Brady 2461, 6441, 3481 User Manual

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Brady

Bradyprinter Models 2461, 3481, and 6441

Operator’s Manual

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CG Triumvirate is a trademark of Agfa Corporation. CG Times based upon Times New Roman under license from the Monotype Corporation.

Firmware (Software) Agreement

The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is licensed for used only on a single printer in the user’s Trade or Business.

The User agrees not to, and not to authorize or permit any other person or party to duplicate, or copy the Firmware or the information contained in the non-volatile or programmable memory. The firmware (Software) is protected by applicable copyright

laws and Licensor retains all rights not expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss, including direct, incidental, economic, special, or consequential damages, arising out of the use or inability to use the Firmware (Software).

Information in this document is subject to change without notice and does not represent a commitment on the part of Brady Worldwide, Inc. No part of this manual may be reproduced or transmitted in any form or by any means, for any purpose other than the purchaser's personal use, without the expressed written permission Brady Worldwide Inc.

Part Number: 88-2241-21

Revision: C

Agency Compliance and Approvals:

UL1950 Information Technology Equipment

C US

Listed

C22.2 No. 950-M93

EN60950

For 230 Volt Operation (Europe): Use a cord set, marked “HAR,” consisting of a min H05VV-F cord which has a minimum 0.75 square mm diameter conductors, provided with an IEC 320 receptacle and a male plug for the country of installation rated 6A, 250V

Für 230 Volt (Europa): Benützen Sie ein Kabel, das mit “HAR” markiert ist, bestehend mindestens aus einem H05VV-F Kabel, das mindestens 0,75 Quadratmillimeter Drahtdurchmesser hat; sowie eine IEC320 Steckdose und einen für das Land geeigneten Stecker, 6A, 250 Volt.

As an Energy Star Partner, the manufacturer has determined that this product meets the Energy Star guidelines for energy efficiency.

The manufacturer declares under sole responsibility that this product conforms to the following standards or other normative documents:

EMC: EN 55022 (1993) Class B

EN 50024 (1998)

Safety: This product complies with the requirements of

EN 60950/All:1997

Gost-R

Resolution S.I.C. & M., No. 799/99

FCC: This device complies with FCC CFR 47 Part 15 Class A.

þ Note: This 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 instructions in this manual, it 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.

Important Safety Instructions:

The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance instructions in the literature accompanying this unit.

This unit has been carefully designed to provide years of safe, reliable performance. However, as with all electrical equipment, there are some basic precautions that you follow to avoid personal injury or damage to the printer:

Ø Before using the printer, carefully read all the installation and operating

instructions.

Ø Observe all warning instruction labels on the printer.

Ø Install the printer on a flat, firm surface.

Ø Do not place the printer on or near a heat source.

Ø To protect your printer from overheating, make sure no openings on the

printer are blocked.

Ø Never insert anything into the ventilation slots and openings of the printer.

Ø Do not use the printer near water or spill liquid into it.

Ø Ensure that the AC power source matches the ratings listed for the printer.

(If unsure, check with your dealer or local utility provider.)

Ø Do not place the AC power cord where it can be stepped on. If the AC

power cord becomes damaged or frayed, replace it immediately.

Ø If the printer ever needs repair, consult only qualified, trained service

personnel. No user-serviceable parts are inside; do not remove the cover.

Printer Overview

1.0 About the Printer ...........................................................1

1.0.1 Standard Features...........................................2

1.0.2 Optional Features ...........................................2

1.1 Option Installation .........................................................5

1.2 Hardware Components .................................................6

Getting Started

2.0 Unpacking the Printer ...................................................7

2.0.1 Inspection ........................................................8

2.0.2 Additional Requirements .................................8

2.1 Media and Ribbon Selection .........................................9

2.1.1 Print Quality Controls.......................................9

Setting Up the Printer

3.0 Installation...................................................................11

3.0.1 Communications............................................12

3.1 Loading Media ............................................................14

3.1.1 Roll Media .....................................................15

3.1.2 Fan-Fold Media .............................................16

3.2 Media Sensor Adjustment...........................................17

3.3 Loading Ribbon...........................................................18

3.4 Quick Media Calibration..............................................20

3.5 Outputting Labels........................................................21

3.5.1 Rewinding......................................................21

3.5.2 On-Demand Dispensing ................................23

3.5.3 Cutting ...........................................................25

Using the Front Panel

4.0 Operation ....................................................................27

4.0.1 Ready Mode: Normal Operation ....................27

4.0.2 Menu Mode: Configuration ............................28

4.0.3 Quick Test Mode: Print Test Labels...............29

4.0.4 Indicator Lights ..............................................30

4.0.5 LCD ...............................................................30

4.0.6 Resetting the Printer......................................31

4.0.6.1 Soft Reset ........................................31

4.0.6.2 Level One Reset ..............................31

4.0.6.3 Level Two Reset ..............................31

4.1 The Menu System.......................................................32

4.1.1 Entrance and Exit Prompts ............................33

4.1.2 Media Settings...............................................34

4.1.3 Print Control ..................................................35

4.1.4 Printer Options...............................................37

4.1.5 System Settings.............................................39

4.1.6 Communications............................................47

4.1.7 Diagnostics ....................................................53

4.2 Display Messages.......................................................54

4.2.1 User Prompts and Condition Messages ........54

4.3 Quick Test Mode.........................................................56

4.3.1 Print Quality Label .........................................56

4.3.2 Configuration Label .......................................57

4.3.3 Quick Ribbon Test Label ...............................58

4.3.4 Dot Test Pattern Label...................................59

4.3.5 Validation Label .............................................60

4.3.6 User Defined Label ........................................60

Maintenance and Adjustments

5.0 Media Sensor Calibration............................................61

5.0.1 Standard Calibration......................................61

5.0.2 Advanced Entry Calibration ...........................65

5.1 Printhead Adjustments................................................71

5.1.1 Leveling Cam Adjustment..............................71

5.1.2 Burn Line Adjustment ....................................72

5.2 Printhead Replacement ..............................................73

5.3 Maintenance Schedule ...............................................74

5.3.1 Cleaning the Printhead ..................................75

5.3.2 Cleaning the Platen Roller .............................76

5.3.3 Cleaning Interior and Exterior Surfaces .........77

5.4 Application Version Updates.......................................77

5.4.1 Updating from Ready Mode...........................78

5.4.2 Updating from Download Mode .....................79

5.4.3 Possible Problems during an Update ............80

5.5 Boot Loader Program Updates ...................................81

Troubleshooting

6.0 Problem Resolution.....................................................83

6.1 Fault and Warning Messages .....................................87

6.2 Hex Dump Mode .........................................................93

Specifications

7.0 General Specifications ................................................95

7.1 Media and Ribbon Requirements................................97

Appendix A

ASCII Control Code Chart...................................................99

Appendix B

Available Fonts and Bar Codes.........................................101

Appendix C

Module Assignments.........................................................109

Print Resolutions and Maximum Label Widths..................109

Available Speeds and Default Settings .............................110

iii

Appendix D

GPIO Port Description ......................................................111

Appendix E

Menu System Multi-Language Support.............................113

Advance File Handling Information ...................................116

Appendix F

Saving a Configuration File...............................................119

Warranty Information ................................................121

Glossary........................................................................125

Index ...............................................................................129

1.0 About the Printer

Congratulations on your purchase of a Bradyprinter Model 2461, 3481, and 6441 hereafter referred to as ‘the printer’, blends the rugged durability of diecast construction with state-of-the-art electronics and user-friendly features to redefine the standard in industrial thermal printers.

This manual provides all the information necessary for everyday printer operation. To begin printing labels, refer to the instructions provided with the label-creation software you have chosen. If you wish to write custom label programs, a copy of the Programmer’s Manual is included on the enclosed Accessories CD.

To grow with all of your printing needs, the design of the printer allows most upgrades to be performed easily by an operator; see Section 1.1. The following subsections detail the standard features, available options and a hardware overview.

1.0.1 Standard Features

This printer offers the following standard features:

Bradyprinter Standard Features Listing

Feature

Printhead Density (Dots Per Inch) 203 300 600 Direct Thermal Printing X X X On-Demand and Batch Printing X X X Rotating Media Hub X X X Media Tear Bar X X X Fan-fold media capability X X X Flash memory 1MB 2MB 2MB SDRAM 8MB 16MB 16MB RS-232 interface port X X X IEEE 1284 Compliant parallel interface port Liquid Crystal Display X X X EFIGS (multi-language display and configuration label support) X X X AGFA Scalable font engine X X X

2461 3481 6441

X X X

Model

1.0.2 Optional Features (available except as noted)

The printer offers the following optional features:

Light-Duty (Backing-Only) Cutter

A rotary-type mechanism to automatically cut material with a maximum thickness of .005” (.127mm) into minimum lengths of 1.25 inches (31.8 mm).

Standard Cutter

A rotary-type mechanism to automatically cut material with a maximum thickness of .010” (.254mm) into minimum lengths of 1.25 inches (31.8 mm).

Cutter Tray

An adjustable tray that will collect and hold up to 200 cut labels or tags.

External Keyboard Support

An interface for the connection of the Passport™ keyboard.

External Media Rewinder

Separate device with and 8” roll capacity to rewind labels and backing material.

Font Expansion Card (cannot be used with the I/O Expansion card)

A slide-in circuit card assembly with 8MB Flash memory expansion for International Language Printing Capability (ILPC) and/or additional fonts and graphics. ILPC consists of one of the following:

Ø CG-Times (Western European) Scalable font Ø Kanji Gothic B Scalable font Ø Simplified Chinese GB Scalable font Ø Korean Hangul Scalable font

Internal Media Rewinder

An internal hub with a six-inch outer diameter capacity to wind printed labels, or only backing material when a Peel and Present Mechanism is attached.

ILPC – CG Times Firmware

The printer’s firmware can be upgraded to include the ILPC CG Times font. This supports the Enhanced Language Code Pages.

I/O Expansion Card (specify features at time of order)

Standard features* of this slide-in circuit card assembly include:

Ø General purpose (GPIO) interface for external printer and device control. Ø Time and date calendar (Real Time Clock) function for label time stamping.

Optional feature: Ø 8 MB Flash memory expansion for graphics and/or additional fonts

including International Language Printing Capability (ILPC).

LAN Interface

A slide-in circuit card assembly that provides for network connectivity, allowing multiple users on various platforms to share the same printer.

*Item unavailable for the 2461 model

Peel and Present Mechanism (requires the Internal Rewind option)

An output control device that automatically separates printed labels from the backing material and allows subsequent printing to occur only after the removal of a previously printed label. Minimum label length for peeling is 1.5 inches (38 mm).

Present Sensor

An output control device that allows subsequent printing to occur only after the removal of a previously printed label.

RS-422 Serial Interface*

Single-drop interface hardware to support greater distances from the host at communication rates of up to 38,400 baud.

Thermal Transfer (specify configuration at time of order)

A printing method that uses ribbon to produce exceptional image clarity, as compared to most direct thermal media types. This option must be specified for use with either ‘coated side in’ ribbon or ‘coated side out’ ribbon.

Twinax/Coax Interface

A slide-in circuit card assembly that provides connectivity to AS/400 and System/3X Twinax host system or 3270-type host system. Cable included.

*Item unavailable for the 2461 model.

1.1 Option Installation

The following table lists the available options and the recommended qualification level of the installer. For detailed information concerning a specific option, contact your dealer or Technical Support.

