Avery 6035 Equipment Manual
MONARCH
DOS-based
PATHFINDER
System
Ultra
TC6035EZEM Rev. C 10/98 ©1998 Monarch Marking Systems, Inc. All rights reserved.
Each product and program carries a respective written warranty, the only
warranty on which the customer can rely. Monarch reserves the right to make
changes in the product and the programs and their availability at any time and
without notice. Although Monarch has made every effort to provide complete
and accurate information in this manual, Monarch shall not be liable for any
omissions or inaccuracies. Any update will be incorporated in a later edition of
this manual.
©1998 Monarch Marking Systems, Inc. All rights reserved. No part of this
publication may be reproduced, transmitted, stored in a retrieval system, or
translated into any language in any form by any means, without the written
permission of Monarch Marking Systems, Inc.
Trademarks
Monarch, Pathfinder, and Ultra are registered trademarks of Monarch Marking Systems, Inc.
6035, 6076, 6093, and 6094 are trademarks of Monarch Marking Systems, Inc.
Datalight is a registered trademark of Datalight, Inc.
ROM-DOS is a trademark of Datalight, Inc.
Monarch Marking Systems, Inc.
P.O. Box 608
Dayton, OH 45401
STATEMENT OF WARRANTY ON MONARCH MACHINES
Limited Warranty
THIS LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES OR
REPRESENTATIONS EXPRESSED OR IMPLIED, INCLUDING MERCHANTIBILITY OR
FITNESS FOR BUYER’S PURPOSES. THERE IS NO WARRANTY WHICH EXTENDS
BEYOND THE LIMITED WARRANTY.
The Monarch product covered by this limited warranty is warranted to be free from defects in
materials and workmanship for a period of one (1) year from the date of shipment to the
original purchaser.
This limited warranty does not cover damage by accident, abuse or violence, or use by the
original purchaser of other than the standard supplies furnished by or meeting the
specification of Monarch, or the Monarch product is operated or maintained contrary to the
instructions provided by Monarch. The warranty is void if the machine is altered or repaired
by other than Monarch representatives.
This warranty does not include the furnishing of ribbons, ink rollers, tags, labels, or other
supplies.
The Monarch product requiring warranty service may be shipped to the nearest authorized
Monarch service facility with the transportation charges PREPAID. Monarch is NOT
responsible for damage that occurs during shipment if the product is not shipped in the
original Monarch packaging. The Monarch product will be repaired free of charge during the
warranty period.
This warranty is valid only in the United States.
TABLE OF CONTENTS
Laser Scanner Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Printer Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operator’s Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GETTING STARTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Turning on the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Charging the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Charging the Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Changing the Battery Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
LOADING SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Loading for Peel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Printing in On-Demand Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Loading for Non-Peel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Printing in Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removing Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
BASIC OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
About the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reading the Printer Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
About the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-line/33 Key Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
8-line/48 Key Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
About Data Entry Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
8-line/48 Key Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Using Numeric/Normal Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Using Upper-case Alpha Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
TC6035EZEM Rev. C 10/98
Table of Contents i
Using Lower-case Alpha Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Special Key Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Using Function Key Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Using Delete Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Using the Alt and Ctrl keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Restarting the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
USING THE LASER SCANNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Scanning a Bar Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cleaning the Scanner Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Scanning Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Clearing Supply Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Cleaning the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Cleaning the Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cleaning the Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Storing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
USING DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Checking Display Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Checking Keyboard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Testing the Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Testing the Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Checking the Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Checking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Displaying Machine Totals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Performing Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Calibrating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Checking Hardware Version Information . . . . . . . . . . . . . . . . . . . . . 7-20
Checking Software Version Information . . . . . . . . . . . . . . . . . . . . . . 7-21
Exiting the Diagnostics Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
ii Table of Contents
TC6035EZEM Rev. C 10/98
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SPECIFICATIONS AND ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Supply Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
TC6035EZEM Rev. C 10/98
Table of Contents iii
INTRODUCTION 1
The Monarch® DOS-based PATHFINDER® Ultra® printer can act
as a data collection device, a printer, or both.
