Boca Systems Micro Plus User Manual

Micro Plus Ticket PrinterMicro Plus Ticket Printer

Users Manual

INCLUDES MOUNTING

INFORMATION FOR

VERTICAL UNIT

BOCA SYSTEMS, INC.

© 1996 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 Pag e

1.0 Introduction 1

2.0 Unpacking the Printer 2

3.0 A tour of your printer 3-4

4.0 Installation 5

5.0 Configuration 6

6.0. Standard Interface Pinouts 7

7.0 Thermal Paper - Theory and Specification 8

8.0 Maintenance and Adjustments 9-14

9.0 Spare Parts List 15-16

10. Troubleshooting Guide 17-18

Table of Figures and Appendices Pag e

Figure 1 Packaging 2

Figure 2 Micro Plus Ticket Printer 3

Figure 3 Side view with door open 3

Figure 4 Rear view 4

Figure 5 Side view with electronics exposed 4

Figure 6 Ticket loading 5

Figure 7 Slider Adjustment 6

Figure 8 Optical Devices 10

Figure 9 Print head removal 12

Appendix A Operator Menu options through control panel

Appendix B Site Preparation drawing

Appendix C FGL Printer Comparison Char t

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 per ipheral 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 per iod of one year

from the date of shipment when subject to normal use and ser vice. 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 retur ned 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.

EXTENDED WARRANTY PLAN - BOCA offers extended warranty plans for all printer
models.These plans cover all parts and labor. All 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 extended warranty. The
customer, at his option, may request BOCA to ship individual par ts to expedite simple
repair procedures. In certain cases where the customer is unable to wait for the nor­mal repair cycle, BOCA will ship an exchange printer within one business day after
notification by the customer. All freight charges are the responsibility of the customer.

ii

1.0 Introduction

The BOCA Micro Plus is a direct thermal ticket printer with an internal (locked) storage
compartment designed for point of sale ticketing environments. This manual will
provide the user with general information regarding printer set-up, configuration and
troubleshooting. Please consult the programming guide for additional technical 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 repor t it immediately to

BOCA.

Tel: [phone] Fax: [phone]
The following items should be in the box:

a) Ticket Printer
b) Vertical mounting top plate (optional)
c) AC power cord
d) Interface cable (optional)
e) Programming guide
f) This manual

2

Figure 1 - Packaging

3.0 A Tour of Your Printer

ticket output slot

LCD

control panel

Figure 2 - Micro Plus ticket printer

Figure 3 - Micro Plus side view

Entrance Slot

optical devices

internal ticket compartment

3

Figure 4 - Micro Plus rear view

on/off switch

interface connector (shown with cable)
fuse holder (2amp slow blow)

AC connector

entrance slot

Figure 5 - Micro Plus side view with

electronics exposed

4

main logic board
hold down strap

power supply logic board
110/220v Selector Board

4.0 Installation

The Micro Plus ticket printer is designed to be mounted on a desktop or on a shelf.The
Micro Plus is available with an optional mounting plate for installation within a counter.
However, prior to site preparation and installation, the printer should be powered up
and run in the self test mode. Lay the printer flat on a counter as shown in figure 3
with the cover removed. Ver ify that voltage selector is properly set for your line voltage
(110/220v) as shown in figure 5. Attach the AC cord and interface connector into
the proper connectors as shown in figure 4. Turn power on (figure 4). The LCD will
display PAPER OUT. Begin loading tickets through the entrance slot (figure 5) with a
smooth motion until the printer automatically positions the ticket.
NOTE: Tickets should be loaded with the black mark facing down. Two typical ticket
formats and feed directions are shown below (figure 6).

FEED DIRECTION

2

5.5

Black Mark on

3.25

Underside of
Ticket

1.975

Black Mark on
Underside of
Ticket

Figure 6 - Ticket feed direction

After the ticket is automatically positioned (the READY LED will be illuminated), press
the TEST button located on the control panel (figure 2) to pr int a test ticket. Verify that
the printer properly works with your system by issuing a ticket through your computer
system.

You may now install the pr inter in the desired location or prepare for in-counter installa­tion using the instructions shown in appendix B. Adequate room should be provided
beneath the printer for cables and ventilation.