Suggested Experience Level for Option Installation

Option Qualified Installer

Cutter Tray Operator

Cutters: Light and Standard Duty Operator

Passport External Keyboard Operator

Font Expansion Card Certified Technician

Internal Rewind Operator

I/O Expansion Card Certified Technician

LAN Interface Certified Technician

Peel and Present Mechanism Operator

Present Sensor Operator

RS-422 Serial Interface Certified Technician

Thermal Transfer Assembly Operator

Twinax/Coax Interface Certified Technician

1.2 Hardware Components

The following drawing highlights the user-assessable components of the printer. Items denoted with an asterisk (*) are optional equipment.

2.0 Unpacking the Printer

Inspect the shipping container(s) for damage; if evident, immediately notify the shipping company to report the nature and extent of the damage.

The printer has been carefully packaged to avoid damage during transit. In order to operate the printer, you will need to remove the tape and foam placed there for shipment. Complete the following steps prior to connecting power or attempting to load media.

Œ With the arrow on the box pointing up,

open the box.

• Remove Accessories Box.

Ž Tilt the printer on its side and slide the

printer out of its box.

• Place the printer in an upright position and remove the packing foam, plastic bag, and tape.

þ Note: It is a good idea to save the carton and packaging materials in the

event that future shipment is required.

2.0.1 Inspection

After removing the printer from the packaging material, check the contents of the package. In addition to this manual, the following items should be included:

Ø Printer Ø Power Cord Ø Accessories CD Ø Any special or additionally

purchased items.

2.0.2 Additional Requirements

The following items are necessary to produce labels. Contact your dealer or a customer support representative for advice on which media and software may best suit your needs.

Ø A serial or parallel interface cable; see Section 3.0.1 Ø Applicable media; see Section 2.1 for suggestions and Section 7.1 for

requirements.

Ø Applicable software

2.1 Media and Ribbon Selection

The following is a limited overview of media characteristics. For complete information and advice regarding your specific application needs, always consult a qualified media specialist or a Media Representative.

Media Selection – Direct Thermal Consider three important factors when selecting direct thermal stock:

• The abrasive qualities of the material that covers the thermal reactive layer of the paper.

• The ability of that layer to control the chemical reaction that occurs when the image is “burned”.

• The amount of heat required to create an image on the paper.

Media Selection – Thermal Transfer Consider three important factors when selecting thermal transfer media

combinations:

• The label top coating and ribbon combinations affect image quality.

• Ribbon backcoating is highly recommended. It provides protection for the

printhead, and may also provide an anti-static coating.

• For additional printhead protection, use ribbon with a slightly greater width than the overall width of the label and backing material.

2.1.1 Print Quality Controls

The printer provides flexibility with a comprehensive set of print controls. Of these, the amount of heat applied by the printhead and the rate of media movement will have the most effect on the barcodes, text, and graphics being printed. Low cost direct thermal stocks, for example, have raised reaction temperatures and therefore require higher heat values and slower print speeds to make a clear image on the media. In general, there are four methods of controlling print quality:

• The first is the ‘Media Type’ menu setting, which should be set to match the media being used. For example, when printing with ribbon use the thermal transfer setting.



• The second method would be to change the ‘Print Control / Heat’ menu

setting (selectable as ‘Heat Setting’ in most software programs). Increasing this value causes more energy to be transferred to the media, resulting in a darker image. If the image is too dark, reduce this value or increase the print speed.

• The next method would be to change the ‘Print Control / Print Speed’ menu setting (also selectable as ‘Print Speed’ in most software programs). Changing the print speed changes the amount of time the media is under the printhead. Slowing the speed allows more time and control for energy to be transferred. Increasing the speed will increase throughput, but may require a higher heat setting.

• The final method, providing only subtle contrast changes, would be to change the ‘Custom Adjustments / Darkness’ menu setting.

You will find that printing barcodes and detailed images on less expensive direct thermal and thermal transfer media at higher speeds can be tricky. At one heat setting, the images will fade and at the next higher heat setting, the images will bleed. This is because the reaction temperature of the media is so high that at higher rates of speed, it cannot react fast enough. To print fine images at higher speed, media with lower reaction or release temperatures are required. On the slower end of the print rate settings, crisper images are possible because the media is not being stretched beyond its limits.

The following table is intended for reference only (for specific application information, consult your media specialist or a Media Representative).

Direct Thermal Media Type Print Speed* Print Energy

Fasson 300 HD Direct Thermal Facesheet Fasson 300 MD Direct Thermal Facesheet

Thermal Transfer

Media Type

Ribbon

Type

Great Label TTL GPR Plus

10-12**

Speed*

Energy

10-12** Medium Medium

Medium

Image

Durability

MaxWax

IIMAK Versamark

Coated Paper,

Wax 2 - 10 Low Low

Uncoated Paper, Tag Stock, Some Films, Some Synthetics

Coated Paper, Glossy

Wax/Resin 2 - 8 Medium High

Paper, Tag Stock,

Some Synthetics, Films Synthetics, Films Resin 4 - 6 High High

*Values given in inches per second (IPS) **Highly recommended for optimum print quality at speeds above 10 IPS.

3.0 Installation

This section explains how to connect the printer, and load it with media and ribbon.

þ Note: When connecting the AC Power Cord or interface cables to the printer,

ensure the Power On/Off Switch is in the ‘Off’ position.

Œ Place the printer on a firm, level surface.

• Turn ‘Off’ the Host Computer and ensure that the Power Switch on the

Printer is in the ‘Off’ position.

Ž Depending upon your interfacing requirements, connect the appropriate

interface cable between Host Computer and Printer; see Section 3.0.1.

• Connect the AC Power Cord to the receptacle on the back of the Printer, and then plug the AC Power Cord into a properly grounded outlet. (The power supply in the printer automatically detects, then adjusts to the applied line voltage; see Section 7.0 for the acceptable voltage ranges.)

If connecting the printer to a network, refer to the additional documentation supplied with the network option.

3.0.1 Communications

Using a data detection process, the interface selection occurs automatically in the printer. At power-up, the printer begins monitoring the interface ports for activity. When the host transmits data, the printer port detecting this data is set ‘active’ and remains active as long as data flow continues. Once the incoming (received) data flow stops and the Host Timeout Value (see Section 4.1.6) is exceeded, the detection process will be repeated. In addition, should the data flow stop before a complete label format is received, the format will be ignored and must be sent to the printer again.

þ Note: To change an active port immediately, cycle the printer power ‘Off’

and ‘On’.

Parallel Port:

The parallel interface has two menu-selectable modes of operation: unidirectional or bi-directional. Uni-directional mode is forward channel

communication and requires a Centronics cable with a 36 pin male connector. Bi-directional mode is IEEE 1284 Compliant, using forward and reverse channel communications. In this mode, data can be sent to the host provided it is also IEEE 1284 Compliant and has supporting software. This mode requires an IEEE

1284 cable with a Centronics 36 pin male connector.

NIC Adapter (optional):

The NIC Adapter has several menu-selectable modes; see Section 4.1.6 for details. Refer to the information provided with the option for connection requirements. The following items are accessible from the back of the printer:

• The LED Indicators provide operational information: A green LINK LED indicates a good network connection. A green 100 LED indicates a 100BASE-T network connection. The ACT LED (activity) flashes green or red when the server is ready for use.

• The Test Button will cause a NIC Configuration label to print.

• The Ethernet Reset button will reset the NIC Adapter .

þ Note: Following initialization, the printer will indicate ‘Ready’; however, the

NIC Adapter will not be ready to receive data until its ‘boot-up’ process is completed. Depending upon the NIC Adapter configuration, this process may take up to two minutes to complete.

Serial Port:

The serial interface supports RS-232C and, if equipped, RS-422 communications. The following list of serial port settings is menu-selectable and must match the host computer’s serial port settings; see Section 4.1.6.

• Baud Rate (serial communication speed)

• Word Length

• Word Parity

• Number of Stop Bits

• Handshaking Protocol

In addition to the port settings, the serial interface cable wiring must have specific connections (pin-outs) for proper data exchange between the host and printer. The different serial cable pin-outs, suggested applications, and part

numbers are shown below (contact your reseller for ordering information).

Serial Interface Cable Listing (all models, except as noted)

Null Modem (MXM) “PC” (DB9P) to Printer

Part Number 556000 Part Number 556001

For connection to other DCE equipment. Flow control is only Xon/Xoff.

For connection to a PC compatible with DB9P communication ports. Flow control can be either Xon/Xoff or CTS/DTR.

“PC” (DB25P) to Printer RS-422 Connection

Part Number 556002 Part Number N/A

For connection to a PC compatible with DB25 communication ports. Flow control can be either Xon/Xoff or CTS/DTR.

Diagram provided only as a reference.

This optional interface is not available for

the 2461 model.

3.1 Loading Media

Begin loading as follows:

Œ Raise the Access Cover.

• Rotate the Printhead Latch forward and raise the Printhead Assembly.

Ž Slide the Media Guide out away from the frame and then lower it to the

down position.

• If using roll media, the Media Hub can accept 3.0-inch (76mm) and 1.5- inch (38mm) cores. To use 1.5-inch cores, first slide off the 3 Inch Hub by grasping and then pulling it firmly outward.

• Proceed according to the type of media you are using: either go to Section

3.1.1 for Roll Media or go to Section 3.1.2 for Fan-Fold Media.

3.1.1 Roll Media

This loading method is roll type media applications. To load:

Œ Slide the Roll Media

onto the Media Hub until it rests against the Backstop.

• Route the media as shown: under the Media Idler, through the Media Sensor, then out the front of the printer.

Ž Raise and slide the

Media Guide over until it rests lightly against the edge of the media.

• Position the Media Sensor; see Section 3.2.

• If your application uses thermal transfer media, load ribbon (see Section

3.3); otherwise continue.

‘ Lower the Printhead Assembly and rotate the Printhead Latch completely

back into the locked position. Close the Access Cover.

’ Turn ‘On’ the printer. After ‘Ready is displayed, press and hold the FEED

key until at least one label gap or mark is advanced; see Section 3.4.

If using less than full width media, adjust the Leveling Cam; see Section 5.1.1.

3.1.2 Fan-Fold Media

This loading method is for tag and fan-fold type media applications. To load:

Œ Bring the media in through the Bottom or the Rear Media Slot. (If using

reflective stock, ensure that the mark is facedown.)

• Depending upon the entry point, route the media as shown: if through the Rear Media Slot, route the media over the Media Hub; or, if through the Bottom Media Slot, route the media over the Media Rewind Hub.

Ž Continue routing the media under the Media Idler, through the Media

Sensor and out the front of the printer.

• Raise and slide the Media Guide over until it rests lightly against the edge of the media.

• Position the Media Sensor; see Section 3.2.

‘ If your application uses thermal transfer media, load ribbon (see Section

3.3); otherwise continue.

’ Lower the Printhead Assembly and rotate the Printhead Latch completely

back into the locked position. Close the Access Cover.

“ Turn ‘On’ the printer. After ‘Ready is displayed, press and hold the FEED

key until at least one label gap or mark is advanced; see Section 3.4.

If using less than full width media, adjust the Leveling Cam; see Section 5.1.1.

3.2 Media Sensor Adjustment

The Media Sensor needs to be positioned so that the printer can detect the presence of media and the top-of-form (except for continuous stock, where the TOF is set through programming; see Label Length, Section 4.1.2). To adjust:

Œ With media loaded, as described in Section 3.1.1 or 3.1.2, grasp the Slide

Tab and move the Sensor Eye Mark into position over media according to the table below.

• If loading media, return to the media loading instructions.

Media Sensor Selection and Adjustment

Media Type Sensor Eye Mark Position

Die-cut Near the middle of the label Gap

Notched Centered over the notch Gap

Reflective Centered over the black mark Reflective

Continuous Near the middle of the media Continuous

See Section 4.1.2 for Sensor Type selection.

