Boca Systems LEMUR-FDIO User manual

LEMUR - FDIO FLIGHT STRIP PRINTER
USER MANUAL
July 11, 2018

Revision Listing
Rev
Date
Comments
1.0
1/10/2018
Released for Production
1.1
6/18/2018
Updated photos on pages
4,5,6,12,17,22,29,31,34,40,41 & 43
1.2
7/11/2018
Updated default setting in section 6.0

Table of Contents
FCC NOTICE................................................................................................................1
WARRANTY INFORMATION .......................................................................................1
1.0 Introduction.............................................................................................................2
2.0 Unpacking the Printer..............................................................................................2
3.0 Important Safety Information...................................................................................3
4.0 Printer Tour.............................................................................................................4
5.0 Installation and Flight Strip Loading ......................................................................10
6.0 Control Panel Options...........................................................................................12
7.0 Maintenance and Adjustments............................................................................17
7.1 Paper Guide and Print Head Assembly..........................................................17
7.1.1 Thermal Print Head (Cleaning & Replacement) ..........................................18
7.1.2 Cut Opto .....................................................................................................20
7.1.3 Load SQ Opto.............................................................................................20
7.1.4 Platen (Rubber Driver Roller)......................................................................21
7.1.5 Ticket Width Adjustment .............................................................................21
7.2 Cutter Assembly.............................................................................................22
8.0 Removal & Replacement of Major Assemblies......................................................23
8.1 Logic Board Removal/Replacement ..............................................................24
8.2 Cut Opto Removal/Replacement....................................................................26
8.3 Load SQ Opto Removal/Replacement...........................................................27
8.4 Control Panel Removal/Replacement ............................................................29
8.5 Power Switch Board Removal/Replacement..................................................30
8.6 Platen Removal/Replacement........................................................................31
8.7 Cutter Assembly Removal/Replacement........................................................34
9.0 Specifications........................................................................................................36
9.1 Interfaces and Pinouts ...................................................................................37
9.2 General..........................................................................................................38
10.0 Spare Parts List with Visual References .............................................................39
11.0 General Printer Testing Guidelines .....................................................................44
11.1 Lemur-FDIO Flight Strip Printer Setup .........................................................46
11.2 Firmware Test Plan......................................................................................49
12.0 Troubleshooting Guide........................................................................................50

List of Addendum
Addendum A - Purchased Components - Performance Data / Data Sheets
Addendum B - Mechanical Drawings and Parts List
Addendum C - Wiring Diagrams
Addendum D - Schematics

1
FCC NOTICE
NOTE: The equipment has been tested and found to comply with the limits for a class B 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 the user’s 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.
WARRANTY INFORMATION
BOCA warrants the equipment manufactured and sold by it to be free from defects in material and
workmanship under normal use and service for a specified period of time. Parts damaged by
negligence or misuse (bad ticket stock, improper operating conditions, etc.) are excluded from this
warranty. Warranties for printers are 1 year from date of shipment. All warranty work is to be
performed either by BOCA or by an authorized BOCA service center. Shipping charges to the repair
center are the customer's responsibility. BOCA will pay for the equipment's return via ground service.
Please go to the link below if you have any reported issues with your new BOCA printer.
www.bocasystems.com/onlinesupportform.html
Equipment damaged in shipping should be reported immediately both to BOCA and to the shipper.

2
1.0 Introduction
The BOCA Lemur-FDIO is a direct thermal flight strip printer. This device is capable of connecting to
the FAA host computer, printing, cutting and stacking Domestic and Oceanic flight strips. This manual
will provide the user with general information regarding printer set-up, operational instructions and
detailed technical information. Please see the Programming Guide for information related to interface
protocol along with special features for the FDIO application.
2.0 Unpacking the Printer
The printer is shipped in a ruggedized container. Please save packing material for future use.
Remove the printer and accessories from the box and inspect for obvious damage. If damage is
noticed, please report it immediately to BOCA. Email: [email protected] Tel: [phone]
Fax: [phone]
The following items should be in the box:
a) Lemur- FDIO printer
b) Hopper (output)
c) Hopper (input)
d) AC cable
With top box removed

