8,1
57600,E,7,1
115200,N,8,1
115200,E,7,1
KYOCERA Brown circuit board with black colored print surface.
TDK Green circuit board with silver colored print surface. Default Value
The following is an overview of what
each Menu option does:
values
MINI/MICRO?
Defines the type of printer.
MINI Is for a printer with a Cutter Assembly (factory default)
MICRO Is for a printer without a Cutter Assembly
PRINT SPEED?
Controls the speed the ticket travels at. Also effects the print quality.
The numbers range from 0 - FASTEST to 7 - SLOWEST. 3 is factory default.
DIAGNOSTIC MODE?
Please consult your Programming Guide
Your choices are YES or NO. NO is factory default.
TICKET TYPE?
Defines how the optos are configured on the paper guide assembly.
NORMAL
Both optos are inline with each other (usually mounted on a black bracket
)
ATM
Feed opto is mounted under the thermal head and cut opto is attached to the cutter
assembly.
LABEL
Same as ATM but the cut opto is a see through type.
SPECIAL TICKET
This option is for a printer with a ticket load switch.
(factory default)
STATUS ENABLED?
Sets status response protocols.
Here are the following choices:
TRANSPARENT MODE?
Please consult your Programming Guide
Your choices are YES (Enabled) or NO (Disabled). YES is factory default.
PAPER MODE?
Is generally used only for test purposes. It may also be used on roll stock with no
black marks on the ticket.
Your choices are YES (Enabled) or NO (Disabled). NO is factory default.
HEAD DPI?
Defines thermal head dpi (dots per inch)
Your choices are 200 or 300. 300 is factory default.
11
NONE Disables the XON/XOFF and status response protocols
SERIAL Enables the XON/XOFF and status response protocol for the serial port (factory default)
PARALLEL Enables bi-directional parallel statusresponses if printer is configured as bi-directional.
SER/PAR Enablesb both bi-directional parallel and serial status responses
USB Enables USB status responses
USB/SER Enables USB and serial status responses
USB/PAR Enables USB and bi-directional parallel
USB/SER/PAR Enables USB, bi-directional parallel and serial status responses
SPECIAL HEAD?
Is used when a special paper path size is installed (2.125”, 2.5”, 2.7”...)
Here are the following choices:
PATH TYPE?
Defines the number of paper paths used.
Here are the following choices:
BUFFER MODE?
Defines when the printer will go busy.
Here are the following choices:
CLEAR DOWNLOAD?
Clears those items downloaded by the operator (PCX or softfonts).
Your choices are YES or NO.
DEFAULT SETTING
Resets the printer back to the factory default setting.
Your choices are YES or NO.
INC CUT1 COUNT?
Enables the operator to move the cut or tear position to the left (towards the ticket
entrance area). Cut counts are increments of .003” for 300dpi and .002” for 200dpi.
The count value is changed by depressing CHOICES.
16 is factory default.
DEC CUT1 COUNT?
Enables the operator to move the cut or tear position to the right (towards the ticket exit
area). Cut counts are decrements of .003” for 300dpi and .002” for 200dpi. The count
value is changed by depressing CHOICES. 16 is factory default.
12
NO NO special head (factory default)
O
N P1 SINGLE PATH PRINTER ONLY. DUAL PATH PRINTER PATH #1
ON P2 DUAL PATH PRINTER PATH #2
ON BOTH DUAL PATH PRINTER BOTH PATHS
REV ADJ2 P1 DUAL & SINGLE PATH PRINTER WITH REV ADJ2 PATH ONLY
REV ADJ2 P2 DUAL PATH PRINTER WITH REV ADJ2 PATH ONLY
R
EV ADJ BOTH DUAL PATH PRINTER WITH REV ADJ2 PATH ONLY
PATH 1 Locks a Dual path printer onto path#1 (all single path printers) (factory default)
PATH 2 Locks a Dual path printer onto path #2
DUAL Is used for Dual path printer
DUAL SUPPLY Please consult your programming Guide (Dual Printer Supplement)
VENTEK DUAL Special settings only used by certain customers.