Sensing Required

þ Note: Changes to the start of print position can be made using the Print

Control/Row Adjust or Row Offset (see Section 4.1.3).

3.3 Loading Ribbon

Ribbon is required with thermal transfer media. Depending upon the type of Ribbon Supply Hub (see the next page for examples), the printer must use either ribbons with the ‘coating side in’ or ribbons with the ‘coating side out’. To load:

þ Note: Using a ribbon that is slightly wider than your media (and liner, if any)

will help protect against printhead wear.

Œ With the access cover raised and the printhead assembly up, position the

ribbon to be dispensed in the direction appropriate for the Ribbon Supply Hub.

• Slide the ribbon onto the Ribbon Supply Hub until it rests against the hub’s flange.

Ž Route the ribbon under the Ribbon Idler, out the front of the printer and

then up around to the Ribbon Take-Up Hub, winding it several times in a clockwise direction to secure it in place.

• If loading media, return to the media loading instructions. Otherwise, lower the Printhead Assembly and rotate the Printhead Latch completely back into the locked position. Close the Access Cover.

Removal:

When the supply is exhausted, pull the empty core from the Ribbon Supply

Hub and discard it. To remove used ribbon: grasp the Ribbon Take-Up Hub, pull outward, then squeeze to collapse the hub and take off the ribbon.

þ Note: Directional Arrows near the Ribbon Supply Hub indicate the correct

ribbon route. Ribbon is available with the ink (coating) layer wound ‘in’ or ‘out’. These types are not interchangeable for use with the printer.

Ribbon Routing Diagrams

‘Coating Side In’ Ribbon Supply Hub

‘Coating Side Out’ Ribbon Supply Hub

3.4 Quick Media Calibration

At the factory, the printer is calibrated to sense a wide range of media types. Quick Media Calibration fine-tunes the media sensor for your gap, notch or reflective media application (this is not required for continuous media). Perform this calibration during initial set-up or after changing your media type. To calibrate:

Œ Ensure that media is loaded (see Section 3.1), that the Media Sensor is

• Press and hold the FEED key. The printer will begin advancing media;

Upon successful completion, the ‘Calibration Completed’ message will flash; the printer will feed to the next label TOF and ‘Ready’ will be displayed. (A ‘Warning Low Backing’ message may appear if using notched media or media on a transparent liner; however, the calibration was successful).

þ Note: Media containing large gaps may require a change in the ‘Paper Out

When ‘Uncalibrated’ is displayed, follow the Media Sensor Calibration procedure in Section 5.0.

adjusted (see Section 3.2), and that the printer is idle.

allow at least one label gap or mark to advance under the sensor during this process.

Distance’ setting; see Section 4.1.2.

Calibration Hints:

In certain cases, the printer may have trouble differentiating between the label and liner. If the printer stops feeding in the middle of a label or if ‘Cannot Calibrate’ is displayed, try calibrating over a longer distance:

• Press and hold the FEED key to allow two gaps or marks to advance under the sensor.

If the printer continues to stop in the middle of a label, or if ‘Cannot Calibrate’ is displayed again:

• Press and hold the FEED key to allow three or more gaps or marks to advance under the sensor.

If this method also fails, see Media Sensor Calibration, Section 5.0.

3.5 Outputting Labels

In addition to directly outputting labels from the printer, there are several optional output configurations available.

3.5.1 Rewinding

With the Internal Media Rewinder option, the printer can wind the printed labels and backing material. To rewind labels:

þ Note: When winding labels, do not allow the outer diameter of the roll to

exceed 6 inches (154 mm) on the Media Rewind Hub.

Œ Remove the Front Fascia.

• Remove the Tear Plate by

first removing the Thumbscrew.

Ž Position the Rewind Plate

on the printer and install and tighten the Thumbscrew.

• If installed, remove the Rewind Retainer and Media Clip from the Media Rewind Hub (see drawing next page).

• Load media as described in Section 3.1, press the FEED key and advance approximately 20 inches (51 cm) of media.

‘ Route the media back to the Media Rewind Hub, as shown below.

’ Insert the leading edge into a Slot on the Media Rewind Hub then insert the

Media Clip into a Slot to secure it in place.

“ Position the Rewind Retainer lightly against the edge of the media on the

Media Rewind Hub. Tighten the Thumbscrew to secure the retainer in place.

” Manually rotate the Media Rewind Hub to remove any slack in the media.

Close the Access Cover.

Removal: Remove the Rewind Retainer and Media Clip. Grasp the end of the hub. While

pulling outwardly, squeeze the hub together to collapse it and then slide off the labels.

3.5.2 On-Demand Dispensing

When equipped with the Peel and Present option, labels are dispensed from the printer one at a time, separated automatically from the liner for immediate application.

Œ With the Peel and Present

Mechanism installed on the printer, pull outward on the Latch and allow the Roller Bracket to swing forward.

• With media loaded as described in Section 3.1, press the FEED key to advance approximately 20 inches (51 cm) of media. Remove all of the labels from the backing material.

Ž Route the backing material through the Roller Bracket as shown (the

backing should go under the top black roller, then out).

• Raise the Roller Bracket up to its latched position.

• If installed, remove the Media Clip and the Rewind Retainer from the Media Rewind Hub. Route the Backing Material around the Media Rewind Hub, as shown.

‘ Insert the leading edge into a Slot on the Media Rewind Hub then insert the

Media Clip into a Slot to secure it in place.

’ Position the Rewind Retainer lightly against the edge of the backing on the

Media Rewind Hub. Tighten the Thumbscrew to secure the retainer in place.

“ Manually rotate the Media Rewind Hub to remove any slack in the media.

Close the Access Cover.

For on-demand printing, ensure that the Present Sensor has been enabled; see Section 4.1.4.

Removal:

Remove the Rewind Retainer and Media Clip. Grasp the hub. Pull the hub

outward then squeeze to collapse it and slide off the backing material.

3.5.3 Cutting

When equipped with one of the cutter options, cut labels are dispensed from the printer.

Œ Ensure the leading edge of media is clean, straight and firmly attached to the

liner.

• Load media according to Section 3.1, except route the media out through the Opening of the Cutter Assembly.

Ensure the Cutter has been enabled; see Section 4.1.4.

Pressing again will return the printer to normal

4.0 Operation

The front panel is comprised of three indicator lights, a Liquid Crystal Display and five mode-dependant keys. The selectable modes (Ready, Menu and Quick Test) and the related functions of the printer keys are detailed below.

4.0.1 Ready Mode: Normal Operation (Ready Light ‘On’)

Œ The PAUSE key temporarily suspends printing.

operation.

• The FEED key advances one label, and clears any

corrected faults. Pressing and holding cause the printer to perform

a Quick Media Calibration ; see Section 3.4.

Ž The CANCEL key ‘pauses’ the printer and then

prompts you for confirmation. If yes, the current job is cancelled. The printer remains paused.

Pressing and holding four seconds will reset the printer and clear temporary host settings (soft reset).

• The MENU key toggles between the Ready and

Menu Modes. In the Ready Mode, pressing and holding four seconds will change the display contrast.

• The TEST key enters (or exits) the Quick Test

Menu.

4.0.2 Menu Mode: Configuration (Ready Light ‘Flashing’)

Œ The DOWN ARROW key scrolls to the previous

menu item on the same menu level. It also decrements numerical values in most menu selections.

• The UP ARROW key scrolls to the next menu

item. It also increments numerical values in most menu selections.

Ž The ENTER key selects the function, item or

displayed value. It also moves between selections within multiple parameter fields.

• The ESCAPE key moves to the previous menu

level, and finally back to the Ready Mode.

4.0.3 Quick Test Mode: Print Test Labels

þ Note: The Quick Test Mode functions are disabled while processing data

from communications interfaces until the Host Timeout value expires.

Œ The DOWN ARROW key scrolls to the previous

test function.

•

The UP ARROW key scrolls to the next test

function.

The ENTER key will change the selected test label

quantity of 2, 100, 1000, or 9999 (except the ‘Configuration Label’, quantity of one). Holding down the key scrolls quantities.

•

The ESCAPE key will exit the Quick Test Mode

without printing.

•

The TEST key will print the selected test label at the selected quantity. During test label printing, this key also functions as a cancel key (the printer will prompt you for confirmation before cancellation occurs).

You can program a time delay between the printing of test labels using the ‘Print Test Rate’ feature; see Section 4.1.7.

The display provides several types of information:

•

4.0.4 Indicator Lights

4.0.5 LCD

Œ ‘On’ indicates that the printer is powered ‘On’

and, after initialization, it indicates the Ready Mode.

‘Slow Flashing’ indicates the Menu Mode. ‘Fast Flashing’ indicates data is being received

and processed.

• ‘On’ indicates a ‘Paused’ condition.

Ž ‘Slow Flashing’ indicates a Warning.

‘Fast Flashing’ indicates a Fault. (For a list of these messages, see Section 6.1.)

Œ Liquid Crystal Display

Following a brief power-up sequence

(initialization), the ‘Ready’ message.

The time and date, if the printer has received it

from one of the following: the host, the front panel setting, or the Time and Date option.

• A label counter during a batch print job.

• The Menu System when in the Menu Mode.

Any prompt, condition, downloading, warning,

or fault message.

4.0.6 Resetting the Printer

Depending upon the method used, there are three reset levels possible:

4.0.6.1 Soft Reset

To reset the printer and clear any temporary host settings:

With the printer ‘On’, press and hold the CANCEL key for approximately four seconds.

4.0.6.2 Level One Reset

To return the printer to the factory default settings or, if saved, to restore the Factory Setting File:

Œ Turn ‘Off’ the printer.

• Press and hold the PAUSE and CANCEL keys while turning ‘On’ the

printer; continue to depress the keys until the ‘SYSTEM RESET’ message flashes.

þ Note: This reset has the same effect as the System Settings/Set

Factory Defaults selection in the menu system. (See Section 4.1 for a listing of the factory default settings and Section 4.1.5 for information about the Factory Setting File.)

4.0.6.3 Level Two Reset

To return the printer to the factory default settings, and clear all the calibration and adjustment parameters:

Œ Turn ‘Off’ the printer.

• Press and hold the PAUSE, FEED, and CANCEL keys while turning ‘On’

the printer; continue to depress the keys until the ‘SYSTEM RESET’ message flashes.

þ Note: After executing a Level 2 Reset, the media calibration must be

performed; see Section 5.0. A listing of the factory default settings can be found in Section 4.1.

4.1 The Menu System

Printer operation can be controlled through the user interface, allowing the operator access to these six menu system branches:

• Media Settings

• Print Control

• Printer Options

• System Settings

• Communications

• Diagnostics

While in the menu system, the current selection will be indicated with the ‘*’ symbol next to the displayed item on the LCD, and selections designated with the ‘§’ symbol will require a printer reset before becoming effective. Changes made can be saved so that, in the event that power is lost or removed, the new settings will be retained. A reset will be automatically invoked when exiting the menu system and answering ‘Yes’ to the ‘Save Changes’ prompt.

The same functional commands from the host computer may, in some cases, override the printer’s menu settings. In addition, as a security feature for the prevention of accidental or unauthorized changes, the menu system has a password protection feature.

þ Note: In the following subsections, the factory default settings are denoted

with the ‘²’ symbol. Selections denoted with the ‘♦’ symbol can only

be changed through the menu system - all other selections can be overridden by host software commands. Consult the Programmer’s Manual for specific information.

4.1.1 Entrance and Exit Prompts

With ‘Ready’ displayed on the LCD, press the key to enter the Menu Mode.