3
3.0 Important Safety Information
WARNING: The appearance of this symbol indicates the proximity of
an exposed high voltage area. Please follow all directions carefully for
your personal safety. You must read the following safety information
carefully before working on the printer.
As a safety precaution, all service to the printer should be done by qualified persons with
power off and the AC cord unplugged from the printer. Following any procedure requiring the
removal of covers and/or doors, please verify that they have been properly attached and
fastened prior to operating the printer.
WARNING: Provide an earthing connection before the mains plug is connected to the mains. And,
when disconnecting the earthing connection, be sure to disconnect after pulling out the mains plug
from the mains.
WARNING: Power Cord Set: This must be approved for the country where it is used:
U.S.A. and Canada
▪The cord set must be UL-approved and CSA certified.
▪The minimum specification for the flexible cord is:
▪No. 18 AWG
▪Type SV or SJ
▪3-conductor
▪The cord set must have a rated current capacity of at least 10A.
▪The attachment plug must be an earth-grounding type with a NEMA 5-15P
(15A, 125V) or NEMA 6-15P (15A, 250V) configuration.
WARNING: The appliance coupler (the connector to the unit and not the wall plug) must have a
configuration for mating with an EN60320/IEC320 appliance inlet.
WARNING: The socket outlet must be near to the unit and easily accessible.

4
4.0 Printer Tour
The following photos are presented for the purpose of familiarizing the user with the Lemur-FDIO
Flight Strip Printer.
Figure 1 –Lemur-FDIO Flight
Strip Printer and accessories
Input Hopper
Output Hopper
Lemur- FDIO
Flight Strip Printer

5
Figure 2 –Front View

6
Figure 3 –Control Panel
LCD Display
LCD Dimmer
Selection Buttons
LED Indicator Lights

7
Figure 4 –Rear View
ON/OFF Power
A/C Power Receptacle
USB Connector
Ethernet Connector
RS422 Connector

8
Figure 5 –Top View
Cover Removed

9
Figure 6 –Entry Paper Guide
Insert Strips Here

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5.0 Installation and Flight Strip Loading
The Lemur-FDIO printer is designed to be mounted either on a desktop or shelf. Prior to site
preparation, installation and loading of flight strips, the printer should be powered up and run in the
following self-test mode:
•Place the printer on a counter top.
•Attach the AC cord and interface cable into the proper connectors.
•Install output hopper to catch the flight strips.
•Turn power on via the switch located on the rear of the unit (see Fig. 4). The LCD will display
PAPER OUT and the red PAPER OUT LED will be illuminated.
The Lemur- FDIO has been designed to accept the following FAA flight strip types:
1. Domestic Strip ...............1.0 x 8.0 inches...................NSN 7530-01-453-5094
2. Domestic 1/2 Strip...............1.0 x 8.0 inches...................NSN 7530- 01-468-4668
3. Oceanic Strip............1.317 x 8.0 inches...............NSN 7530-01-435-187
Please note that the Lemur- FDIO has been factory configured for the Domestic strip (1) shown
above. Please consult section 6.0 for instructions on re-configuring the unit to a different flight strip
format via STRIP SELECTION menu option.
Loading instructions:
Load flight strips into the input hopper and locate the hopper at a distance behind the printer to allow
for the smooth feed of strips to the entrance guide on the Lemur-FDIO. Ensure that the stack of strips
is loaded into the hopper so that the arrow (on the bottom of the strip), which indicates feed direction,
is loaded into the printer accordingly.
Cover Removal / Installation:
The cover may be removed by turning the knob on top to the unlocked position and then lift up on the
cover.