5

5.0 Configuration

The Micro Plus is factory configured for a variety of customer requirements. The print­er is available in a standard FGL20 electronics package or with an enhanced FGL40
package. Standard resolution is 200dpi and 300 dpi is available as an option.
Please see Appendix C for the comparison of FGL 20 and 40.

The printer is available in a number of fixed ticket widths or with an optional adjustable
paper path (see figure 7). The printer is factory configured for either serial or parallel
interface (see pinouts in section 6.0).

A number of other features including baud rate, cut count and print speed are also fac­tory set but can be modified (Operator Menu) through the control panel as described in
Appendix A. Most users will never have reason to change the options in the Operator
Menu.

Slider Adjustment for 4.0” adjustable feature

1. Feed stock into the paper path.

2. Loosen thumb screws on slider.

3. Move slider towards the stock until it touches it.

1

4. Back slider away from the stock a little (

5.Tighten thumb screws

CAUTION:

Do not adjust slider tight against ticket
stock.This will cause a feed problem.

Ticket stock will move from side to side if
the slider is adjusted too far away from
the the ticket stock.

/32”)

Thumb Screws

Figure 7 - Slider adjustment

6

6.0 Standard Interface Pinouts

6.1 Serial Pinouts

RS232 (Standard) RS232 (PC type)

Pin Function Pin Function

2 Printer Transmit 2 Printer Receive
3 Printer Receive 3 Pr inter Transmit
7 Ground 5 RTS (+5Vdc)
5,20 DTR (Printer Ready) 6 DTR (Printer Ready)
4,22 RTS (+5Vdc) 7 Ground

8 CD (+5Vdc)

6.2 Typical RS232 Pin Connections

(Standard)
25 PIN PC

BOCA CPU
2 3 RXD
3 3 TXD
7 7 GND
20 6 DSR
20 5 CTS*
20 8 CD*

(Standard)

9 PIN PC

BOCA CPU
2 2 RXD
3 3 TXD
7 5 GND
20 6 DSR
20 1 CD*
20 8 CTS*

* Optional Connection

6.3 Parallel Pinout

Pin Function

1 Strobe (negative)
2-9 Data (DB0-BD7)
10 ACK (negative)
11 BUSY
12 PAPER OUT
15 ERROR (negative)
18 Ground

(PC Type)

25 PIN PC

BOCA CPU
2 2 TXD
3 3 RXD
5 5 CTS*
6 6 DSR
7 7 GND
8 8 CD*

(PC Type)

9 PIN PC

BOCA CPU
2 3 TXD
3 2 RXD
5 8 CTS*
6 6 DSR
7 5 GND
8 1 CD*

NOTE:The above pinouts may vary on certain printers due to special customer
request.

7

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 disr upt
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-ther mal 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.

100 and 200 dpi usage

BOCA TLD7, TLD7R, TLD5, SF7, P8
Ricoh 120TLD, 120LCSB, 120LD

300 dpi usage

BOCA HS7, SFHS7
Ricoh 150TLA

Please note that the 300 dpi papers may be used on 100 and 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.

8

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 parts alignments,
adjustment and replacement.

For discussion purposes, the printer consists of two major modules or assemblies:

• Paper guide and print head 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 ticket stock to the thermal print
head where thermal printing takes place. Additionally, this assembly houses the drive
platen and optical detectors. If necessary, the total assembly can be removed from the
unit if necessary, 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 Devices (see figure 8)

There are two identical opto devices mounted on a black aluminum bracket beneath
the paper guide. The opto on the left controls automatic ticket loading and the opto on
the right controls tear position. Removal or adjustment of either 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 ticket stock was
manufactured to proper specifications.

The ticket load opto 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. If stock is loaded in properly then re-adjust the opto position to the
right (1/16” increments) until the desired position is reached. If the motor activates too
soon, slide the opto torards the left.

9

The printer should advance the ticket just beyond the edge of the cabinet. The position
of the tear can be controlled by changing the cut count setting in the OPERATOR
MENU (see Appendix A). If you are not able get the desired tear position, then make
sure your ticket stock was manufactured to proper specifications.

Once a year the optos eyes should be blown off with air.

FEED DIRECTION

Ticket Load

Circuit board

Opto Eyes

Ticket Cut/ Tear

Circuit board

Paper Guide

Black Aluminum

Bracket

5

/64”

Allen Head

Screws

Wht/Red/Blk

Wires

TO LOGIC

BOARD

5

/64”

Allen Head

Screws

On some models these
connectors plug into the
back of the circuit board

Grn/Red/Blk

Wires

Figure 8 - Optical Devices

10

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 inter val 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.