þ Note: While in the Menu Mode, the printer will stop processing new DPL

(or bitmapped) data.

MENU MODE Depending upon the configuration of the

printer, the following Entrance and Exit Prompts may be displayed when accessing or leaving the Menu System.

ENTER PASSWORD 0 0 0 0

KEEP HOST CHANGES? ENTER = YES

SAVE CHANGES? ENTER = YES

You are attempting to enter the Menu Mode. Security has been enabled and now the correct user-definable password is required for access the Menu Mode functions. You are now entering the Menu Mode. Existing Host commands have affected the configuration of the printer. Pressing ENTER will save these changes; otherwise, the printer will revert to previously saved settings. You are now exiting the Menu Mode, but have made changes to the printer’s settings. Pressing ENTER will reconfigure your printer according to these changes; otherwise, the printer will revert to previously saved settings.

þ Note: If changes have been made that

require a reset, the printer will automatically invoke that reset.

4.1.2 Media Settings

MEDIA TYPE Selects the printing method.

DIRECT THERMAL

²THERMAL TRANSFER

For use with heat sensitive media. For use with media requiring a ribbon to

create an image.

SENSOR TYPE Selects the top-of-form (TOF) sensing

method for the media.

²GAP

The printer recognizes the TOF by sensing gaps in the media.

CONTINUOUS

No TOF sensing. The LABEL LENGTH setting determines the length.

REFLECTIVE

The printer recognizes the TOF by sensing reflective (black) marks on the media.

LABEL LENGTH

²04.00in (0-99.99)

MAXIMUM LABEL LENGTH

²16.00in (0-99.99)

When the Sensor Type is set to Continuous, this value is used to determine the TOF.

Sets the maximum length between TOF marks (gap or reflective). If this limit is exceeded, a top of form fault is declared.

PAPER OUT DISTANCE

²00.25in (0-99.99)

Sets the length of travel before an Out of Stock condition is declared.

LABEL WIDTH Sets the maximum limit for the printable

surface width. Objects extending beyond this limit will not print; see Appendix C for the default values.

SENSOR CALIBRATION ♦

Adjusts the printer to sense your media.

PERFORM CALIBRATION

ADVANCED ENTRY

SENSOR LEVELS

SENSOR GAIN

The user follows steps to allow the printer to calculate the empty, gap (or mark), and paper values to set the media sensor. The user directly inputs the best values to adjust the media sensor.

Sets threshold values for the media sensor parameters. Manual entry for paper, gap (or mark), and empty thresholds. Observe A/D reading and set SENSOR GAIN. Adjusts the sensitivity of the sensor for custom label stock.

4.1.3 Print Control

Refer to Section 2.1.1 for detailed information on print quality controls.

HEAT

²10 (0-30)

PRINT SPEED Controls the rate of label movement during

FEED SPEED Controls the rate of label movement between

REVERSE SPEED Controls the rate of label movement during

ROW OFFSET

²00.00in (0-99.99)

COLUMN OFFSET

²00.00 in (0-99.99)

PRESENT DISTANCE

²0.00 in (0-4.00)

Controls the ‘burn-time’ of the printhead. This is the equivalent of Heat Setting on most label software programs.

the printing process; see Appendix C.

printing areas; see Appendix C.

backup positioning for start of print, cutting or present distance; see Appendix C.

Shifts the vertical start of print position. This is the user setting for row adjustment.

Shifts the horizontal, left-justified start of print position to the right without shifting the Label Width termination point to the right. This is the user setting for Column Adjust.

Sets the label stop position past the start of print. When the next label format is received, the printer will automatically backfeed to the start position. If a quantity of more than one label is printed without a present sensor enabled, or if the present distance is set to zero, the printer will operate without reversing.

Print Control (continued)

CUSTOM ADJUSTMENTS ♦

DARKNESS XX (1-64)

ROW ADJUST XXX DOTS (0-128)

COLUMN ADJUST XXX DOTS (0-128)

PRESENT ADJUST XXX DOTS (0-128)

These factory adjustments independently change the listed parameters to finely tune the printer and compensate for slight mechanical differences sometimes evident when multiple printers share label formats. In addition, each of the following adjustments has no factory default setting and restoring factory defaults will NOT affect these settings.

Controls the printhead strobe time to finetune the HEAT setting. Shifts the vertical start of print position upward in dots to fine-tune the ROW OFFSET setting; see Appendix C. Shifts both the horizontal start of print position and the LABEL WIDTH termination point to the right in dots to fine-tune the COLUMN OFFSET setting; see Appendix C. Adjusts the label stopping position in dots to fine-tune the PRESENT DISTANCE setting; see Appendix C.

4.1.4 Printer Options

MODULES Memory available for user storage of

graphics, fonts and label formats. (The physical presence of the respective memory module must be detected to show the function selections for that module in the menu system.) See Appendix C for a listing of all possible modules.

PRINT DIRECTORY

PRINT FILE

FORMAT MODULE

DELETE FILE

PACK MODULE

PRESENT SENSOR Used for on-demand label dispensing, where

ENABLED

Prints a label directory of selected, or of all available modules, the available space on these modules, the files present, and the type of module and files. The user may select from a list of available files for sample printing. The user may select from a list of available modules for formatting – all data will be erased. The user may select from a list of available files for deleting (protected modules will not appear). Bytes will NOT be retrieved until the module that contained the deleted file is packed. Packing the module removes files marked as deleted and defragments existing file structures to recover space.

a printed label blocking the sensor will inhibit further printing until removed. (The physical presence of the Present Sensor must be detected to show the ENABLE/DISABLE selections.)

Enables the sensor for on-demand printing.

²DISABLED

NOT INSTALLED

Disables the sensor. No sensor is detected.

Printer Options (continued)

CUTTER Used to cut media into separate labels. (The

physical presence of a cutter must be detected to show the ENABLE/DISABLE selections.)

ENABLED

Enables label cutting.

²DISABLED

NOT INSTALLED

Disables the cutter. No cutter is detected.

GPIO PORT Model dependant option used to interface the

printer to an external controlling device (see Appendix D).

GPIO

Input control signal is required to print a label.

ENABLED

²DISABLED

END OF PRINT

ACTIVE LOW

ACTIVE HIGH

LOW PULSE

HIGH PULSE

Enables external signal control. Disables the GPIO.

Programmable signal output.

4.1.5 System Settings

CONFIGURATION FILE Options for storage and recall of printer

configuration files. See Appendix F for details.

RESTORE AS CURRENT

SAVE SETTING AS

DELETE FILE

FACTORY SETTING FILE

INTERNAL MODULE

²1024 KB

DEFAULT MODULE

²D

SCALEABLE FONT CACHE

²312 KB

SINGLE BYTE SYMBOLS Selects the code page used to print single

²PC_850 MULTILINGUAL

Provides a list of available configuration files. Selecting a file from the list causes a printer reset; afterward, the printer is configured according to the activated file. Saves the entire effective configuration of the printer to a file. Unique names with up to nineteen characters are possible. Provides a list of available configuration files. Files selected are immediately removed, freeing the module.

þ Note: A currently activated file cannot

be deleted.

Provides a list of available configuration files. The selected file will be restored whenever a Level 1 reset is performed; see Section 4.0.6.2.

Sets the number of 1K blocks allocated for the internal RAM ‘D’ module. Available memory dependent upon model; see Appendix C.

Sets the default module used to store files when no other module is specified; see Appendix C.

Sets the number of 1K blocks allocated for the scaleable font engine. Available memory dependent upon model; see Appendix C.

byte fonts unless otherwise specified in DPL.

61 selectable sets are standard; see the Programmer’s Manual for details.

System Settings (continued)

DOUBLE BYTE SYMBOLS When equipped with the ILPC option, this

selects the code page used to print double byte fonts unless otherwise specified in DPL; see the Programmer’s Manual for details.

JIS

Japanese Industry Standard

SHIFT JIS

EUC

²UNICODE

Shift Japanese Industry Standard Extended UNIX Code Unicode (including Korean) Government Bureau Industry Standard;

Chinese (PRC)

BIG 5

Taiwan encoded

TIME AND DATE Allows the user to set Time and Date.

MEDIA COUNTERS Internal record of inches printed and time of

use.

ABSOLUTE COUNTER

Shows the number of inches printed since being set at the factory. Not resettable by the user.

RESETTABLE COUNTER

The number of inches printed since the last reset. User may reset.

RESET COUNTER

Resets the resettable counters to zero.

PRINT CONFIGURATION Prints the effective configuration of the

system. In addition, if settings were changed that require a reset to become effective, this will be indicated with the ‘§’ symbol.

A ‘•’ symbol next to the printed item indicates that it was changed via the host but not saved in non-volatile memory.

vvvv–represents the model number of

wwxx

ww –

represents the hardware

software feature levels up to

yyyyyy

zzz

System Settings (continued)

CONFIGURATION LEVEL To upgrade the application program

(resident software) version of the printer, the hardware and software compatibility levels must match for the update to be accepted. This information is displayed here; it is also printed on a configuration label.

PRINTER KEY

Each printer has a unique KEY number in the following form:

vvvv-wwxx-yyyyyy-zzz

Where:

the application loaded

– represents the hardware /

software feature level, where:

feature level of the main board:

PA = PCB 51-2178-xx TB = PCB 51-2301-xx

xx – represents the software

feature level:

10 = Standard DPL 11 = 2461 20 = Internal CG Times

Font

The printer will accept

UPGRADE PRINTER CODE

the ‘xx’ value. (This feature level requires authorization

to upgrade.) – is a manufacturing date code – is a unique time stamp

This function is used to upgrade the software feature level of the printer, authorization is required.

System Settings (continued)

SET FACTORY DEFAULTS Parameters in this menu listing with the ‘²’

symbol are the designated defaults.

SET FACTORY DEFAULTS

Overwrite the current settings with the factory default settings or, if selected, will restore the Factory Setting File.

þ Note: The reset will be automatic. If no

Factory Setting File is used, all menu settings will be restored except CUSTOM ADJUSTMENTS, and the media and ribbon sensor calibrations.

FORMAT ATTRIBUTES Affects the manner in which overlapping text

and graphics are treated as the label is printed. Consult the Programmer’s Manual for details.

TRANSPARENT

Intersecting text strings, images, and bar codes will not be printed. (An odd number of overlapping objects will print.)

²XOR

Intersecting text strings, images, and bar codes print on top of one another.

OPAQUE

Interacting text strings, images, and bar codes are obliterated by those formatted last. Each character cell is treated as opaque.

IMAGING MODE ♦

Instructs the printer whether to pre-image the label format.

þ Note: This selection can affect the accuracy of time-stamped labels and label throughput.

²MULTIPLE LABEL

The printer images multiple labels as memory permits, achieving the fastest throughput; however, if time-stamping, the time will reflect the moment the label is imaged rather than when actually printed.

SINGLE LABEL

The printer images the next label only after the previous label has been successfully printed. Single processing provides timestamps that are more accurate, but it slows label throughput time.

System Settings (continued)

PAUSE MODE When enabled, Pause Mode suspends

printing between each label until the PAUSE key is pressed.

ENABLED

Printer requires operator to press the PAUSE key after each label.

²DISABLED

Printer completes label batch without pausing between labels.

SECURITY ♦

Provides the user with the ability to password protect all printer settings made through the operator panel.

SELECT SECURITY

Enable or disable the menu system’s security feature.

ENABLED

Password protected.

²DISABLED

MODIFY PASSWORD

No protection. Modify the password required to access the

menu system when security is enabled.