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To install the cover back in place, make sure the knob is in the unlocked position. Fit the cover onto
the opto of the printer and turn the knob to the locked position.
Verify that the printer is configured to use the correct flight strip type. If not, remove the cover of the
Lemur-FDIO and adjust the adjustable paper guide by hand (see section 7.1.5) so that the flight strip
is guided properly, without making it too tight. You will also need to use the control panel to configure
the print format, as described in the Programming Guide. After the printer is properly configured, feed
the flight strips into the entry paper guide (see Fig 6) with the green side facing up until the printer
automatically positions the strip.
The Lemur- FDIO can print three test strips:
(1) BLANK Strip (by pressing BLANK STRIP)
(2) DIAGNOSTIC Strip (by simultaneously pressing BLANK STRIP and ON/OFF buttons with printer offline)
(3) CONFIGURATION Strip (by simultaneously pressing MENU and ON/OFF buttons with printer offline)

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6.0 Control Panel Options
The Lemur-FDIO allows the user to adjust various printer options through the front control panel.
The printer has four LED lights on the control panel. All LEDs will illuminate briefly after power up.
•DATA flashes green when the printer is receiving data
•READY green when the printer is ready
•CHECK PAPER red when the printer is out of paper
•PAPER JAM red when there is a paper jam
Single Key Press
•Press the “ON/OFF”LINE button - the printer will toggle between online and offline modes.
The current on/off line state is displayed on the LCD display and the “READY”light is
illuminated when the printer is online and ready to receive data.
•Press the “BLANK STRIP”button - the currently selected blank flight strip will print.
Multi-Key Press
•Enter factory menu - press and hold the “MENU”button first, and while continuing to keep the
“MENU”button depressed, press and hold the “ON/OFF LINE”button for approximately two
seconds. Once the printer enters the menu system the LCD will display “FACTORY MENU”.
•Print a diagnostic ticket - press and hold “ON/OFF LINE”button first, and while continuing to
keep the “ON/OFF LINE”button depressed, press the “BLANK STRIP”button. A printer
diagnostic strip will print which displays a few lines of text using the special flight strip printer
fonts. The current printer’s firmware revision is shown at the bottom of the diagnostic strip.
•Print a configuration ticket - press and hold “ON/OFF LINE”button first, and while continuing to
keep the “ON/OFF LINE”button depressed, press the “MENU”button. A configuration ticket
will print containing the printer’s current configuration settings.
FACTORY MENU Under normal operating conditions an operator can explore all of the menu
settings, but any changes to the printer’s parameters will be ignored. Modifying the printer’s
configuration settings by issuing the appropriate FGL command is not affected by the state of the
menu.
ON/OFF LINE: Scrolls
through choices in
individual menu topics
MENU: Selects proper
menu topic (baud rate,
cut count, etc.)
BLANK STRIP: Enters
and saves new values

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To access and view the FACTORY MENU, follow these steps:
1. Flight strips should be loaded into the printer with the printer powered on.
2. Press and hold the MENU button first, and while continuing to keep the MENU button
depressed, press and hold the ON/OFF LINE button for approximately for about 3 seconds.
The LCD will display FACTORY MENU or start scrolling through different settings. Release the
buttons as this time.
3. To scroll through the menu topic, use MENU button to select the topic you wish to view.
4. Press ON/OFF LINE button to scroll through choices in the selected topic. NOTE: A blinking
cursor next to a choice indicates that choice is currently saved in the printer’s memory.
5. Press the MENU will enable you to select other topics.
To access and change the FACTORY MENU, follow these steps:
1. Make sure the printer is powered off.
2. Press and hold both the MENU and ON/OFF LINE buttons. While holding the two buttons
power up the printer. Within about 3 seconds the LCD will display FACTORY MENU or start
scrolling through different topics. Release the buttons as this time.WARNING: Improper use
of the factory menu may disable your printer.
3. To scroll through the menu topic, use MENU button to select the topic you wish to change.
4. Press ON/OFF LINE button to scroll through choices in the selected topic. NOTE: A blinking
cursor next to a choice indicates that choice is currently saved in the printer’s memory.
5. Once you have found the new value you want, press BLANK STRIP button. The LCD window
displays EXIT AND SAVE? If you wish to save the new value then press BLANK STRIP
button again.
6. If you do not wish to save the new value then press MENU. The LCD window displays JUST
EXIT? Press BLANK STRIP button to exit the FACTORY MENU without saving new values or
press MENU to enter back into the FACTORY MENU.