SINGLE MODE 1 Go busy after each print command inserted in buffer
SINGLE MODE 2 Go busy after receiving <p> command
MULTIPLE MODE Go busy when the input buffer is full (~4k) (factory default)
INC CUT2 COUNT?
Same as INC CUT1 COUNT? but effects path #2 on a dual path printer.
(Does not apply)
DEC CUT2 COUNT?
Same as DEC CUT1 COUNT? but effects path #2 on a dual path printer.
(Does not apply)
2-SIDED PRINTER?
Only used with 2S ticket printers.
Your choices are YES (Enabled) or NO (Disabled). NO is factory default.
PARK TICKET?
Reverse the ticket to the print position after the last ticket in a group has been printed.
Please consult your Programming Guide. Your choices are YES (Enabled) or NO
(Disabled). NO is factory default.
TICKET MODE?
Defines how the printer will treat multiple tickets. Please consult your Programming
Guide. Your choices are
SINGLE or MULTIPLE. MULTIPLE is factory default.
PRINT MODE?
Defines the automatic ticket length calculation feature.
THERMAL The printer will feed out and then retract a ticket during this measurement.
(factory default)
RIBBON The printer will feed out one blank ticket. This mode is used for label stock to
prevent peeling.
PRINT INTENSITY?
Controls the darkness of ticket print out.
Here are the following choices:
LIGHT
MED LIGHT
NORMAL (factory default)
MED DARK
SHORT HEAD LIFE
SKI MODE?
Enables the operator to set an unprintable area on the first .50” of a ticket.
This is ideally used for label stock. Your choices are YES (Enabled) or NO (Disabled).
NO is factory default
13
FLASH ACK MODE?
Enables or disables an ACK being sent back to the host after a flash operation. Your
choices are
YES (Enabled) or NO (Disabled). NO is factory default.
SOFTWARE BUSY?
Defines if the printer will go busy after each byte is received. Your choices are YES
(Enabled) or NO (Disabled). NO is factory default.
BI-DIRECTIONAL?
Enables or disables the Bi-Directional parallel interface protocol. Your choices are YES
(Enabled) or NO (Disabled). NO is factory default.
TEST TICKET?
This item is used to select various FGL test ticket formats, it has been redefined for
NAV Canada and should not be changed. Please refer to the first menu item “TEST
TICKET TYPE?”.
BASEBALL MODE?
Defines the type of software emulation protocol for certain Baseball teams in the US.
This f
eature is set at the factory and should not be changed. NO is factory
default
USB?
Only used for printer with USB interface connector.
Your choices are YES (Enabled) or NO (Disabled). NO is factory default.
MAGNETICS?
Defines if a printer is set up for magnetics. Your choices are YES (Enabled) or NO
(Disabled). This feature is set at the factory and should not be changed. NO is
factory default.
EXIT AND SAVE !
Will save any changes made to the above menu options.
If you wish to save the new value then press TEST, if not press MENU.
JUST EXIT?
Will exit the menu options without saving any changes.
If you with to exit without saving the new value then press TEST, if not press MENU.
14
15
5.1 THIS SECTION HAS BEEN REMOVED
This page has been left blank intentionally
Flash erase operation incomplete
Error No. Description
Ready
Paper
Jam
1ON OFF
2 Flash Vpp problem
OFF
OFF
Data
Out of
paper
3
4
5
6
7
8
9
10
11
12
13
14
15
OFFON OFF
OFF
Flash byte erase error ON ON OFFOFF
Flash Sequence error
Flash block erase error
Bad flash
Flash program operation incomplete
Flash byte program error
Memory is full
Need a reclaim
Soft font download error
Delete file error
Not assigned
Not assigned
Not assigned
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
Ribbon problem
Error No. Description
Ready
Paper
Jam
1ON OFF
2Processor fault
OFF
OFF
Data
Out of
paper
3
4
5
6
7
8
9
10
11
12
13
14
15
OFFON OFF
OFF
Stepper timeout error ON ON OFFOFF
Paper jam
Not assigned
Not assigned
Not assigned
Not assigned
Not assigned
RAM failure
ROM failure
Cutter failure
Check optos
Not assigned
Power-up initialization problems
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
Status Patterns (Flickering). Flickering errors have much longer
on time than off time.