You can scan bar codes, verify them against data in a database
via a radio in your printer (if you have this option), and return new
data to print a label.
This manual lists the features of your printer, and provides
instructions on charging the battery handle and loading supplies.
The manual also describes how to care for and maintain of your
printer.
Printer Types
The printer comes in two types.
The printer on the left has a 4-line display and 33 keys. The
printer on the right has an 8-line display and 48 keys. Other than
the way things appear on the display or how you use the keys, the
two printers are the same.
The information in this manual applies to both printers, unless
specified otherwise.
TC6035EZEM Rev. C 10/98
Introduction 1-1
Printer Features
The printer features
u
alphanumeric keypad
u
on-demand and continuous printing
u
adjustable supply width capabilities
u
clock/calendar
u
Datalight ROM-DOS 6.22 operating system
u
RS-232 communications
u
graphic printing capabilities
u
display backlight
u
low-power shutdown to conserve the battery
u
radio communication (factory-installed option)
u
laser scanner (factory-installed option)
u
international keypad (factory-installed option).
See Appendix B, "Specifications and Accessories," for a list of
available accessories.
Operator’s Checklist
Before collecting data or printing, you must
1-2 Introduction
4 charge the battery handle. (See "Charging the Battery
Handle" in Chapter 2.)
4 attach a fully charged battery handle. (See "Changing the
Battery Handle" in Chapter 2.)
4 load your supplies. (See "Loading for Peel Mode" or
"Loading for Non-Peel Mode" in Chapter 3.)
TC6035EZEM Rev. C 10/98
GETTING STARTED 2
After you unpack your printer, charge the battery handle first and
then attach it to the printer.
Turning on the Printer
When you first turn on the printer, our logo appears. You’ll also
notice a line moving horizontally across the bottom of the display.
The movement of this line is tied to the progression of tasks the
printer must do to get ready. When the printer finishes, the line
and logo disappear. If they don’t disappear, see Chapter 8,
"Troubleshooting."
Charging the Battery
The printer is powered by a 12VDC NiCd battery pack in the
handle. You can use and recharge the battery handle daily for
approximately two years.
See the label on the bottom of the handle for battery
recycling and disposal information.
A stored battery handle loses 2 to 3% of its charge per day.
Do Not store a battery handle for a long period of
time because it may lose its charge. If storing the
printer for longer than a month, charge the battery
once a month or leave the battery attached to the
printer and plugged in to a trickle charger.
TC6035EZEM Rev. C 10/98
Getting Started 2-1
Extremely hot or cold environments will change the discharge
rate. Charge the battery handle only when it is drained. If you
charge a battery that already contains a charge, you decrease the
battery’s charge capacity and life. Always fully discharge and
charge the battery handle.
The following will decrease battery operating time:
u
using the laser scanner
u
communicating via radio frequency
u
enabling the backlight
u
printing (especially when printing large amounts of data on the
supply, or when printing in on-demand mode).
CAUTION
Always keep a charged handle attached to the
printer. Storing the printer without a handle may
erase or alter the memory.
To ensure maximum battery charge cycles, charge the battery
handle only when the printer indicates that it needs to be charged.
Before operating the printer, charge the battery handle and attach
it to the printer. You can use one of the following chargers:
Charger Approximate Charging Time
6093-07 Fast Charger
6094-01 Four Station Charger
2-2 Getting Started
1.5 hours
1.5 hours
TC6035EZEM Rev. C 10/98
Charge time may vary depending on the type
of battery and the degree to which the battery
was drained. For example, high capacity
batteries may take one or two
hours longer to charge.
When using or storing the charger:
u
Do Not wrap the cord arou nd the ch arger.
u
Do Not pull or put unusual stress on the cord.
Before using the charger, inspect the cord for bare wires. Do Not
use a charger with bare wires.
Use only a manufacturer-approved charger.
Refer to the Battery Addendum for more information on battery
usage.