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The chart below lists the present menu topics. These topics are subject to change.
The following is a brief overview of some representative Menu options:
STRIP SELECTION? Select blank flight strip format to be assigned to blank strip button on the control panel.
DOMESTIC
Domestic Strip - 1.0 x 8.0 inches - NSN 7530-01-453-5094 (default)
Domestic ½ Strip - 1.0 x 8.0 inches - NSN 7530- 01-468-4668
OCEANIC
Oceantic Strip - 1.317 x 8.0 inches - NSN 7530-01-435-1872
INC CUT1 COUNT? Moves the cut position to the left (towards the ticket entrance area). Cut counts are increments of
.003”. Depressing CHOICES changes the count value. 16 is factory default. For a 300dpi printer the INC value should
not exceed 35. Going beyond these values will cause reliability issues.
DEC CUT1 COUNT? Moves the cut/ position to the right (towards the ticket exit area). Cut counts are decrements of
.003”. Depressing CHOICES changes the count value. 16 is factory default.
PRINT INTENSITY? Controls the darkness of printout. Here are the following choices:
LIGHT
MED LIGHT
NORMAL
(factory default)
MED DARK
SHORT HEAD LIFE
BAUD RATE? Controls the serial interface: baud rate, parity bit, data bits and stop bits. Here are the following choices:
(2400,N,8,1 is default)
1200,N,8,1
4800,N,8,1
19200,N,8,1
38400,E,7,1
1200,E,7,1
4800,E,7,1
19200,E,7,1
57600,N,8,1
1200,O,7,1
4800,O,7,1
19200,0,7,1
57600,E,7,1
2400,N,8,1
9600,N,8,1
28800,N,8,1
115200,N,8,1
2400,E,7,1
9600,E,7,1
28800,E,7,1
115200,E,7,1
2400,O,7,1
9600,0,7,1
38400,N,8,1
OPERATOR MENU
STRIP SELECTION?
INC CUT1 COUNT?
DEC CUT1 COUNT?
PRINT INTENSITY?
BAUD RATE?
MINI/MICRO?
PRINT SPEED?
DIAGNOSTIC MODE?
TICKET TYPE?
STATUS ENABLED?
PAPER MODE?
CLEAR DOWNLOAD?
DEFAULT SETTING?
PARK TICKET?
TICKET MODE?
INC MINIREV?
DEC MINIREV?
INC TOP ADJ?
DEC TOP ADJ?
USB?
USB DEVICE TYPE?
ETHERNET?
IP ADDRESS?
SUBNET MASK?
DEFAULT GATEWAY?
DNS SERVER?
SPEED/DUPLEX?
EXIT AND SAVE?
JUST EXIT

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MINI/MICRO? Defines if printer has a cutter. Factory set do not modify.
MINI cutter (default)
MICRO no cutter
PRINT SPEED? Controls the print speed and the print quality. Printer should not be run at a print speed of 0 as it may
cause ticket
jams. The numbers range from 0 - FASTEST to 7 - SLOWEST. (3 is factory default).
DIAGNOSTIC MODE? Your choices are YES or NO. NO is factory default. YES places the printer into a mode where it
prints both printable and control characters to assist in isolating data transmission issues. (NO is default)
TICKET TYPE? Defines how the optos are configured on the paper guide assembly. (FACTORY PRESET / SHOULD
NOT BE CHANGED)
NORMAL
Both optos are in line with each other (usually mounted on a black bracket)
GAP
A gap opto is installed on the cutter to detect gap in ticket stock.
LABEL
Same as GAP but the cut opto is to detect black mark on stock.
SPECIAL TICKET
This option is for a Micro MB or a printer with a ticket load switch (default)
STATUS ENABLED? Sets status response protocols. (FACTORY PRESET / SHOULD NOT BE CHANGED)
NONE
Disables the XON/XOFF and status response protocols
SERIAL
Enables the XON/XOFF and status response protocol for the serial port
PARALLEL
Enables bi-directional parallel status responses if printer is configured as bi-directional
SER/PAR
Enables both bi-directional parallel and serial status responses.
USB
Enables USB status responses
USB/SER
Enables USB and serial status responses (default)
USB/PAR
Enables USB and bi-directional parallel
USB/SER/PAR
Enables USB, bi-directional parallel and serial status responses
PAPER MODE? It may also be used on roll stock with no black marks on the ticket. (FACTORY PRESET / SHOULD
NOT BE CHANGED).
YES
Configured for use with media that does not have a black timing mark.
NO
Paper mode disabled (default)
RECEIPT
Only for a Lemur-R & Lemur-C receipt model printers
PARTIAL CUT
Enables both bi-directional parallel and serial status responses.
PARTIAL CUT ###
Only for Lemur-R & Lemur-C receipt model printers set to partial cut mode.
RX MODE
Enables USB and serial status responses
CLEAR DOWNLOAD? Clears those items downloaded by the operator to Flash memory. Your choices are YES or NO.
(NO is default)
DEFAULT SETTING? Defaults the printer back to its original factory settings. Your choices are YES or NO. (NO is
default)
PARK TICKET? Reverse the ticket to the print position after the last strip in a group has been printed. Your choices are
YES or NO. (YES is default) (FACTORY PRESET / SHOULD NOT BE CHANGED)
TICKET MODE? Defines how the printer will treat multiple flight strips. Your choices are SINGLE or MULTIPLE.
(SINGLE is factory default).
INC MINIREV? Allow horizontal positioning of the flight strip data within the printable area of flight strip to be adjusted.
This control is primarily used to adjust the print position right at the factory and is not normally needed during normal
printer operation. (0279 is default value)