Status Patterns (Flashing). Flashing errors have equal
on and off time.
5.2 Control Panel Indicator
18
6.0 Interface Pinouts
Serial Pinouts
RS232 (Standard)
Pin Function
2Printer Transmit
3Printer Receive
7Ground
5,20 DTR (Printer Ready)
4,22 RTS (+5Vdc)
Typical RS232 Pin Connections
* Optional Connection
19
(Standard)
25 PIN PC
BOCA CPU
23RXD
32TXD
77GND
20 6 DSR
20 5 CTS*
20 8 CD*
(Standard)
9 PIN PC
BOCA CPU
22 RXD
33 TXD
75 GND
20 6 DSR
20 1 CD*
20 8 CTS*
Parallel Pinouts
Pin Function
1 Strobe (negative)
2-9 DATA (DBØ - DB7)
10 ACK (negative)
11 BUSY
12 PAPER OUT
15 ERROR (negative)
18 Ground
7.0 Thermal Paper - Theory & Specification
The print head’s life expectancy is composed of both a mechanical and an electrical component. Both of
these factors are strongly influenced by the quality of the thermal paper used.
MECHANICAL
The print head has a theoretical rating of 60 kilometers. This number is based upon the assumption that
the head will be used with a good quality, top coated thermal paper. Uncoated and poorly top coated
thermal papers are abrasive to the print head and have been found to wear through the head after less
than one kilometer.
Other factors which may contribute to premature mechanical wear are the use of non-thermal inks and
stray metallic particles stuck in ticket perforations. Certain inks colors such as opaque white (which contains titanium dioxide) are also highly abrasive.
Unfortunately, there are no available devices for quantitatively measuring the abrasiveness of a given
ticket. Fortunately, we have developed a slightly subjective, but effective method of weeding out overly
abrasive ticket stock.
ELECTRICAL
Each heat element, dot, on the print head has a theoretical life expectancy of 100 million activations.
This is based on the assumption that each activation will cause the dot temperature to approach the
dot’s maximum recommended temperature. Running at lower temperatures will increase the theoretical
life expectancy, while slight temperature increases will seriously (exponentially) degrade the head life.
The thermal paper can affect the electrical head life in two ways. Insensitive, slow to image papers, will
typically encourage the user to increase the voltage to darken the printed image. This will directly
increase the head temperature resulting in reduced head life. Additionally, the higher temperatures will
frequently cause the ink to peel off the ticket and deposit onto the print head. The ink debris will disrupt
the normal transfer of heat from the head to the paper. This further increases the head temperature
above the desired level. The use of non-thermal inks and/or non-top coated papers also will cause the
ink to release and deposit on the print head.
SPECIFICATION
Based upon the above technical information, BOCA has always tried to encourage our customers to use
the proper thermal papers to maximize the life of their print heads. BOCA provides an extensive series
of papers which meet the above criteria for low abrasion and high sensitivity. We have also tested and
approved a number of Ricoh thermal papers which meet our criteria. While we have not had the opportunity to test other manufacturers’ thermal papers, we feel confident that other papers manufactured with
the above goals in mind should be acceptable for use in our printers. The following list of papers have
been approved by BOCA.
300 dpi usage
BOCA HS7
Please note that the 300 dpi papers may be used on 200 dpi printers. In fact, doing so will
increase the
electrical life of the head as this will allow the head to operate at a lower temperature. DO
NOT use 300
dpi heads with 200 dpi paper.
20
8.0 Maintenance and Adjustments
Your ticket printer is solidly constructed and has been designed for high volume use. It
requires minimal care to provide maximum service.
This section provides an overview of printer maintenance, including part alignments,
adjustment and replacement.
For discussion purposes, the printer consists of three major modules or assemblies:
• Paper guide and print head assembly
• Cutter assembly
• Logic board assembly
As a safety precaution, all service to the printer should be done with power off
and the AC cord unplugged from the printer.