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 NOT UNPLUG CABLE FROM PRINT HEAD.

3. Lift up on the cam lock assembly (located above the head mounting block) to
remove pressure from the thermal head. (see figure 9a)

4. Lift up on the head mounting block/thermal head to remove. (see figure 9b)

5. Clean the ther mal pr int head surface (the side that makes contact with the paper)
with isopropyl alcohol. (see figure 9c)

6. Install the head by reversing the above procedures.

7. Restore pressure to the head by pushing down on the cam lock assembly.

8.The printer in now ready for operation. If the pr int 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.

11

Figure 9a - Pr int Head removal

Figure 9b - Pr int Head removal

Remove these two unmarked screws to
replace print head.

Figure 9c - Print Head removal

12

Clean this surface.

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.
(NOTE:The platen may require more frequent cleaning in dusty environments
or when using inferior ticket stock.)

8.3 Logic Board and Power Supply Board

The printed circuit boards used in this product have been manufactured using surface
mount technology. The pr inted circuit boards cannot be effectively repaired in the field
and should be returned to the manufacturer if repair is required.

Your printer has two large printed circuit boards. The Power Supply Logic Board plugs
into the Main Logic Board. This section describes board removal and proper
installation. ALL SERVICE SHOULD BE DONE WITH POWER OFF AND THE AC

CORD UNPLUGGED FROM THE PRINTER.

13

8.3a Power Supply Logic Board (Removal)

1. Gain access to the Logic Board Assembly by removing the sheet metal ticket tray.

2. Remove the Logic Board Assembly “hold down strap”. (see figure 5)

3. Unplug connectors going to the power supply logic board.

4. Unlock power supply board by pulling up and away from the 40 pin connector and
the two brass fasteners.

5. Lift board and remove.

8.3b Power Supply Logic Board (Installation)

1. Align holes on Power Supply Board with the 40 pin connector and the brass
fasteners and press straight down.

2. Press down in the area of connector JCUT to properly the seat board.

3. Attach connectors going to the power supply logic board.

4. Install Logic Board Assembly “hold down strap.”

8.3c Main Logic Board (Removal)

1. Remove the Power Supply Logic Board as described in section 8.3a.
All connectors on the Power Supply Logic Board should stay attached.

2. Unplug connectors going to the main logic board.

3. Use a screwdriver to gently wedge logic the board from the fasteners.

4. Lift board and remove.

8.3d Main Logic Board (Installation)

1. Align Main Logic Board so that the four mounting holes are above the four
fasteners.

2. Press logic board straight down onto the brass fasteners.

3. Attach connectors going to the main logic board.

4. Install Power Supply Logic Board as described is section 8.3b.

8.4 General Cleaning

The interior of the printer should be cleaned whenever this is a visible accumulation of
dust. Use a small vacuum for cleaning. Be careful not to jar any of the printer’s parts
loose.

14

9.0 Spare Parts List

PART # DESCRIPTION

P19-1000 AC CORD
P31-1000 AC FILTER
492121 ANTI STATIC BRUSH (2” OR 3.25”)
P45-1009B EARING, EJECT BLOCK (LARGE)
04107GMN BEARING, EJECT MOTOR
422557-188 CABLE RIBBON, THERMAL HEAD (BS2008)
422557-18 CABLE RIBBON,THERMAL HEAD (3.25” & 4.0”) 18”
422557-16 CABLE RIBBON,THERMAL HEAD (3.25” & 4.0”) 16”
422558-16 CABLE RIBBON,THERMAL HEAD (BS2002 & BS3002)
422558-11 CABLE RIBBON, DATA CABLE
422558-11C CABLE RIBBON, DATA CABLE (dual I/O ports)
422559-13 CABLE RIBBON, CONTROL PANEL 13”
422559-9 CABLE RIBBON, CONTROL PANEL 9”
421414-2 CABLE,THERMAL HEAD (3.25”) For 421570 PCB’s
421212-1 CABLE,THERMAL HEAD (2.00”) For 421570 PCB’s
420881VW6SC2 COVER,VGHOST 3.25”200DPI SC2
432020 CAM LEVER, PAPER GUIDE