UNITS OF MEASURE Selects the measurement system in which

the system’s settings are represented in the menu system and on configuration labels.

METRIC

Metric standard: Lengths in millimeters and Counters in centimeters.

²IMPERIAL

Inch standard: Lengths and Counters given in inches.

•

System Settings (continued)

þ Note: As indicated, the following menu selections will only appear

according to the model of your printer.

PLUS EMULATION This instructs the firmware to process

specific DPL data as would the Prodigy Plus® printer without all of the variations.

ENABLED

This list of exceptions will be updated with new firmware releases:

Data Terminator – I 2 of 5 Barcodes

(IDs D, J, and L), the first nonnumeric character processed will terminate the barcode data field.

Bar Size – I 2 of 5 Barcode (ID L),

when the bar size is specified greater than P (25), the size is automatically decreased to 10.

Human Readable Fonts – The EAN

and UPC barcodes (IDs B, C, F, G, M, and N) print a fixed font size.

The column position, bar code

height, line width, and column offset commands are interpreted as 200 DPI calculations.

²DISABLED

The above exceptions are disabled.

2461 Model

ALLEGRO EMULATION This instructs the firmware to process

specific DPL data as would the Allegro® printer without all of the variations.

ENABLED

The row position is calculated based on 194 DPI.

²DISABLED

The above exception is disabled.

System Settings (continued)

þ Note: As indicted, the following menu selections will only appear according

to the model of your printer.

DPI EMULATION For users who want to print DPL files

intended for a 203 or 300 DPI printer.

²DISABLED

Label formats interpreted as intended for 600 DPI.

300 DOTS PER INCH

Label formats interpreted as intended for 300 DPI.

203 DOTS PER INCH

Label formats interpreted as intended for 203 DPI.

6441 Model

System Settings (continued)

SOP EMULATION Enables the <STX>O and <STX>f print

positioning commands to allow backward compatibility with label formats designed for other printers. (When changing these values, the printer will automatically feed two labels to setup the new print position.)

110 (PRODPLUS)

Emulates the Prodigy Plus® printer.

220 (ALLEGRO)

250 (PRODIGY)

²DISABLED

Emulates the Allegro® printer. Emulates the Prodigy™ printer.

No emulation, natural start of print position.

BACK AFTER PRINT When the present distance is set with the

cutter, present sensor or GPIO option enabled, this setting determines the timing of the label back up.

ENABLED

Commands the printer to immediately back up the label after the cut operation, the GPIO start of print signal is received, or the present sensor is clear. It provides the advantage of faster throughput.

²DISABLED

The printer will not initiate repositioning until the next label is ready to print. May help prevent the curling of the label edge.

MENU LANGUAGE ♦

Selects the language in which the menu system messages and configuration label are shown. Only languages that are resident will be available.

²ENGLISH

FRENCH

English French

ITALIAN

GERMAN

SPANISH

USER DEFINED

Italian German Spanish User defined, downloaded language(s).

4.1.6 Communications

SERIAL PORT A♦

BAUD RATE

38400 28800 19200 ²9600 4800 2400 1200

PROTOCOL

²BOTH SOFTWARE HARDWARE NONE

PARITY

²NONE ODD EVEN

DATA BITS

7 ²8

STOP BITS

Controls the communications settings for Serial Port A.

Determines the serial communication rate. 38400 bits per second

28800 bits per second 19200 bits per second 9600 bits per second 4800 bits per second 2400 bits per second 1200 bits per second Sets the data flow control (handshaking) method. Uses both handshaking methods. XON/XOFF CTS/DTR No flow control is used. Sets Word parity

No parity Odd parity Even parity Sets Word length

Seven bit Word length Eight bit Word length Sets the number of stop bits

²1 2

SERIAL PORT B♦

PARALLEL PORT A♦

PORT DIRECTION

²UNI-DIRECTIONAL

BI-DIRECTIONAL

One stop bit Two stop bits

Same as Serial Port A, for an optional connection. If not present, this displays ‘NOT INSTALLED’ when accessed.

Controls the communications settings for Parallel Port A.

Determines if messages are sent from the printer to the host via the parallel port.

One-way printer communication. Enables IEEE 1284 back-channel operation.

Communications (continued)

PARALLEL PORT B♦

Same as Parallel Port A, for an optional Ethernet connection. If not present, this displays ‘NOT INSTALLED’ when accessed.

þ Note: If the ‘LOCKED’ message appears when attempting to access the NIC

ADAPTER menu, the printer may have active print requests or multiple users may be trying to access these parameters (for example, during simultaneous telenet sessions).

NIC ADAPTER♦

Network Interface Card Adapter (optional). If not present, this displays ‘NOT INSTALLED’ when accessed.

NIC Adapter firmware version V3.6/5(010212) DM or later is required to support the described functionality.

After making changes to these parameters, save the changes, exit the menu system, and cycle the printer’s power ‘Off’ and ‘On’ for the changes to take effect.

þ Note: With the NIC Adapter installed, a boot process (taking up to two minutes, depending upon the configuration) must be completed before the printer recognizes the option as ‘installed’. During this time, the NIC Adapter will not be accessible or configurable; "NOT INSTALLED" will be indicated when in the menu system or on a Configuration Label. After the process, you will be able to configure the options provided using the menu system.

IP ADDRESS

The static IP address of the NIC Adapter. This is in standard dotted-decimal format.

SUBNET MASK

The static subnet assigned to the NIC Adapter.

DEFALUT GATEWAY

The network gateway address the NIC Adapter should use.

Communications (continued)

PROTOCOL

IP LAT

²ENABLED

DISABLED

MOP

²ENABLED

DISABLED

APPLETALK

²ENABLED

DISABLED

NETWARE

²ENABLED

DISABLED

LAN MANAGER

²ENABLED

The network protocols recognized by the NIC Adapter.

This protocol is always supported. Local Area Transport is a DEC VMS

network protocol that requires a LAT license number. Protocol is enabled by default.

Ignore LAT protocol. Select this option if LAT is not needed.

Enables the DEC MOP protocol. Ignore the MOP protocol. Select this option

if MOP is not needed.

The AppleTalk protocol is enabled by default. Ignore the AppleTalk protocol. Select this option if AppleTalk is not needed.

Allow the printer to be driven from an NDS Novell Print Queue.

Netware is enabled by default. Ignore the Netware protocol. Select this

option if Netware is not needed.

Enable DLC/LAN Manager protocol.

DISABLED

Ignore LAN Manager protocol.

Communications (continued)

DISCOVERY

DHCP

²ENABLED

DISABLED

BOOTP

²ENABLED

DISABLED

This is the address discovery method used by the NIC Adapter if a static address is not utilized. If no server for any of the discovery methods is found, the static value specified above is used.

þ Note: For faster NIC Adapter boot times, disable any discovery methods not used.

Dynamic Host Control Protocol. Automatically assign IP address from a DHCP Server.

DHCP is enabled by default.

WARNING! An IP Address assigned by a DHCP has precedence over any static IP Address stored in the NIC Adapter.

Disable DHCP.

þ Note: Select this option to insure any

static IP stored is used by the NIC Adapter. A UNIX based automatic IP address

assignment controlled by a BOOTP server. BOOTP is enabled by default.

Disable BOOTP.

RARP

²ENABLED

DISABLED

Reverse Address Resolution Protocol. RARP is enabled by default.

Disable RARP. This should be selected if RARP is not needed.

Communications (continued)

HOST SETTINGS Settings which affect all communications

with a host.

HOST TIMEOUT ²10 SEC (1-60)

The number of seconds a communications port must be idle before the printer may process data from a different port. This value is also used to “timeout” an image / label format download.

CONTROL CODES ♦ Allows the operator to change the prefix of

the software commands interpreted by the printer.

²STANDARD CODES

Hex 01 = SOH command; Hex 02 = STX command; count-by = ^; Hex 1B = ESC; Hex 0x0D = Carriage Return

ALTERNATE CODES

Hex 5E = SOH command; Hex 7E = STX command; count-by = @; Hex 1B = ESC; Hex 0x0D = Carriage Return

ALTERNATE CODES 2

Hex 5E = SOH command; Hex 7E = STX command; count-by = @; Hex 1B = ESC; Hex 0x7C = Carriage Return

ALTERNATE CODES 3

Hex 5E = SOH command; Hex 23 = STX command; count-by = @; Hex 1B = ESC; Hex 0x0D = Carriage Return

FEEDBACK CHARACTERS

Returns a Hex 1E, [RS], after each label successfully prints, and a Hex 1F, [US], after each batch of labels is printed.

ENABLED

Feedback characters are sent to the host.

²DISABLED

ESC SEQUENCES

²ENABLED

DISABLED

No feedback characters are sent.

Allows data containing invalid ESC control code sequences to be processed.

Normal printer operating mode. ESC sequences are ignored and the data is

processed. Bitmapped font downloads are disabled in this mode.

Communications (continued)

HEAT COMMAND

²ENABLED

DISABLED

SPEED COMMANDS

²ENABLED

DISABLED

Allows the user to disable the DPL Heat Command, providing compatibility with other printers.

Normal printer operating mode. DPL Heat Commands are ignored. The heat

value is controlled via the menu setting; see Print Control, Section 4.1.3.

Allows the user to disable the DPL speed commands (Print, Feed, and Reverse).

Normal printer operating mode. DPL speed commands are ignored. The

print, feed and reverse speeds are controlled via the menu setting; see Print Control, Section 4.1.3.

4.1.7 Diagnostics

HEX DUMP MODE Most commonly used for troubleshooting.

Prints data and instructions received from the host rather than interpreting them as label formats; see Section 6.2.

ENABLE

Prints raw ASCII data received from the host rather than executing the commands.

²DISABLE

Executes and prints label formats (normal operating mode).

OPTIONS TESTING Tests currently installed options

TEST PRESENT SENSOR

Performs a functional test of the Present Sensor circuitry.

TEST CUTTER

Performs a functional test of the optional cutter mechanism and circuitry.

PERFORM TEST 1 TIME

The cutter will cycle 1, 10 or 100 times (selectable). The results of each attempt will be displayed.

MONITOR GPIO INPUT

TEST GPIO OUTPUTS

PRINT TEST RATE (MIN) ²0 (0-120)

The number of minutes to delay between the printing of batches of labels in Quick Test Mode.

SENSOR READINGS Analog Sensor readings are displayed.

THR TRAN RIBM 24V à 255 255 255 255

Live sensor values are displayed. View can be toggled with forward and reverse keys. Maximum values are shown in this example: thermistor sensor, transmissive (gap) media sensor (TRAN is replaced with REFL when the SENSOR TYPE is set to ‘reflective’), ribbon sensor, 24 volt power supply sensor.

ß PS HD RANK 255 255 255

Present sensor, head down sensor, printhead ranking resistor.

RIBBON SENSOR LIMITS Displays ribbon sensor ADC low and high

values used for motion detection.

RIBBON ADC LOW HIGH

070 164

Approximate default values are shown here (actual values will vary).

4.2 Display Messages

The printer displays several different types of information (if not in the menu system or Quick Test Mode):

Ø User Prompts and Condition Messages (also see Section 4.1.1 for a listing

of the Enter/Exit Prompts)

Ø Application and Boot Loader Updating Messages (see Section 5.4 and 5.5) Ø Fault and Warning Messages (see Section 6.1)

4.2.1 User Prompts and Condition Messages

User Prompts alert the operator to a required action. Condition Messages are used to indicate an operational state.

User Prompts and Condition Messages

Displayed Message Description Condition(s)

The printer is trying to clear a fault condition.

A media calibration is being performed.

The CANCEL or TEST key was pressed during a batch job.