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DEC MINIREV? Allow horizontal positioning of the flight strip data within the printable area of flight strip to be adjusted.
This control is primarily used to adjust the print position left at the factory and is not normally needed during normal printer
operation. (0279 is default value)
INC TOP ADJ? Allow vertical positioning of the flight strip data within the printable area of flight strip to be adjusted. This
control is primarily used to adjust the print position down at the factory and is not normally needed during normal printer
operation. (0001 is default value)
DEC TOP ADJ? Allow horizontal positioning of the flight strip data within the printable area of flight strip to be adjusted.
This control is primarily used to adjust the print position up at the factory and is not normally needed during normal printer
operation. (0001 is default value)
USB? Activates the USB interface. Your choices are YES or NO. (YES is default) (FACTORY PRESET / SHOULD
NOT BE CHANGED)
USB DEVICE TYPE? Enables the printer’s USB device class to be changed. Your choices are PRINTER, HID and serial.
(Default is HID).
ETHERNET? Enables the Ethernet port setting to be changed.
NO
Ethernet not enabled
YES
Uses the IP address that has been set in the printer by the customer or manual
selection
Diagnostics
This feature should not be used
Valid Packets
This feature should not be used
DHCP Enabled
Automatically attempts to get an IP address from Local Server (Default)
DHCP/SUB/GATE
Automatically attempts to get an IP address/Subnet Mask/Gateway from Local Server
DHCP/NR
Automatically attempts to get an IP address from Local Server and then register the
name with the local NetBIOS name server usually the WINS Server
DHCP/SUB/GATE/NR
Automatically attempts to get an IP address/Subnet Mask/Gateway from Local Server
and then register the name with the local NetBIOS name server usually the WINS
Server
IP ADDRESS? Enables the printer’s Ethernet IP Address to be manually changed. 000.000.000.192 is default if Ethernet
port is not connected to the network.
SUBNET MASK? Enables the printer’s Ethernet Subnet Mask value to be changed. 0.0.0.0 is default if Ethernet port is
not connected to the network.
DEFAULT GATEWAY? Enables the printer’s Ethernet default Gateway value to be changed. 010.000.000.192 if Ethernet
port is not connected to the network.
DNS SERVER? Enables the printer’s Ethernet default DNS server value to be changed. 000.000.000.192 is default if
Ethernet port is not connected to the network.
SPEED/DUPLEX? Enables the printer’s Ethernet speed and duplex setting to be changed. Your choices are AUTO-
NEGOTIATE (default), 100Mbps/FULL, 100Mbps/HALF, 10Mbps/FULL and 10Mbps/HALF.
EXIT AND SAVE! Will save any changes made to the above menu options. If you wish to save the new value then press
ON/OFF LINE button, if not press MENU button.
JUST EXIT? Will exit the menu options without saving any changes. If you wish to exit without saving the new value then
press ON/OFF LINE button, if not press MENU button.