09-18-5061 CONNECTOR, J7 on 421570 & 421818 logic boards
421671 CONTROL PANEL
421671-1MIN CONTROL PANEL, COVER COMPLETE (Mini MB)
422560-1 CONTROL PANEL DECAL, MINI MB
422560-2 CONTROL PANEL DECAL, FGL40 & FGL20 (vertical)
422560-3 CONTROL PANEL DECAL, FGL40 & FGL20 (horizontal)
421682-** DEFLECTOR, PAPER GUIDE (** Printer Dependent )
P50-1008 DRIVE BELT,110T
P50-1012 DRIVE BELT,105T
P50-1003 DRIVE BELT,102T
P50-1011 DRIVE BELT,100T
P51-1002 DRIVE PULLEY, 32T
P51-1011 DRIVE PULLEY, 30T
P51-1010 DRIVE PULLEY, 22T
P51-1007 DRIVE PULLEY, 20T
P33-1005 EJECT MOTOR ASSY.
422076 EXIT DEFLECTOR,VERTICAL (UPPER)
421597V4 MINISC EXIT DEFLECTOR,VERTICAL (LOWER)

28F001 FLASH MEMORY
421828-2 FLASH EXPANSION BOARD ( 2MEG)
421828-1 FLASH EXPANSION BOARD ( 1MEG)
422506 FLASH EXPANSION BOARD ( 1MEG) FGL 40 or FGL 20
P54-1002 FAN,EXHAUST
P54-1011 FAN COVER, FILTER HOLDER
P54-1050 FILTER, FAN
431022-2 FLIP UP DOOR KIT (2.00”)
431022-3 FLIP UP DOOR KIT (3.25”)
431022-4 FLIP UP DOOR KIT (4.00”)
P40-1012 HOLD DOWN PLATE SCREW
P29-1002 FUSE, 2A SB
421359-1TOH HEAD MTG. BLOCK 2.00” TAKE OUT HEAD ASSY.
421359-2TOH HEAD MTG. BLOCK 3.25” TAKE OUT HEAD ASSY.
421359-3TOH HEAD MTG. BLOCK 4.00” TAKE OUT HEAD ASSY.
422190-1 INTERFACE BOARD,PARALLEL ( for FGL 40 & FGL 20)
422190-2 INTERFACE BOARD,PC serial (for FGL 40 & FGL 20)
422190-3 INTERFACE BOARD,SERIAL std. (for FGL 40 & FGL 20)
KN-500B KNOB, DRIVE ROLLER ASSY.
P49-1009 LATCH POST,CABINET (MINI PLUS)
TM161A LCD DISPLAY (for FGL 40 & FGL 20)
422589-20 LCD DISPLAY CABLE

COVER MTG. HARDWARE (SCREW,FL,LW)

15

PART # DESCRIPTION

P55-1002 LOCK, MINI PLUS (#305)
422270 LOGIC BOARD ASSY. (only) FGL 40
422188 LOGIC BOARD ASSY. (only) FGL 20
422189 LOGIC BOARD,POWER SUPPLY ( for FGL 40 & FGL 20 )
430894 LOGIC BOARD,MTG. CLIPS
421428 OPTO MTG. BRACKET
422264 OPTO DETECTOR ASSY. (surface mtg. IC’s)
422007-F OPTO DETECTOR, ATM FEED
422007-C OPTO DETECTOR, ATM TEAR OR CUT

421366-1WHMIC Paper Guide Top Plate w/ guide rollers
422234 PLATEN 1.328” SPECIAL
4215085M2 PLATEN 2.00” 200 OR 300 DPI
4215085M3 PLATEN 3.25” 200 OR 300 DPI
4215085M4 PLATEN 4.00” 200 OR 300 DPI
B421943 POWER DOWN PROTECTION BD. FGL IV
B421946 POWER DOWN PROTECTION BD. FGL II
421370-5M PRESSURE BLOCK ASSY.