TC6035EZEM Rev. C 10/98
Getting Started 2-3
To charge the battery handle with the fast charger:
1. Turn the printer off.
2. Remove the battery handle (see "Changing the Battery
Handle").
3. Plug the round connector of the charger into the socket on the
battery handle.
4. Plug one end of the power cable into the charger and the
other end into a grounded (three prong) electrical outlet of the
correct voltage.
Refer to the instructions that come with the charger for more
information.
Battery Handle
Charger
2-4 Getting Started
Connector
TC6035EZEM Rev. C 10/98
Charging the Backup Battery
The printer has a rechargeable Nickel Metal Hydride (NiMH)
battery that backs up the battery handle. If both batteries are
completely drained when you turn on the printer, a CMOS error
occurs. You will receive one or two error messages (depending
on the type of problem).
This message appears if power is lost.
WARNING CMOS FAILURE
DEFAULTS RESTORED
This message appears if data is corrupted.
WARNING - CMOS
CHECKSUM INVALID
DEFAULTS RESTORED
If you receive either message:
1. Press any key after each message. The printer attempts to
finish booting.
2. Replace the drained battery handle with a fully-charged
battery handle and turn the printer on.
The length of time it takes for the NiMH battery to recharge varies
(up to eight hours), depending on
u
the options you have on your printer.
u
if, how, and how long you use the printer while recharging.
The battery handle may drain before the NiMH battery is fully
charged (probably after four hours, depending on the factors
listed above). This drainage affects recharging performance. For
example, an hour of printing, scanning, radio communications, or
just sitting untouched takes different amounts of power. To avoid
this drainage, you may need to switch battery handles or plug the
printer into a fast charger while recharging the NiMH battery.
TC6035EZEM Rev. C 10/98
Getting Started 2-5
The best bet for a quick recharge is to place a powered-on printer
Latch
on a fast charger and leave it alone for eight hours.
Changing the Battery Handle
To change the battery handle:
1. Important. Turn the printer off.
2. Hold the latch down while you slide the battery handle off
towards the keypad.
3. Slide a fully charged battery handle onto the printer until it
stops.
2-6 Getting Started
Make sure the latch clicks when you attach
the battery handle.
TC6035EZEM Rev. C 10/98
LOADING SUPPLIES 3
The printer uses thermal supplies:
u
synthetic labels
u
paper labels and tags
u
specialty paper.
See Appendix B, "Specifications and Accessories," for available
supply sizes.
There are two methods for loading supplies:
u
Peel mode is for labels only. Load the supplies in peel
mode when printing in on-demand mode or when printing
and applying labels.
u
Non-peel mode is for tags, strips of labels, or specialty
paper. Load the supplies in non-peel mode when printing
in continuous mode.
See your System Administrator to find out which
mode you need.
TC6035EZEM Rev. C 10/98
Loading Supplies 3-1
Loading for Peel Mode
Peel mode separates labels from the backing paper, which allows
you to print and apply labels immediately. You must load labels in
this mode when the on-demand sensor is enabled.
Confirm all loading procedures with your
System Administrator, because these
procedures can vary depending on the
application you are running.
To load your labels:
1. Turn the printer on. The printer initializes.
2. Start the application and maneuver to the point where it
prompts you to load the supplies.
3. Press the latch buttons as shown, and open the supply cover
completely.
3-2 Loading Supplies
Supply Cover
Latch Button
TC6035EZEM Rev. C 10/98
4. Pull back the supply lock tab.
5. Squeeze or pull apart the supply holder at its base so it
adjusts to the size of your supply roll. You can set it at 1.2",
1.5", and 2.0".
Do not move the supply holder without pulling
back the supply lock tab first.
Supply Holder
TC6035EZEM Rev. C 10/98
Loading Supplies 3-3
6. Press the supply lock down to lock the supply holder in place.
7. Remove the seal from the supply roll. Peel and discard the
first four inches of labels from the backing paper. Tear evenly
across the supply strip.
8. Place the supply roll as shown in
the supply holder so that it feeds
labels from the bottom. The black
marks on the labels should be
facing down.
9. Hold the printer upright and gently press down on the label
deflector as shown. It may be stiff.
Label Deflector
3-4 Loading Supplies
TC6035EZEM Rev. C 10/98
10. Feed all four inches of the backing paper over the peel bar
and under the applicator roller and the label deflector.
Applicator Roller
Peel Bar
Label
Deflector
11. Push the label deflector up until it snaps into place.
12. Partially close the supply cover to the first position (until it
clicks once).
Do Not close the cover completely at this step
or label jams may occur.
TC6035EZEM Rev. C 10/98
Loading Supplies 3-5
13. Hold the supply edge between the feed and pinch rollers, and
then press the trigger or a key assigned by your System
Administrator until all slack is removed. Discard the extra
labels that feed.
Feed Roller
Pinch Roller
14. Close the supply cover completely.
Printing in On-Demand Mode
In on-demand mode, the printer prints a label each time you
remove the previously printed label. Whether you are printing in
on-demand mode depends on the application you are running.
Ask your System Administrator if you are printing in this mode.
3-6 Loading Supplies
Before you begin printing, make sure the
handle is fully charged and attach the safety
strap of the printer to your wrist.
TC6035EZEM Rev. C 10/98
Most likely, the application you are running will have you print
labels in on-demand mode as follows:
1. Press the trigger (or other key your System Administrator
assigns).
2. Apply the label.
Subsequent labels print automatically after you apply each label.
As each prints, apply the label.
To remove excess backing paper,
gently tear down.
TC6035EZEM Rev. C 10/98
Loading Supplies 3-7
Loading for Non-Peel Mode
Non-peel mode feeds the supply through the printer in one
continuous strip. Use non-peel mode to print strips of labels,
tags, or specialty paper.
To load your supply:
1. Turn the printer on. The printer initializes.
2. Start the application and maneuver to the point where it
prompts you to load the supplies.
3. Press the latch buttons as shown and open the supply cover
completely.
Supply Cover
3-8 Loading Supplies
Latch Button
TC6035EZEM Rev. C 10/98
4. Pull back the supply lock tab.
5. Squeeze or pull apart the supply holder at its base so it
adjusts to the size of your supply roll. You can set it at 1.2",
1.5", and 2.0".
Do not move the supply holder without pulling
back the supply lock tab first.
Supply Holder
TC6035EZEM Rev. C 10/98
Loading Supplies 3-9
6. Press the supply lock down to lock the supply holder in place.
7. Remove the seal from the supply
roll.
8. Place the supply roll as shown in
the supply holder so that it feeds
labels from the bottom. The black
marks on the labels should be
facing down.
Specialty paper has no black marks.
9. Feed the supply under the applicator roller and over the label
deflector.
Applicator Roller
Label Deflector
10. Press the trigger or a key assigned by your System
Administrator until all slack is removed. Discard extra
supplies.
11. Close the supply cover completely.
3-10 Loading Supplies
TC6035EZEM Rev. C 10/98
Printing in Continuous Mode
In continuous mode, the printer prints one supply or a strip of
supplies all at once. Supplies may be thermal labels, tags, or
specialty paper. Whether you are printing in continuous mode
depends on the application you are running. Ask your System
Administrator if you are printing in this mode.
Before you begin printing, make sure the
handle is fully charged and attach the safety
strap of the printer to your wrist.
Most likely, the application you are running will have you print
labels in continuous mode as follows:
1. Press the trigger (or other key the System Administrator
assigns).
2. When printing stops, cut the supply and remove the strip.
Removing Supplies
To remove supplies:
1. Peel Mode Only. Tear the backing paper just above the pinch
roller.
2. Open the supply cover completely.
3. Twist the supply roll or core while pushing down, and then pull
forward to remove.
TC6035EZEM Rev. C 10/98
Loading Supplies 3-11
3-12 Loading Supplies
TC6035EZEM Rev. C 10/98
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