The printer is paused or offline.

A label is awaiting removal.

Occurs when the FEED key is pressed after the correction of a fault.

The FEED key was pressed and held.

The current print batch will be cancelled if ENTER is pressed; the remaining labels will not be printed.

The printer is in a paused

condition.

The Present Sensor option is enabled and a label blocks the sensor. Remove the label to continue printing.

User Prompts and Condition Messages (continued)

Displayed Message Description Condition(s)

Normal power-up and soft reset condition.

The media calibration is not set.

The print job is being processed.

Follows the ‘SYSTEM

RESET IN PROGRESS’

message after a reset or

power-up.

Occurs when the user

resets the printer via the

host or Front Panel.

Perform calibration; see

Section 5.0.

Batch status indication,

updated with each label

printed.

4.3 Quick Test Mode

This section explains the functions of the resident Quick Tests, accessible by pressing the key on the Front Panel.

þ Notes: (1) With the exception of the Configuration Label, all Quick Test

labels require 4-inch (102mm) wide media to print the entire format. If using narrower media, change the Label Width setting (Section

4.1.2) to match your media’s width to avoid printing on the platen.

(2) During any Quick Test, press the key or the key to stop printing.

(3) Using the ‘Print Test Rate’ feature (Section 4.1.7), a time delay can be set for printing labels in Quick Test Mode.

4.3.1 Print Quality Label

The Print Quality Label provides an indication of overall print quality at a preselected heat and speed setting. This format consists of compliant bar codes in fence and ladder orientations, assorted font sizes, and graphic fill patterns. These can be used to ensure conformance, as well as aesthetics. To print a Print Quality Label:

Œ Press the key.

• Use the key to

scroll to ‘Print Quality Label’.

Ž Use the key to

select a quantity; see Section

4.0.3.

• Press the key to

start printing.

4.3.2 Configuration Label

The Configuration Label provides valuable printer database information, as detailed in Section 4.1.

þ Note: The Configuration Label content can vary with the application version

and printer model. To print all information, the media cannot be less than 2 inches wide (51mm) and the Label Width setting must match the

To print a Configuration Label:

Œ Press the key.

• Use the key to scroll

Ž Press the key to

width of the media being used (see Section 4.1.2).

to ‘Print Configuration’.

start printing.

4.3.3 Quick Ribbon Test Label

The Quick Ribbon Test Label features a compliant picket-fence bar code that can be used to verify thermal transfer and print quality functions. To print a Quick Ribbon Test Label:

Œ Press the key.

• Use the key to scroll to ‘Ribbon Test Label’. Ž Use the key to select a quantity; see Section 4.0.3.

• Press the key to start printing.

indicates correct printhead

faulty printhead. See

Section 5.3.1 for cleaning

4.3.4 Dot Test Pattern Label

The Dot Test Pattern Label features patterns that exercise all of the thermal elements (dots) of the printhead. The resulting label (see examples below) can be an indication of the printhead’s condition. To print a Dot Test Pattern Label:

Œ Press the key.

• Use the key to scroll to ‘Dot Test Pattern’.

Ž Use the key to select a quantity; see Section 4.0.3.

• Press the key to start printing.

Good Test Pattern Label:

Even pattern consistency

is operation.

Faulty Test Pattern Label:

Streaks indicate a dirty or

instructions.

4.3.5 Validation Label

The Validation Label is another useful tool for evaluating overall print quality. To generate a Validation Label:

Œ Press the key.

• Use the key to scroll to ‘Validation Label’.

Ž Use the key to select a quantity; see Section 4.0.3.

• Press the key to start printing.

4.3.6 User Defined Label

The User Defined Label will reprint the last label printed (unless the printer was powered-off between the printing of the last label and the request to print a user defined label). This label is recalled from the print buffer and can be any of the Quick Test labels, a label format from the host, or a label format recalled from a memory module.

5.0 Media Sensor Calibration

In addition to the Sensor Type selection, Media Sensor calibration ensures that each label is detected correctly and reliably. Perform calibration when the ‘Uncalibrated’ message is displayed. Two different methods are available to calibrate the printer: Standard and Advanced Entry.

5.0.1 Standard Calibration

Standard Calibration is appropriate for most media types. During the process, the printhead assembly can be raised for visual access to the media and media sensor. In addition, displayed sensor readings can be used to indicate the best position over the media, which is helpful when using small, position-critical TOF notches or marks. Three readings are required:

• Empty: No media in the sensor.

• Gap (or Mark): Only the backing, notch, or reflective mark in the sensor.

• Paper: The label (with the liner attached) in the sensor.

To perform a Standard Calibration:

Step Operator Action Displayed Message Comment

(Media should be loaded

and the appropriate Sensor Type selected.)

Turn ‘On’ the printer.

Press the key. Raise the printhead

assembly.

Wait until the printer initializes (about six seconds).

You are entering Menu Mode.

Standard Calibration (continued)

Step Operator Action Displayed Message Comment

Press the key to

enter the Media Settings menu.

Press the key

and scroll to ‘Sensor Calibration’.

Press the

key.

See Section 4.1.2

for menu layout.

Press the key to abort this

procedure.

You are beginning

the standard calibration procedure.

Press the key. Remove the media from

the Media Sensor then press any key.

This sets the

parameter for the ‘empty’ value.

Where ‘yyy’ is a

numerical value representing the current sensor reading.

Standard Calibration (continued)

Step Operator Action Displayed Message Comment

Proceed according to

your media type: Die-cut stock: strip the

media from the backing and then reinsert it into the sensor; adjust the Sensor Eye Mark over the center of the backing.

Notched stock: adjust the Sensor Eye Mark over the center of the notch.

Reflective stock: Adjust the Sensor Eye Mark over the center of the facedown black mark.

Continuous stock: go to Step 8.

Press any key to continue.

Or, for reflective media:

This sets the

parameter for the ‘gap’ or ‘mark’ value.

Where ‘yyy’ is a numerical value representing the current sensor reading: useful in locating the best sensor position.

þ Note: Never

position the sensor over a perforation when recording a sensor reading.

þ Note: Do not move the position of the Media Sensor after it has been

adjusted.

Position the label (and

backing, if any) under the Sensor Eye Mark.

þ Note: If using

preprinted media, ensure the label area under the sensor is free of preprinted text, graphics or borders.

Press any key to

This sets the

parameter for the ‘paper’ value.

Where ‘yyy’ is a numerical value representing the current sensor reading.

continue.

Standard Calibration (continued)

Step Operator Action Displayed Message Comment

Observe the display.

Or, for reflective media:

Or, for continuous media:

The calibration

was successful. See note below if

another message was displayed.

10 Exit upon successful

calibration: Back out of the menu tree by

The printer is now ready to begin printing.

repeatedly pressing the

key.

If using gap or reflective media, press and hold

If this calibration was not successful, go to Section 5.0.2.

the FEED key. The printer will begin advancing media; allow at least one label gap (or mark) to advance under the sensor.

þ Note: A ‘Warning Low Backing’ message indicates that the calibration was

successful with notched media or media on a transparent liner; see Section 6.1 for details on this and other possible messages.

5.0.2 Advanced Entry Calibration

Advanced Entry Calibration is the alternate method for special-case media types. The procedure has two parts:

1) Using different sampling algorithms, displayed sensor readings have to be listed for each label and TOF value.

2) From this data, the best algorithm is chosen; then those values are manually entered for the ‘Paper’, ‘Gap’ (or ‘Mark’), and ‘Empty’ variables.

Advanced Entry Calibration will override all previous calibration settings; this method should be used only when Standard Calibration has failed.

To perform an Advanced Entry Calibration:

Step Operator Action Displayed Message Comment

(Media should be loaded

and the appropriate Sensor Type selected.)

Turn ‘On’ the printer.

Press the key. Raise the printhead

assembly.

Press the key to

enter the Media Settings menu.

Press the key

and scroll to ‘Sensor Calibration’.

Press the

key.

Wait until the printer initializes (about six seconds).

You are entering Menu Mode.

See Section 4.1.2

for menu layout.

Press the

key to abort this

procedure.

You are entering

the calibration submenu.

Advanced Entry Calibration (continued)

Step Operator Action Displayed Message Comment

Press the key

to scroll to ‘Advanced Entry’.

Press the key.

Press the key. Place the label under the

Sensor Eye Mark and lower the printhead assembly.

10 Press the key

to select the setting (denoted by an ‘*’) and then record the sensor reading (the ‘yyy’ value) in a table similar to the one shown after Step 12, as a Label Value .

Next, press the key to increment the Gain Number.

Repeat this step for each of the Gain Numbers (00-32).

-OR-

You are entering

Advanced Entry Calibration.

Press the

key to abort this

procedure.

You are beginning the Advanced Entry Calibration.

If using preprinted media, ensure the label area under the sensor is free of preprinted text, graphics or borders.

Where ‘yyy’ is a numerical value representing the current sensor reading: useful in locating the best sensor position.

þ Note: Never

position the sensor over a perforation when recording a sensor reading.

Advanced Entry Calibration (continued)

Step Operator Action Displayed Message Comment

11 Proceed according to

your media type: Die-cut stock: strip the

media from the backing and then reinsert it into the sensor; adjust the Sensor Eye Mark over the center of the backing.

Notched stock: adjust the Sensor Eye Mark over the center of the notch.

Reflective stock: Adjust the Sensor Eye Mark over the center of the

Or, for reflective media:

Where ‘yyy’ is a

numerical value representing the current sensor reading: useful in locating the best sensor position.

þ Note: Never

position the sensor over a perforation when recording a sensor reading.

facedown black mark.

Press the key to select the setting and then record the sensor reading in a table similar to the one shown after Step 12, as a TOF

Value.

Next, press the key to increment the Gain Number.

Repeat for each of the Gain Numbers (00-32).

þ Note: Do not move the position of the Media Sensor after it has been

adjusted.

Advanced Entry Calibration (continued)

Step Operator Action Displayed Message Comment

12 From the data collected in

Steps 10 and 11, where both the sensor readings are above 20, subtract each Label Value from the corresponding TOF Value.

Or, for reflective media:

Both sensor

readings must be above 20.

These are the Difference Values.

From the resulting list, find the largest Difference Value (see example below). Its associated Gain Number will provide the best algorithm for your media.

For example, if your compiled data had the values shown in this table, Gain Number 8 would be chosen because it has the highest Difference Value (146) where both the Label Value and the TOF Value are above 20.

Gain

Number

00 255 254 1 01 251 240 11 02 241 213 28 03 231 182 49 04 219 150 69 05 212 119 93 06 200 88 112 07 189 58 131 08 178 32 146 09 167 19 N/A 10 156 17 N/A 11 146 16 N/A 12 136 15 N/A … … … … 31 116 14 N/A 32 112 14 N/A

Label Value

TOF

Value

Difference

Value

Advanced Entry Calibration (continued)

Step Operator Action Displayed Message Comment

13 Using the

select the Gain Number determined in Step 12. Press the key to select the setting.

key,

Or, for reflective media:

Selection is

denoted with an ‘*’.

14 Œ Place the media in the

Media Sensor. Record the sensor reading and label it ‘P’ (paper).

• Place the backing, mark, or notch in the Media Sensor. Record the sensor reading and label it ‘G’ or ‘M’ (Gap or Mark).

Ž Remove all media.

Record the sensor reading and label it ‘E’ (Empty).

15 Press the key.

Then press the key.

Or, for reflective media:

Where ‘yyy’ is

a numerical value representing the current sensor reading.

The sensor readings must be manually entered into the printer now.