KF2002 PRINT HEAD,THERMAL (2.00” 200 DPI)
* BS2002 PRINT HEAD,THERMAL (2.00” 200 DPI)
BS3002 PRINT HEAD, THERMAL (2.00”300 DPI)

KF2003 PRINT HEAD,THERMAL (3.25” 200 DPI)
* BS 2003 PRINT HEAD,THERMAL (3.25” 200 DPI)
BS3003 PRINT HEAD, THERMAL (3.25”300 DPI)

KF2004 PRINT HEAD,THERMAL (4.00” 200 DPI)
* BS2004 PRINT HEAD,THERMAL (4.00” 200 DPI)
BS3004 PRINT HEAD, THERMAL (4.00”300 DPI)

OPTO MTG. HARDWARE (SCREW,FW, LW)

KF2008 PRINT HEAD,THERMAL (8.00” 200 DPI)
* BS2008 PRINT HEAD,THERMAL (8.00” 200 DPI)

421639-4 SILENT CUTTER ASSY.4”
421639-8 SILENT CUTTER ASSY.8”
P33-1006 SILENT CUTTER MOTOR (ONLY)
P33-1006-G SILENT CUTTER MOTOR WITH GEARS

422371-1 SILENT CUTTER MOTOR PINION GEAR
420816-5M4SC2 SILENT CUTTER MTG. BRACKET
P28-1015 SILENT CUTTER MICRO SWITCH
421555 SILENT CUTTER RELAY BOARD
P44-1011 SPRING, PRESSURE ADJ. BLOCK
422590 STEPPER MOTOR ASSY. (FGL40 & FGL 20)
P28-1013 SWITCH, POWER (4 tab)
P28-1012 SWITCH,TEST
421724 TAKE OUT HEAD CAM LOCK ASSY. (Complete)
421421-VM2 TOP PLATE, STD (MINI 2.00”, 11.68” x 13.00”)
421421-WMST TOP PLATE, STD (MINI 3.25”, 11.68” x 13.00”)
421421-4 TOP PLATE, STD (MINI 4.00”, 11.68” x 13.00”)
421421-WSPEC TOP PLATE, FULL SIZE (MINI 3.25”, 14.5” x 14.5” )
421444 TOP PLATE, MINI PLUS (2.00”)
421500-SM TRANSFORMER,TORIOD (FGL40 & FGL 20)

SILENT CUTTER MOTOR GEAR BOX (ONLY)

As of December/95 the 422264 opto took the place of the 421056 opto.

16

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 to fault isolation in the

If you need additional help, please contact BOCA at

field.

Tel: [phone] Fax: [phone]

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.
d. If main fuse keeps blowing then check that the printer’s AC voltage board is set

for the correct voltage.

2. POWER IS ON BUT NO OPERATION

a. Check all electrical connections on the printer.
b.Unplug the ther mal head and tur n on the printer.

If printer works, replace the thermal head.
c. Replace the Power Supply board.
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.With pr inter powered on feed the ticket stocking into the printer until it stops.

Depress the test button a couple of times. If the printer reset the ticket stock

properly then the feed opto position needs to be adjusted. Consult “Optical

Devices” in Section 8.1.5.
e. Replace ticket load opto.
f. Replace ticket tear opto.
g. Replace the Power Supply board.
h.Replace the Main logic board.

4. ERRATIC TEAR 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 Devices” in Section 8.1.5.
c. Check that the platen is clean. Consult “Rubber Drive Roller” in Section 8.1.7.
d. Replace ticket TEAR opto.
e. Replace ticket load opto.
f. Replace the Power Supply board.
g. Replace the Main logic board.

17

5. ERRACTIC PRINT POSITION

a. See # 4

6. 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. Clean print head. Consult “Thermal Print Head” in Section 8.1.6.
d. Adjust print intensity setting via the control panel (see Appendix A)
e. Replace thermal head.

7. POOR PRINT OUT (white voids in print out)

a. Clean print head. Consult “Thermal Print Head” in Section 8.1.6.
b.Replace ther mal head.

8. 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 Power Supply board.
e. Replace the Main logic board.

9. 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 eyes. Consult “Optical Devices” in Section 8.1.5.
d. Replace ticket cut opto.
e. Replace ticket feed opto.

10. PRINTER SKIPS TICKETS AND DIES

a. See # 9.

18

The FGL20 and FGL40 printers allow the user to adjust various printer options through the
control panel.

CHECK

MENU

PAPER

Selects proper menu topic (baud rate, cut count, etc.)

PAPER
JAM

TEST

DATA

Enters new value / Also saves new values.

Scrolls through choices in individual menu topics.