8.1 Paper Guide and Print Head Assembly
The principal function of this assembly is to guide the flight strip stock to the thermal
print head where thermal printing takes place. Additionally, this assembly houses the
drive platen, optical detector and ticket load switch. If necessary, the total assembly
can be removed from the unit. However, all replacements and adjustments of the components of this assembly can be done without removing the total assembly. The most
common adjustments and replacements regarding this assembly follows:
8.1.5 Optical Device (see figure 8)
There is one opto device mounted on an aluminum bracket beneath the paper guide.
The opto controls ticket cut position. Removal or adjustment of the opto should be
done without removing the bracket from the paper guide.
The opto position is factory set and adjustment should not be necessary
.
Caution: Before making any opto adjustments make sure your flight strip stock
was manufactured to proper specifications. The printer should cut the ticket just
behind the perforation. The ticket should never be cut in front of the perforation.
The position of the cut can be controlled by changing the cut count setting in the
OPERATOR MENU (see Section 5.0 - Standard Configuration).
Once a year the optos eyes should be blown off with air. This interval will vary depending upon the environment and the quality of the ticket stock.
21
8.1.5.5 Ticket Load Switch
The ticket load switch should be positioned such that the printer automatically activates
the stepper motor at the proper time when tickets are loaded into the printer. When
loading tickets, the stepper motor should turn on when the ticket stops in front of the
thermal head. At this point, the ticket will be grabbed out of your hand and fed into the
printer. If the motor does not activate, make sure the ticket stock is loaded into the
printer properly.
22
F
EED DIRECTION
Figure 8 - Optical Device
O
ptical Device, Ticket Cut
P
aper Guide
Grn/Red/Blk
Wires
5
/64”
Allen Head
Screws
On some models these
c
onnectors plug into the
back of the circuit board
TO LOGIC
BOARD
Figure 8a - Ticket Load Switch
(Print Head removed)
8.1.6 THERMAL PRINT HEAD
The print head should be cleaned periodically to prevent debris from building up on the
print element. The required cleaning interval varies greatly depending on the quality of
the ticket stock and the amount of dust entering the print area. Excessive dirt build up
on the print head will result in reduced quality. Continuing to run the print head in a
dirty condition will reduce its life expectancy as it is unable to diffuse its heat properly.
There are two pressure adjustment set screws (10-32 x
1
⁄8) located in the spring plate
above the print head. (See Figure 9a) Athough these set screws are factory set, the
pressure can be adjusted for a variance in paper thickness or to fine tune after a print
head has been replaced.
The thermal print head can be removed for cleaning or replacement, as follows:
(Please refer to figures 9a - c)
1. Make sure power is off and the AC cord is disconnected from the printer.
2. DO NO
T UNPLUG CABLE FROM PRINT HEAD.
3. Lift up the print head release lever (located above the head mounting block) to
remove pressure from the thermal head. (see figure 9a)
4. Lift up the head mounting block/thermal head to remove. (see figure 9b)
5. Clean the thermal print head surface (the side that makes contact with the paper)
with isopropyl alcohol. (see figure 9c)
8. The printer in now ready for operation. If the print quality is still poor then the
thermal head needs to be replaced.
9. To replace print head remove ribbon connector from print head and then remove
print head from mounting block by removing two unmarked screws. (see
figure 9b)
8.1.7 Rubber Drive Roller (Platen)
The rubber drive roller should be cleaned once a year to prevent paper dust from
building up on the roller. Clean drive roller with a paper towel and alcohol.
1. Unlock the thermal head and tilt back to gain access to platen.
2. Clean the full length of the platen.
3. Rotate the platen clockwise and repeat step 2, continue in the same manner for
one full revolution of the platen.
4. Close or lock the thermal head. Printer in now ready for normal operation.
23
6. Install the head by reversing the above procedures. For printers with Boca cutter assembly
make sure the thermal head goes under the cutter assembly. (see figure 9d) Make sure print
head is not installed improperly (see figure 9e)
7. Restore pressure to the head by pushing down on the cam lock assembly. You shouldn’t
have to use excessive force to lock the cam lock assembly in place.
Figure 9a - Print Head removal
Figure 9b - Print Head removal
Adjustment set screws
24
Remove these two unmarked screws to
replace print head.
Figure
Figure
Figure9c
9e
9d- Print Head removal
Clean this surface
.