Advanced Entry Calibration (continued)

Step Operator Action Displayed Message Comment

16 Press the key.

Using the or the

key, set the

‘Paper’ level to the value determined in the previous step. Press the key to set the entry (indicated by the ‘*’) and advance the menu.

Repeat for the ‘Gap’ (or ‘Mark’) and ‘Empty’ levels.

Or, for reflective media:

The selection

will flash and the display heading will change to indicate the item for entry.

17 After all entries have been

made, press the key to back out of the menu and then press the key to save the settings and return to the Ready Mode.

From ‘Ready’, press the FEED key to advance to the next label TOF.

þ Note: If the Advanced Entry Calibration fails, try the following procedure.

Re-enter Media Settings / Calibration / Advanced Entry / Sensor Gain

and lower the selected Gain Setting number by one (to make the sensor less sensitive). Select the new Gain Setting, save the changes, exit the menu, and then test your media. Repeat the procedure until a usable media setting is obtained.

that fades across the label

. To correct this,

decrease the setting of the Printhead

complete image with even print contrast

5.1 Printhead Adjustments

To ensure consistent print quality over a wide range of media types and dimensions, the printer is equipped with a Leveling Cam adjustment and a Burn Line adjustment.

5.1.1 Leveling Cam Adjustment

When printing on less than full width media, use the Leveling Cam to adjust the right side of the Printhead Assembly for even pressure distribution. To adjust the Leveling Cam:

Œ With media loaded in the printer, download your label format (or use a

Quick Test format) and begin batch printing.

• While observing the printed labels, rotate the Leveling Cam counter- clockwise to an over-adjusted position (see Example 1, below).

Ž Next, rotate the Leveling Cam clockwise, one click at a time, until the

printed labels contain a complete, even image (see Example 2).

Whenever labels of a different width are used, readjust the Leveling Cam.

þ Note: Under-adjustment of the Leveling Cam: Problems can include ribbon

wrinkling, label tracking, and platen roller and printhead wear.

Example 1 – Over adjustment:

Too much adjustment produces an image

Leveling Cam.

Example 2 – Correct adjustment:

The proper adjustment produces a

across the label (see note below).

5.1.2 Burn Line Adjustment

The Burn Line has been adjusted at the factory for strict compliance using 6.5mil (.0065 inch) media, ensuring print quality across a majority of media types. In extreme cases, however, if media of a different thickness or rigidity is used (for example, heavy tag stock), print quality can change. Try the suggestions in Section 2.1.1 and 5.3.1. If print quality remains unacceptable, an adjustment may be required. Typically, thicker media requires a slight forward adjustment, while thinner media requires a slight backward adjustment.

If you have questions, contact a qualified technician or Technical Support before proceeding.

To adjust the Burn Line:

Œ Load the printer with your media

(and ribbon, if required), lower the printhead assembly and rotate the printhead latch back into the locked position.

• Loosen the two Locking Screws approximately ¼ turn counterclockwise.

Ž Turn the Adjustment Screws counter-clockwise until the burn line is past

the platen roller vertex. Print a Validation Label from the Quick Test menu; see Section 4.3.5. The label should look light and uneven.

• Tighten the Locking Screws just until they are ‘snug’ (tight enough to remove any play in the printhead assembly, yet loose enough to allow the Adjustment Screws to move the printhead).

• Turn each Adjustment Screw clockwise about a ¼ turn (or an 1/8 turn for finer adjustments, see note below). Print another Validation Label and examine the print quality. Repeat this step until the labels are produced with even print contrast (darkness) and acceptable print quality are produced.

þ Note: When the Locking Screws are ‘snug’, turning the Adjustment Screws

counter-clockwise will not move the printhead outward; if you have adjusted the printhead too far inward, restart the entire procedure.

‘ Tighten the Locking Screws. Print a final Quick Test label to verify the

adjustment.

5.2 Printhead Replacement

þ Note: The printhead is fragile; use extreme care when handling and never

use a sharp object on the surface. If you have any questions or concerns regarding this procedure, contact a qualified technician or Technical Support before proceeding.

If the printhead must be replaced, Locating Pins eliminate the need for printhead alignment after the installation. To replace the printhead:

Œ Touch a bare metal part of the printer’s

frame to discharge any static electricity that may be present.

• Turn ‘Off’ and unplug the printer. Open the access cover, if ribbon is installed, remove it.

Ž With the printhead locked in the down position, loosen the Printhead

Mounting Screw (it will remain captivated in the assembly).

• Rotate the printhead latch forward. While holding the Printhead, raise the assembly. Disconnect the two Cables and then remove the old Printhead.

• While carefully holding the new Printhead, connect both Cables.

‘ Position the Printhead

onto the Locating Pins in the Printhead Assembly and secure in place with the Printhead Mounting Screw. (Do not overtighten this screw.)

’ Clean the Printhead; see Section 5.3.1.

“ Reload ribbon (if removed), lower the printhead assembly, and rotate the

printhead latch back, into the locked position. Plug in and turn ‘On’ the printer. Print a Validation Label from the Quick Test menu; see Section

4.3.5. If necessary, adjust the print darkness to match that of the previous printhead using the Print Control/Custom Adjustments/Darkness setting in the menu; see Section 4.1.3.

5.3 Maintenance Schedule

The following list and table detail the recommended items, techniques and schedules to help you safely and effectively clean the printer.

• Isopropyl alcohol

• Cotton swabs

• A clean, lint-free cloth

• Soft-bristle brush

• Soapy water/mild detergent

• Compressed air

For your safety and to avoid damaging the printer, turn ‘Off’ and unplug the printer before cleaning; and take proper precautions

CAUTION

Area Method Interval

Printhead Using a cotton swab dampened with isopropyl

when using isopropyl alcohol, a flammable liquid.

Recommended Cleaning Schedule

alcohol, clean the printhead from end to end, removing all build-up. See Section 5.3.1.

WARNING! Before cleaning, allow time for the

printhead to cool.

Clean after each roll or box of labels, or after each roll of ribbon.

Platen Roller

Media

Path / Tear

Plate

Media Sensor

Interior Soft-brush or compressed air. Remove all build-

Exterior Mild detergent. Remove all build-up. See

Cutter Refer to the documentation supplied with the

Using a cotton swab dampened with isopropyl alcohol, rotate the platen and remove all buildup. See Section 5.3.2.

Compressed air / soft-bristle brush and isopropyl alcohol. Remove all build-up along the path that the ribbon and paper follow through the printer.

Compressed air. If needed, a swab dampened with isopropyl alcohol. Remove all build-up.

up. See Section 5.3.3.

Section 5.3.3.

option.

Clean after each roll or box of labels, or after each roll of ribbon.

As needed, based on a weekly visual inspection.

Monthly or as needed.

As needed.

As directed.

5.3.1 Cleaning the Printhead

If print quality declines (symptoms include non-compliant bar codes, print dropouts, streaks; see Section 4.3.4), the typical cause is debris build-up on the printhead. Furthermore, when the build-up is not removed it may lead to element failure, greatly reducing the life of the printhead. To clean the printhead:

Œ Turn ‘Off’ and unplug the printer.

• Open the access cover. Unlock the Printhead Latch and raise the Printhead

Assembly. Move media and ribbon away from the printhead as necessary.

Ž Using a cotton swab moistened, not soaked, with isopropyl alcohol gently

wipe away any build-up on the Printhead surface, paying close attention to the Burn Line. Allow the printhead to dry.

• Replace the ribbon and media. Lower the Printhead Assembly and rotate the Printhead Latch completely back, to the locked position.

• Close the cover. Plug in and turn ‘On’ the printer. Feed several labels to normalize tracking.

CAUTION

NEVER use a sharp object to clean the Printhead.

5.3.2 Cleaning the Platen Roller

A platen roller contaminated with grit, label adhesive, or ink can cause a decline in print quality and, in extreme cases, cause labels to stick and wrap around the roller. To clean the platen roller:

Œ Turn ‘Off’ and unplug the printer.

• Open the access cover. Unlock the Printhead Latch and raise the Printhead

Assembly. Remove media and ribbon.

Ž Using a Cotton Swab dampened with isopropyl alcohol, clean the Platen

Roller; manually rotate the roller and repeat, cleaning the entire surface. Allow the Platen Roller to dry.

• Replace ribbon and media.

• Lower the Printhead Assembly and rotate the Printhead Latch completely

back, to the locked position.

‘ Close the access cover. Plug in and turn ‘On’ the printer. Feed several labels

to normalize tracking.

CAUTION

NEVER use a sharp object to clean the Platen Roller.

5.3.3 Cleaning Interior and Exterior Surfaces

Interior Surfaces: During operation, dust particles from the media build-up inside the printer. Then, as the media is pulled through the printer, the particles can become attached and cause voids on the printed labels. To prevent this, turn ‘Off’ and unplug the printer. Remove all media. Using a soft bristle brush or compressed air, clean out the interior of the printer.

Exterior Surfaces: The outer surfaces of the printer should be cleaned using a general-purpose cleanser. Never use abrasive cleansers or solvents. To clean, turn ‘Off’ and unplug the printer. Using a soft cloth or sponge dampened with the cleanser, wipe the exterior surfaces until clean.

5.4 Application Version Updates

The printer stores its application program in Flash memory on the Main PCB. A feature is included that allows updates to this program through any printer interface port. Updates can be found at our web site.

There are two modes in which the firmware of the printer can be updated: (1) the Ready Mode, or (2) the Download Mode. Before beginning an update, identify the current version of the printer’s application program by printing a Configuration Label (see Section 4.3.2). Compare that version string to those filenames available from our web site and then download the desired file onto your computer’s hard drive.

Proceed with the printer update accordingly: Ÿ If the current application version is 2.091 or greater, refer to Section 5.4.1

or Section 5.4.2.

Ÿ If the current application version is 2.08 or earlier, refer to Section 5.4.2.

Should an error occur during the download (see Section 5.4.3), the update is aborted. If this process did not reach ‘Erasing Flash’ or ‘Updating Software’, the previous program is left intact;

WARNING

þ Note: Users desiring a foreign language menu: After updating from 2.xx to

otherwise, a successful download must be completed before the printer is operable.

3.xx firmware for the first time, you must also download the EFIGS menu language file. Go to the EFIGS ftp directory and copy

832296.01C (or most current version) to lpt1: /b (the DOS Copy command requires the /b parameter because this file contains binary code).

5.4.1 Updating from Ready Mode

Update Procedure for Application Version 2.091 or greater

Step Displayed Message Operator Action Comment(s)

Using the DOS copy command (where ‘filename’ is the program to be loaded and ‘lpt1’ is the selected interface port), enter the following:

copy filename lpt1:

As an example, this would be entered as:

copy 4212tb~1.zs lpt1

(Where ‘lpt1’ is the host computer’s port; however, this selection can differ to include a serial or other port, as the printer is equipped.)

The Ready Indicator will flash as data is received.

No action required. The new application program

is being stored and verified.

No action required. The printer has reset

automatically and is now displaying the new firmware version.

No action required. The new application is now

running.

þ Note: If ‘Uncalibrated’ is displayed, the printer must be calibrated (see Section

5.0).

5.4.2 Updating from Download Mode

Required Update Procedure for Application Version 2.08 or earlier*

Step Displayed Message Operator Action Comment(s)

Press and hold the PAUSE and TEST keys while turning ‘On’ the printer to enter the Download Mode.

Using the DOS copy command, copy the filename to the printer (see Step 2 in Section

5.4.1).

No action required. The printer is receiving

The Boot Loader version is displayed.

þ Note: This information

will vary with the printer model and Boot Loader version.

The printer is ready to accept the new application version.