CHOICES

To access and use the OPERATOR MENU, follow these steps:

1.Ticket stock should be loaded into the printer. The LCD window displays

FGL40B# or FGL20B#

(# - revision number, incremented for minor revisions ( B - revision letter,

incremented for major revisions)

2. Press both MENU and TEST switches simultaneously for about three seconds.

The LCD window displays OPERATOR 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 OPERATOR MENU without

saving new values or press MENU to enter back into the OPERATOR MENU.

READY

Appendix A - Operator Menu Options

The chart below lists the present menu topics. These topics are subject to change.

OPERATOR MENU!

BAUD RATE?
MINI/MICRO?

PRINT SPEED?

DIAGNOSTIC MODE?

TICKET TYPE?

STATUS ENABLED?

TRANSPARENT MODE

PAPER MODE?

INC CUT1 COUNT?

DEC CUT1 COUNT?

INC CUT2 COUNT?

DEC CUT2 COUNT?

PRINT MODE?

PRINT INTENSITY?

EXIT AND SAVE

JUST EXIT

The following is an overview of what each Menu option does:

BAUD RATE? Controls the serial interface baud rate, parity bit, data bits and stop

bits.
Here are the following choices:

1200,N,8,1
1200,E,7,1
2400,N,8,1
2400,E,7,1
4800,N,8,1
4800,E,7,1

9600,N,8,1 (factory default)

9600,E,7,1
19200,N,8,1
19200,E,7,1

MINI/MICRO? Defines the type of printer.

MINI Is for a printer with a Silent Cutter Assembly (SC2) ( Mini, Mini Plus, Mini MB,

Dual Mini)

MICRO Is for a printer without a SC2 (Micro, Micro Plus, Micro MB, Dual Micro)
(factory default)

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 factor y default.

TICKET TYPE? Defines how the optos are configured on the paper guide assem-

bly.

NORMAL Both optos are inline with each other (usually mounted on a black bracket)

(factory default)

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 Micro MB printer

STATUS ENABLED? Enables or disables the X-ON/X-OFF and status response

protocols.
Your choices are YES (Enabled) or NO (Disabled). YES is factory default.

TRANSPARENT MODE? Please consult your Programming Guide

Your choices are YES (Enabled) or NO (Disabled). NO 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.

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 fac-

tory 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.

INC CUT2 COUNT? Same as INC CUT1 COUNT? but effects path #2 on a dual

path printer.

DEC CUT2 COUNT? Same as DEC CUT1 COUNT? but effects path #2 on a dual

path printer.

PRINT MODE? Defines the automatic ticket length calculation feature.

THERMAL The printer will feed out and then retract a ticket during this measurement. (facto-

ry default)

RIBBON The pr inter will feed out one blank ticket. This mode is used for label stock to pre-

vent 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

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.

INSTALLATION INSTRUCTIONS

Vertical Micro Plus

SITE PREP

ARATION

TOP VIEW OF
COUNTER

Overhang of
Top Plate

Cut out this
surface area

1.00

TOP PLATE INSTALLATION

Note:This Pr inter extends 17.0
inches below the top of the counter.

1.5

9.5

12.0

NOT TO SCALE

(4) 8-32
Studs

Top Plate Top of Unit

1. Attach Top Plate to Top of Unit so that studs protrude thru Top of Printer.

2.Tighten with 8-32 hex nuts and washers (provided) using 5/16 wrench.

Appendix B - Site

Preparation drawing

FGL PRINTER COMPARISON CHART

FGL 20 FGL 40

Alphanumeric LCD Display Y Y
Processing Speed (FGL II = 1) 2 12
Customer Accessible Flash Memory 128 kbytes 128 kbytes
Expansion Memory Option N Y
Maximum Print Speed 8 ips 10 ips
Maximum Print Density 300 dpi 300 dpi
Maximum Printable Area @ 200 dpi 44 84
Maximum Printable Area @ 300 dpi 22 42
PCL4 Interface Option N Y
PCL5 Interface Option N future
Softfont (Hybrid) Option N Y
Full FGL font set N Y
Scaleable FGL Fonts ? Y
PCX Graphics ? Y
FGL Graphics Y Y
Asian Font Option (Japanese, Chinese, etc.) N Y
FGL Interface Y Hybrid
Magnetics Option future Y
Dual Option Y Y
Two Sided Option N Y
Real Time Clock Option N future

Appendix C - FGL Pr inter Comparison Chart