Print Head release lever.
Head is installed wrong. Should
no be sitting on top of the cutter.
8.2 Cutter Assembly
8.4 General Cleaning
The interior of the printer should be cleaned whenever there is a visible accumulation
of dust. Use a small vacuum for cleaning. Be careful not to jar any of the printer’s
parts loose.
25
The SC cutter (SC2) system is a fully integrated rotary cutter mechanism powered by
a DC motor. The SC2 requires no adjustments and is rated for approximately 750,000
cuts.
Wait five seconds before feeding ticket stock into the printer after power up. During this
time the cutter will cycle once. If ticket stock is fed into the printer before five seconds,
a ticket jam could occur.
The cutter should be blown out with air periodically to prevent debris from building up
inside the cutter area. The required cleaning interval varies greatly depending on the
quality of the ticket stock and the amount of paper dust entering the cutter area.
8.3 Logic Board
The printed circuit boards used in this product have been manufactured using surface
mount technology. These printed circuit boards cannot be effectively repaired in the
field and should be returned to the manufacturer if repair is required.
Your printer has one large printed circuit board which houses all control and power
supply circuitry. ALL
SERVICE SHOULD BE DONE WITH POWER OFF AND THE
AC CORD
UNPLUGGED FROM THE PRINTER.
8.2a SC Cutter Assembly (SC2)
NOTE:
THE CUTTER ASSEMBLY MAY VARY DEPENDING ON THE DATE OF
MANUFACTURE OF THE PRINTER
The BOCA cutter (BC2) system is a fully integrated recipricating cutter mechanism
powered by a stepper motor. The BC2 requires no adjustments and is rated for
approximately 750,000 cuts.
When first powering up the printer, be aware of the following:
8.2b Boca Cutter Assembly (BC2)
9.0 PARTS LIST
ITEM Part Numbers Description
1
423182 CABINET, FSP
2 423182CV COVER, FSP
3 423111FSP PRINT CAGE, FSP
4 421366FSP PAPER GUIDE, FSP (LOWER)
5 421367FSP PAPER GUIDE, UPPER
6 422468FSP BEZEL
7 423182-1 FRONT PLATE, FSP
8 420947FSP CONNECTOR PLATE
9 423170FSP SWITCH XFER PLATE
10 421428FSP BKT, OPTO MNTG
11 426816VMINISC2 CUTTER MNTG PLATE (SC2 ONLY)
12 420816FSP BLOCK, CUTTER SPACER (SC2 ONLY)
13 423142-X GLASS RETAINER
14 422234 PLATEN, FSP
15 P49-1011
1
⁄4TURN FASTENER
16 P49-1012 RECEPTACLE, FASTENER
17 422764 MICRO SWITCH
18 421609-1SS SHAFT, ADJ P/G
19 421585FSP COVER, GEAR BOX
20 422888-115 TRANSFORMER
21 3002 PRINT HEAD, 2” 300 DPI
22 421671-1 LCD/CONTROL PANEL ASSEMBLY
23 P31-1001 AC FILTER/POWER SWITCH
24 422920-PC INTERFACE BOARD, PC SERIAL
25 P29-1005 FUSE, 2 AMP SLO-BLO
26 421607-5M4 BLOCK, ADJUSTABLE GUIDE
27 421609-5M4 SLIDE, ADJUSTABLE GUIDE
28 421609-1SS SHAFT, ADJUSTABLE GUIDE (2 PER UNIT)
29 P49-1006 THUMBSCREW, ADJUSTABLE GUIDE (2 PER UNIT)
30 422264 OPTICAL DETECTOR
31 421359-1TOH HEAD MOUNTING BLOCK ASSEMBLY
32 423236 CAM, HEAD PRESSURE
33 421772 CAM SHAFT
34 423072-5M2 SPACER, PRINT CAGE (2 PER UNIT)
35 422560-5 DECAL, CONTROL PANEL
36 FGL42 LOGIC BOARD, FGL42
37 421639-4 CUTTER ASSEMBLY (SC2)
38 P28-1015 SILENT CUTTER MICRO SWITCH (SC2 ONLY)
39 P33-1006 SILENT CUTTER MOTOR (SC2 ONLY)
40 422810 SILENT CUTTER MOTOR GEAR BOX (SC2 ONLY)
41 422371-1 SILENT CUTTER PINION GEAR (SC2 ONLY)
42 P50-1003 DRIVE BELT, 102T
43 P51-1014 DRIVE PULLEY, 20T (SMALL ID 5mm)
44 P51-1011 DRIVE PULLEY, 30T
45 423124 CABLE RIBBON, DATA CABLE SERAIL
46 422559-13 CABLE RIBBON, CONTROL PANEL 13”
47 422559-9 CABLE RIBBON, CONTROL PANEL 9”
48 422892 HARNESS, AC
49 P19-1005 HARNESS, DC
50
51
52
53
54
55
422590
423455
FGL44
X44
X46
Q46
STEPPER MOTOR
BOCA CUTTER ASSY (BC2)
LOGIC BOARD, FGL 44
LOGIC BOARD, X44
LOGIC BOARD, X46
LOGIC BOARD, Q46
26
10.0 Troubleshooting Guide
This is a simplified troubleshooting guide listing some of the typical problems. It is not intended
to provide technical details or repair methods, but can serve as a guide for fault isolation in the
field.
If you need additional help, please contact BOCA at
Tel: (561) 998-9600 Fax: (561) 998-9609
1. NO OPERATION, POWER INDICATOR IS OUT
a. Check the power cord for proper installation at both ends.
b. Check main fuse and replace if blown. (2amp, 250 volt, SB)
c. Check that there is power at the AC receptacle.
2. POWER IS ON BUT NO OPERATION
a. Check all electrical connections on the printer.
b. If cutter motor does not rotate after power up, See # 6.
c. Unplug the thermal head and turn on the printer.
If printer works, replace the thermal head.
d. Replace the Main logic board.
3. POWER IS ON BUT TICKET WILL NOT LOAD
a. See # 2
b. Make sure the print head/cam lock assembly is fully locked in the closed position.
Consult “Thermal Print Head” in Section 8.1.6.
c. Check that the ticket stock is being loaded correctly.
d. Replace ticket load switch.
e. Replace ticket cut opto.
f. Replace the Main logic board.
4. ERRATIC CUT POSITION
a. Check for defective ticket stock. Is the black mark unevenly spaced apart or
light in color? Is the ticket too wide for the paper path?
b. Clean off opto eyes. Consult “Optical Device” in Section 8.1.5.
c. Check that the platen is clean. Consult “Rubber Drive Roller” in Section 8.1.7.
d. Replace ticket cut opto.
e. Replace ticket load switch.
g. Replace the Main logic board.
5. ERRATIC PRINT POSITION
a. See # 4
6. CUTTER DOES NOT CYCLE
a. Check for blockage in the cutter area.
b. Make sure printer is set for MINI. Consult Section 5.0
c. Replace the cutter assembly
d. Replace the Main logic board.
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7. POOR PRINT OUT
(light print out)
a. Make sure the print head/cam lock assembly if fully locked in the closed position.
b. Consult
“Thermal Print Head” in Section 8.1.6.
c. Adjust print intensity setting via the control panel. Consult Section 5.0
d. Replace thermal head.
8. POOR PRINT OUT
(white voids in print out)
a. Clean print head. Consult “Thermal Print Head” in Section 8.1.6.
b. Replace thermal head.
9. NO PRINT OUT
a. Check head cable for electrical connection at both ends
b. Check to make sure head cable is plugged in properly into the thermal head.
c. Replace the thermal head.
d. Replace the Main logic board.
10. PRINTER SKIPS TICKETS WHILE PRINTING
a. Check all electrical connections on the printer.
b. Check position and quality of black mark on the ticket stock.
c. Clean off opto eye. Consult “Optical Device” in Section 8.1.5.
d. Replace ticket cut opto.
e. Replace ticket load switch.
11. PRINTER SKIPS TICKETS AND DIES
a. See # 9.
12. TICKET JAM ENTERING THE CUTTER AREA
a. Check all electrical connections on the printer.
b. Replace cutter assembly.
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