þ Note: The parallel port (LPT1) must be used to write to the printer.

the new image (program).

No action required. The program has been

received and verified; now memory is being cleared of the previous application.

No action required. The new program is being

written into Flash memory. Upon completion, the printer will automatically reset and start the new application.

þ Note: If ‘Uncalibrated’ is displayed, the printer must be calibrated (see Section 5.0).

*This can also be used as an alternate download method for all other version levels.

•

5.4.3 Possible Problems during an Update

The following is list of possible error messages when downloading:

þ Note: If experiencing trouble when attempting to download the file to the

printer, try the following alternate methods:

1) Use Download Mode (see Section 5.4.2).

2) Windows users – try restarting the computer in MS-DOS mode.

3) Use the Windows Driver by Seagull Scientific™ – Device Setting /

Send File to Printer function.

Application Update Error Messages

Displayed Message Descriptions / Causes / Solutions

The printer detected an error during the decompression and transfer of file data from cache storage into the Flash memory. Confirm the version and retry in Download Mode; however, if the problem continues call for service.

The printer could not successfully erase Flash memory. The possible cause is defective Flash memory. Try the download again; however, if the problem continues call for service.

The printer could not successfully write the program into Flash memory. A possible cause is defective Flash memory. Try the download again; however, if the problem continues call for service.

Application Firmware downloaded was not compatible with the printer’s Main PCB. The firmware used was for a different model and not supported by this boot loader version. See Configuration Level, Section 4.1.5.

The printer detected an error in the download. The possible causes include:

An invalid or corrupted file was downloading.

Try saving the file to the host and then download again.

A communications error. Recheck cabling and

port setting.

Software level not authorized for this printer (See Section 4.1.5, Configuration Level/Printer Key.)

5.5 Boot Loader Program Updates

The printer stores the Boot Loader Program in Flash memory on the Main PCB. A feature allows updates to this program via the printer’s interface port. Updates can be found at our web site.

If power is lost while ‘Upgrading Software’ is displayed, the printer will become non-functional and must be returned to the factory for programming or the main logic board must be

WARNING

þ Note: Only printers with an Application Version of 2.09 or greater can

Before beginning the Boot Loader update, identify the printer’s current version. Print a Configuration Label (see Section 4.3.2) and compare that version string to those available from our web site. Download the desired version onto your computer’s hard drive. To update the Boot Loader Program:

Step Displayed Message Operator Action Comment(s)

replaced.

update the Boot Loader Program.

Boot Loader Update Procedure

Using the DOS copy command (where ‘filename’ is the program to be loaded and ‘lpt1’ is the selected interface port), enter the following:

copy filename lpt1:

As an example, this would be entered as:

copy boottb~1.bs lpt1

(Where ‘lpt1’ is the host computer’s output port; however, your selection can differ to include a serial or other port, as the printer is equipped.)

The Ready Indicator will flash as data is received.

No action required. The new program is being

stored and verified.

No action required. The printer has reset

automatically.

No action required. The new application is now

running.

þ Note: If ‘Uncalibrated’ is displayed, the printer must be calibrated (see Section

5.0).

•

6.0 Problem Resolution

Should a problem arise, the information in this section will help you resolve it. The following table lists problems that will not necessarily generate an error message. (For information on messages, see Section 6.1.)

If you have questions, or if problems persist, contact a qualified technician or Technical Support.

If experiencing this problem… Try this solution…

Cannot communicate through

the parallel port:

Cannot load media through the optional cutter:

The LCD is blank, but the Ready Indicator is ‘On’:

Erratic feeding:

Erratic printing (instead of the

label format, strange characters are printed):

Observe the Ready Indicator as the format is sent to the printer. If it does not flash, check the parallel cable type. Also check the protocol and port settings of the printer and host.

Turn ‘Off’ the printer. Ensure that the cutter and cutter cable are properly installed. Turn the printer ‘On’. If the problem continues, call for service.

The display contrast may set too low. Press and hold the MENU key for 10 seconds or until the display reappears.

The printer may require a Quick Media Calibration; see Section 3.4.

The printer may be in Hex Dump Mode;

see Section 6.2.

If using the serial port for communicating,

check both the host and printer port settings; the printer may be set to eight data bits while the host is set to 7 (or vice versa).

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If experiencing this problem… Try this solution…

Intellifont will not print:

Light print on the right side (facing the printer) of the label:

Missing information in the printed label:

Missing print on left or right side of the label:

Intellifont format is Little/Big Endian specific. The printer uses Big Endian. Refer to your font supplier for information.

The Printhead Leveling Cam may be

incorrectly adjusted; see Section 5.1.1.

The Platen Roller may be dirty or worn;

see Section 5.3.2.

Check the label format for character

placement outside the dimensions of the label; all row/column values must allow enough space for the height/length of the characters and bar codes to be printed within the format size.

The available memory may have been

exceeded by the memory requirement of the label format. Try reducing the memory allocated to either the internal module or scaleable font caches; see System Settings / Memory Settings, Section 4.1.5.

• If using serial communications, ensure that

the interface cable meets the requirements found in Section 3.0.1.

Information may be formatted outside the label dimensions. Check your software program label size or check the values in the menu for Print Control / Column Offset and Print Control / Custom Adjustments / Column Offset; see Section 4.1.3.

•

If experiencing this problem… Try this solution…

No power (all indicator lights

are ‘Off”):

Nothing is printing (labels advance normally, but no image is printed):

Verify that the AC power cord connection

has been made at both the outlet and the printer; also, ensure the power switch is ‘On’.

Verify that the AC outlet is functioning, or

try moving the printer to another AC circuit.

• The AC cord may be damaged; replace it.

The line fuse may be blown; call for

service.

Examine the used ribbon for an image: If there is an image on the used ribbon:

Ÿ Verify that the ribbon was properly loaded

per Section 3.3.

Ÿ If properly loaded, the wrong coating

configuration was used. (To verify the inked side, press the adhesive backing of a label against the ribbon surface. Ink will only lift from the coated side of the ribbon.) Clean the printhead (see Section

5.3.1); then replace the ribbon with the correct type for the printer, Section 3.3.

If there is no image on the used ribbon:

• Run any Quick Test Label; see Section 4.3.

If an image printed, then check the protocol and port settings for both the printer and host. These must match.

The heat setting may be too low. Make an

adjustment in the software program or through the Front Panel. (The same functional commands from the host computer override the menu settings.)

The media/ribbon combination may be

incorrect. Contact a Media Representative.

The printhead or printhead cable(s) may be

loose; power ‘Off’ the printer then reconnect; see Section 5.2 for locations.

•

If experiencing this problem… Try this solution…

Nothing happens when trying

to print using a software program:

Poor print quality:

Skips labels when printing:

Unable to print rotated text:

• Ensure that the printer is at READY.

Observe the Front Panel, if the READY

light does not flash as you send the format check the protocol and port settings between the printer and host.

Ensure the interface cable meets the

requirements found in Section 3.0.1.

The printhead may need cleaning; see

Section 5.3.1.

Adjust the Heat and Print Speed settings

through the Front Panel or by host commands; see Section 4.1.3. (The same functional commands from the host computer override the menu settings.)

The media/ribbon combination may not be

compatible; see Section 2.1.

The Printhead Leveling Cam may be

incorrectly adjusted; see Section 5.1.1.

The Platen Roller may be dirty or worn;

see Section 5.3.2.

The Printhead Burn Line may need

adjusting; see Section 5.1.2.

Quick Media Calibration may be needed;

see Section 3.4.

The Media Sensor may be out of position;

readjust the position; see Section 3.2.

The format may be within 1/8 inch of the

label’s edge. Try reducing or moving the format slightly.

The characters may be formatted outside the label dimensions. Ensure the row/column values provide enough room for the height of the characters or bar code to be printed. See the Programmer’s Manual for details.

6.1 Fault and Warning Messages

All printer functions are internally monitored. If a problem (Fault) or a potential problem (Warning) is detected, the Error Indicator (see Section 4.0.4) will be illuminated. A corresponding message will be displayed (if not within a branch of the menu system or in Quick Test Mode). These messages, along with possible solutions, are described below.

Fault Messages:

Fault Messages receive the highest display priority. If more than one fault is detected the display will cycle between messages.

þ Note: To return to normal operation after the printer enters a fault condition,

the fault must be corrected and then the FEED key must be pressed to clear the condition.

Printer Fault Messages

Displayed Message Description Possible Solution(s)

The printer has detected a drop in the 24-volt power supply.

The printer has detected an analog to digital circuit converter failure.

The printer has detected a cutter mechanism fault.

Try cycling the printer power ‘Off’ and ‘On’. If the fault does not clear, call for service.

Try cycling the printer power ‘Off’ and ‘On’.

WARNING! Use extreme care: Turn ‘Off’ the printer and unplug the power cord before examining the cutter and cable.

Make sure the cutter option is properly installed.

Carefully examine the cutter for obstructions.

Printer Fault Messages (continued)

Displayed Message Description Possible Solution(s)

The printer has detected a Direct Memory Access failure.

Consistently low sensor readings were detected.

Consistently high sensor readings were detected.

The printer cannot detect media.

Try cycling the printer power ‘Off’ and ‘On’. If the fault does not clear, call for service.

Press any key to continue. Ensure that media was inserted in the media sensor during the appropriate calibration step; also ensure that the sensor is free of debris. Retry the calibration. If the problem persists, try the ‘Advanced Entry Calibration’; see Section

5.0.2. Press any key to continue.

Ensure that media was removed from the media sensor during the appropriate calibration steps; also ensure that no labels are stuck in the media sensor. Retry the calibration. If the problem persists, call for service.

Try the following:

1) Load media.

2) Ensure that the labels are passing through the Media Sensor.

3) Readjust the Media Sensor over the TOF mark; see Section 3.2.

4) If using media with large gaps, adjust the Paper Out Distance; see Section 4.1.2.

5) Calibrate the printer; see Section 5.0.

Printer Fault Messages (continued)

Displayed Message Description Possible Solution(s)

The printer was unable to complete the Media Calibration; or, the printer was powered off or reset during a ribbon, out of stock or TOF fault.

Press the FEED key in an attempt to clear the message. If necessary, perform a media calibration or correct the related fault condition.

The printer has detected a problem within the print logic.

The system has detected a RAM failure.

Consistently low sensor readings were detected.

Try cycling the printer power ‘Off’ and ‘On’. If the fault does not clear, call for service.

Press any key to continue. Ensure that the reflective mark was inserted facedown in the media sensor during the appropriate calibration step; also, ensure that the reflective mark is made of carbon based ink, and that the sensor is free of debris. Retry calibration. If the problem persists, try an ‘Advanced Entry Calibration’; see Section 5.0.2.

Printer Fault Messages (continued)

Displayed Message Description Possible Solution(s)

Consistently high sensor readings were detected.

The ribbon sensor values have changed, or the printer detects no or only sporadic ribbon supply hub movement.

Press any key to continue. Ensure that media was

removed from the media sensor during the appropriate calibration steps; also ensure that no labels are stuck in the media sensor. Retry the calibration. If the problem persists, call for service.

Try the following:

1) Ensure that ribbon is correctly loaded and that the printhead assembly is latched.

2) Check the ribbon supply and ribbon take up hubs for obstructions that may be stopping movement.

3) Ensure that the ribbon core fits snugly on the ribbon supply hub.

The printer has shutdown to allow the printhead temperature to cool.

4) Ensure that the media and paper combination is not slipping (usually caused by an incorrect match).

Turn ‘Off’ the printer until cool to prevent permanent damage due to an excessive printhead temperature.

Brady 2461, 6441, 3481 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual