Brady and 360X-PLUS, 203X-PLUS, 600X-PLUS, 300X-PLUS User Manual

Bradyprinterä THT Models

300X-PLUS, 600X-PLUS,

203X-PLUS, and 360X-PLUS

Thermal Transfer Printers

User’s Guide

Customer order # 48025L-12
Manufacturer part # 48025LB-12 Rev. 1

Proprietary Statement

This manual contains proprietary information of Brady USA, Inc. It is intended solely for the information and use of
parties operating and maintaining the equipment described herein. Such proprietary information may not be used,
reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of
Brady USA, Inc.

Product Improvements

Continuous improvement of products is a policy of Brady USA, Inc. All specifications and signs are subject to
change without notice.

FCC Compliance Statement

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in
a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instructions, may cause harmful interference to radio communications. However,
there is no guarantee that the interference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined by turning the equipment off and on,
the user is encouraged to try to correct the interference by one or more of the following measures:

Reorient or relocate the receiving antenna.

•

Increase the separation between the equipment and the receiver.

•

Connect the equipment into an outlet on a circuit different than that to which the receiver is connected.

•

• Consult the dealer or an experienced Radio/TV technician for help.

NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the
unit to insure compliance.

“The user is cautioned that any changes or modifications not expressly approved by Brady USA, Inc. could void the
user’s authority to operate the equipment.”

Canadian DOC Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in
the radio interference regulations of the Canadian Department of Communications.

CE Compliance

If the accompanying printer displays the CE mark, it also meets EMC directive 89/336/EEC, with amendments
effective at the time of manufacture.

Liability Disclaimer

Brady USA, Inc. takes steps to assure that its published Engineering Specifications and Manuals are correct;
however, errors do occur. Brady USA, Inc. reserves the right to correct any such errors and disclaims liability
resulting therefrom.

No Liability for Consequential Damage

In no event shall Brady USA, Inc. or anyone else involved in the creation, production, or delivery of the
accompanying product (including hardware and software) be liable for any damages whatsoever (including, without
limitation, damages for loss of business profits, business interruption, loss of business information, or other pecuniary
loss) arising out of the use of or the results of use of or inability to use such product, even if Brady USA, Inc. has
been advised of the possibility of such damages. Because some states do not allow the exclusion or limitation of
liability for consequential or incidental damages, the above limitation may not apply to you.

Copyrights

This copyrighted manual and the label printer described herein are owned by Brady USA, Inc. All rights are
reserved. Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of
up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.

All products and brand names are trademarks of their respective companies. All rights reserved.

 2000 Zebra Technologies Corporation. All rights reserved.

ii Brady X-PLUS Series User’s Guide

I have determined that the Brady printers identified as the

Bradyprinter X- Series Printers

203X- , 300X- , 360X- , and 600X-

PLUS PLUS PLUS PLUS

Zebra Technologies Corporation

Vernon Hills, Illinois 60061-3109 U.S.A.

have been shown to comply with the applicable technical standards of the FCC

™

PLUS

manufactured by:

333 Corporate Woods Parkway

for Home, Office, Commercial, and Industrial use

if no unauthorized change is made in the equipment,

and if the equipment is properly maintained and operated.

Brady X-PLUS Series User’s Guide iii

iv Brady X-PLUS Series User’s Guide

Table of Contents

Introduction

Hello! ........................................1

Unpacking and Inspection ..............................2

Reporting Damage ................................2

Storage and Reshipping .............................2

Media and Ribbon Requirements ..........................3

Power Cord .....................................3

Printer Anatomy 101.................................4

Calibrating the Printer

Purpose .......................................5

Types of Media ...................................6

Non-Continuous Web Media...........................6

Non-Continuous Black Mark Media .......................7

Continuous Media ................................7

Choosing the Print Mode ..............................8

Loading the Media..................................9

Positioning the Media Sensors ...........................10

Transmissive Sensor ..............................10

Black Mark Sensor ...............................12

Loading the Ribbon ................................13

Operator Controls .................................14

POWER Switch .................................14

Front Panel ...................................14

Configuring the Printer ...............................15

Configuring the Software or Printer Driver ....................16

Media and Ribbon Calibration ...........................17

Printing a Test Label ................................19

Brady X-PLUS Series User’s Guide v

Establishing Communication

System Considerations ...............................21

Interfaces ....................................21

Data Specifications ...............................21

Cabling Requirements ...............................22

Printer Basics

Operator Controls .................................23

POWER Switch .................................23

Front Panel Display ...............................24

Front Panel Keys ................................25

Front Panel Lights ...............................26

Roll Media Loading ................................27

Tear-Off Mode .................................27

Peel-Off Mode .................................28

Rewind Mode (for Printers Without the Cutter Option)..............30

Cutter Mode...................................32

Rewind Mode (for Printers With the Cutter Option) ..............34

Fanfold Media Loading ..............................36

Removing the Label Backing Material.......................38

Ribbon Loading ..................................39

Ribbon Removal ..................................41

Configuration

Entering the Setup Mode ..............................43

Changing Password-Protected Parameters .....................44

Leaving the Setup Mode ..............................45

Configuration and Calibration Sequence......................46

vi Brady X-PLUS Series User’s Guide

Routine Care and Adjustment

Cleaning ......................................65

Cleaning the Exterior ..............................66

Cleaning the Interior ..............................66

Cleaning the Printhead and Platen Roller....................66

Cleaning the Sensors ..............................67

Cleaning the Snap Plate.............................68

Cleaning the Cutter Module ..........................70

Lubrication .....................................70

Fuse Replacement .................................70

Adjustments ....................................72

Toggle Positioning ...............................72

Printhead Pressure Adjustment .........................73

Media Sensor Position Adjustment .......................73

Troubleshooting

LED Error Conditions and Warnings .......................75

Print Quality Problems ...............................78

Wrinkled Ribbon ..................................79

Communications ..................................79

Printer Diagnostics .................................81

Power-On Self Test ...............................81

Additional Printer Self Tests ..........................81

Brady X-PLUS Series User’s Guide vii

Specifications

Media Handling ..................................87

Options .......................................87

®

Zebra Programming Language (ZPL II

Bar Codes......................................88

General Specifications ...............................89

Printing Specifications ...............................90

Ribbon Specification ................................90

Media Specifications ................................91

Power Line Cord Specifications ..........................92

).....................88

Appendix

Printer Interface Technical Information ......................93

RS-232/RS-422/RS-485 Serial Data Port....................93

Parallel Data Port ................................97

Index

viii Brady X-PLUS Series User’s Guide

Hello!

Introduction

Thank you for purchasing this high-quality Bradyprinter X-PLUS Series
printer!

n

This manual provides all of the information you will need to operate
your printer.

n

The ZPL IIProgramming Guide Volume I and Volume II
(part # 45540L) show you how to create the perfect label format for your
application.

n

The ZebraNetâNetworking: PrintServer IIäInstallation and User’s
Guide (part # 45537L) explains how you can quickly set up your printer

on an IP network (optional ZebraNet PrintServer II required).

n

There is also a maintenance manual for this printer. This manual
(part # 48152L) contains the information you will need to maintain your
printer.

Brady X-PLUS Series User’s Guide 1

Unpacking and Inspection

Inspect the printer for possible damage incurred during shipment.

n

Check all exterior surfaces.

n

Raise the media access door and inspect the media compartment.

In case shipping is required, save the carton and all packing material.

Reporting Damage

If you discover shipping damage:

n

Immediately notify and file a damage report with the shipping company.

Brady USA, Inc. is not responsible for any damage incurred during
shipment of the equipment and will not repair this damage under
warranty.

n

Keep the carton and all packing material for inspection.

n

Notify your local Brady distributor.

Storage and Reshipping

If you are not placing the printer into operation immediately, repackage it
using the original packing materials. The printer may be stored under the
following conditions:

n

Temperature: -4° to +140° F (-20° to +60° C)

n

Relative humidity: 5 to 85% non-condensing

To ship the printer, carefully pack it in a suitable container to avoid damage
during transit. Whenever possible, use the original container from the
factory. If you use a different container, package the printer carefully to
avoid damage. Brady will not be responsible for shipping damage incurred
due to improper packaging!

CAUTION! When packaging the printer in a rigid container, use

shock mounts or shock-absorbing packing material to
prevent damage to the printer. Before packing, remove
all ribbon and media from the supply and

2 Brady X-PLUS Series User’s Guide

take-up/rewind spindles to prevent damage to the
printer.

Media and Ribbon Requirements

Since print quality is affected by media and ribbon, printing speeds, and
printer operating modes, it is very important to run tests for your
applications.

n

Continuous roll media, fanfold media, or card stock with optional
perforations and registration holes may be used.

n

Printhead life may be reduced by the abrasion of exposed paper fibers
when using perforated media.

n

The ribbon MUST be as wide as or wider than the media being used. If
the ribbon is narrower than the media, areas of the printhead will be
unprotected and subject to premature wear. (When printing in direct
thermal mode, ribbon is not used and should not be loaded in the
printer.)

Power Cord

WARNING! For personnel and equipment safety, always use a

three-prong plug with a ground (earth) connection.

NOTE: Depending on how your printer was ordered, a power cord may or

may not be included. If one is not included, or if the one included
is not suitable for your requirements, refer to “Power Line Cord
Specifications” on page 92.

The power cord connector must be plugged into the mating connector on
the rear of the printer.

Make sure that the POWER on/off switch (located at the back of the printer)
is in the off position before connecting the power cable to an electrical
outlet.

Brady X-PLUS Series User’s Guide 3

Printer Anatomy 101

Depending on the options you have selected, your printer may look slightly
different.

Tear-off/

peel-off

bar

Printhead

lever

Platen

roller

Snap

plate

Lower

roller

Spindle

hook

Ribbon take-up

spindle

Ribbon supply

spindle

Dancer

roller

assembly

Media

guide

Rewind

spindle

(optional)

Only on select models

Media

supply

guide

Media

supply

hanger

Figure 1

4 Brady X-PLUS Series User’s Guide

This chapter of the user’s guide is so important that we’ve printed it on a
different color paper! That way, it will be easy for you to find when you
must calibrate (set up) the printer for your particular application.

Purpose

n

n

NOTE: This procedure must be performed when the printer is first

To calibrate the printer, you must do the following (all of the instructions
are contained in this chapter):

Calibrating the Printer

To calibrate the printer.

To verify that the printer is properly set up by printing a test label.

installed or when it cannot properly detect the top of the label.

n

Determine the type of media (labels) being used.

n

Choose the print method.

n

Position the media sensors (if necessary).

n

Configure the printer and software or driver based on the label being
used.

n

Perform a media and ribbon calibration.

n

Print a test label.

Brady X-PLUS Series User’s Guide 5

Types of Media

Non-Continuous Web Media

Non-continuous web media (refer to Figure 2) refers to individual labels
that are separated by a gap, notch, or hole. When you look at the media,
you can tell where one label ends and the next one begins.

Hole

Label gap (2-4 mm)

Notch

Non-continuous media with a hole or notch

Label gap (2-4 mm)

Non-continuous media with gaps between the labels

(individual labels on a continuous liner)

Figure 2

6 Brady X-PLUS Series User’s Guide

Non-Continuous Black Mark Media

Non-continuous black mark media has black marks printed on the back that
indicate the start and end of each label (refer to Figure 3).

Black mark

Non-continuous media for black mark sensing

Figure 3

Continuous Media

Black mark

Continuous media (refer to Figure 4) is one uninterrupted roll of material
that allows the image to be printed anywhere on the label.

Continuous media (no gaps, holes, notches, or black marks)

Figure 4

Brady X-PLUS Series User’s Guide 7

Choosing the Print Mode

n

Tear-off mode allows you to tear off each label, or a strip of labels, after
it is printed.

n

In Peel-off mode, backing material is peeled away from the label as it is
printed. After this label is removed from the printer, the next one is
printed.

n

When in cutter mode, the printer automatically cuts the label after it is
printed.

n

In rewind mode, the media and backing are rewound onto a core as the
labels are printed.

8 Brady X-PLUS Series User’s Guide

Loading the Media

Figure 5 illustrates one method of media loading. For more detailed
instructions, as well as information about how to load the different types of
media and the various printing modes, refer to the instructions that begin on
page 27.

Printhead lever

Open

Closed

Tear-off/

peel-off

bar

Media

guide

Figure 5

Media

supply

guide

Media

Brady X-PLUS Series User’s Guide 9

Positioning the Media Sensors

The correct positioning of the media sensors is important. It can make the
difference between a perfect label and a call to Technical Support!

Transmissive Sensor

The web or gap sensor, better known as the “transmissive sensor,” detects
the gap between labels.

The transmissive sensor actually consists of two sections: a light source
(the lower media sensor) and a light sensor (the upper media sensor). The
media passes between the two.

The upper media sensor must be positioned:

n

Directly over the hole or notch, or

n

Anywhere along the width of the media if there is a gap between labels.

NOTE: If you are using continuous media, position the upper media sensor

over the media so that the printer can detect an out-of-paper
condition.

10 Brady X-PLUS Series User’s Guide

Adjusting the Upper Media Sensor

Refer to Figure 6. (For clarity, not all printer parts are shown.)

1. Remove the ribbon (if it is installed).

2. Locate the upper media sensor. The upper media sensor “eye” is
directly below the adjustment screw head.

3. Slightly loosen the upper media sensor adjustment screw (Phillips
head).

4. Using the tip of the screwdriver, slide the upper sensor along the slot to
the desired position.

5. Secure the upper media sensor adjustment screw.

Upper media sensor

adjustment screw

Figure 6

Brady X-PLUS Series User’s Guide 11

Adjusting the Lower Media Sensor

Position the lower media sensor (refer to Figure 7) by sliding it in its slot
until it is positioned under the upper media sensor.

Lower

media sensor

Figure 7

Black Mark Sensor

The black mark sensor is in a fixed position and enabled via the front panel
(details in “Configuring the Printer” on page 15).

12 Brady X-PLUS Series User’s Guide

Loading the Ribbon

To load ribbon, refer to Figure 8 (for the 300X-PLUS, 600X-PLUS, and
203X-PLUS) and Figure 9 (for the 360X-PLUS). For more detailed
information, refer to the instructions that begin on page 39.

Printhead

Closed

lever

Open

Printhead

lever

Open

Ribbon
take-up
spindle

Figure 8

Ribbon

take-up

spindle

Ribbon

supply

spindle

Ribbon

supply

spindle

Closed

Figure 9

Brady X-PLUS Series User’s Guide 13

Operator Controls

POWER Switch

The POWER switch is located at the back of the printer above the power
cord and fuse. Turn on the printer.

Front Panel

The step-by-step instructions in this
section tell you which keys to press
and what appears on the liquid crystal
display (LCD) during the calibration
procedure.

For a more detailed explanation of the
front panel keys and lights (as shown
in Figure 10), refer to the instructions
that begin on page 24.

Figure 10

14 Brady X-PLUS Series User’s Guide

Configuring the Printer

The configuration procedure in the next table contains the information you
need to get your printer up and running, but it is not comprehensive. Refer
to page 43 for more information.

n

Enter the configuration mode by pressing the SETUP/EXIT key at the
“PRINTER READY” display.

NOTE: You will need to press the NEXT/SAVE key more than once to

advance to some of the displays.

n

To increase the value, answer “yes,” indicate “on,” or move to the next
selection, use the RIGHT BLACK OVAL key.

n

To decrease the value, answer “no,” indicate “off,” or return to the
previous selection, use the LEFT BLACK OVAL key.

NOTE: When changing parameters, an asterisk (*) in the upper left-hand

corner of the display indicates that you have changed this setting
from what is currently stored in memory.

Brady X-PLUS Series User’s Guide 15

Press Display Shows Action/Explanation

- PRINTER READY Normal printer operation.

DARKNESS

PRINT MODE

MEDIA TYPE

SENSOR TYPE

PRINT METHOD

MAXIMUM
LENGTH

SAVE SETTINGS

Press the BLACK OVAL keys to increase or decrease the print
darkness setting. (You may need to change this setting when
you print your label.)

Press the BLACK OVAL keys to select tear-off, peel-off, cutter,
or rewind mode.

Press the BLACK OVAL keys to select continuous or
non-continuous media type. (If you choose continuous
media, you must also include a label length instruction in
your label format.)

Press the BLACK OVAL keys to select transmissive or black
mark sensing mode. Unless your media has black marks on
the back, leave your printer at the default setting (web).

Press the BLACK OVAL keys to select thermal transfer (if you
are using ribbon) or direct thermal (no ribbon).

Press the BLACK OVAL keys to set the value that is closest to,
but not less than, the length of the label you are using.

Press the BLACK OVAL keys to select:

PERMANENT -- saves the changes when the power is turned

off.

Press NEXT/SAVE to accept the selection.

- PRINTER READY

You have exited the configuration mode and are now ready
to calibrate the printer.

Configuring the Software or Printer Driver

Many printer settings may also be controlled by your printer’s driver or
label preparation software. Refer to the driver or software documentation
for more information.

16 Brady X-PLUS Series User’s Guide

Media and Ribbon Calibration

NOTE: All steps must be performed in the following procedure, even if

only one sensor needs to be adjusted.

1. Press the SETUP/EXIT key.

2. Press the NEXT/SAVE key until “MEDIA AND RIBBON
CALIBRATE” displays.

3. To start the calibration procedure, press the RIGHT BLACK OVAL
key. “LOAD BACKING CANCEL CONTINUE” displays.

4. Open the printhead. Remove approximately 8” (203 mm) of labels
from the media roll, enough so that only the backing material is
threaded between the media sensors when the media is loaded
(refer to Figure 11).

TM

Remove

labels

Figure 11

Brady X-PLUS Series User’s Guide 17

5. Press the RIGHT BLACK OVAL key. The front panel display will
show “REMOVE RIBBON CANCEL CONTINUE.”

6. Either remove the ribbon or slide it as far from the printer frame as
possible.

7. Close the printhead, trapping the ribbon in this position.

8. Press the RIGHT BLACK OVAL key. The front panel will show
“CALIBRATING PLEASE WAIT.”

9. When this part of the calibration process is completed, the display will
read “RELOAD ALL CONTINUE.”

10. Open the printhead. Pull the backing material until a label is positioned
between the media sensors.

11. Either load the ribbon or return the ribbon to its proper position.

12. Close the printhead. Press the RIGHT BLACK OVAL key to perform
the next part of the calibration sequence. “MEDIA AND RIBBON
CALIBRATE” displays. The printer is calibrated when the media stops
feeding.

13. Press the SETUP/EXIT key to leave the programming mode. Choose
“permanent” when SAVE CHANGES displays.

18 Brady X-PLUS Series User’s Guide

Printing a Test Label

To print a test label:

1. Turn off the printer.

2. Press and hold the CANCEL key
while turning on the printer.

A configuration label, which shows the
printer’s currently stored parameters,
will print (similar to the one shown in
Figure 12).

Figure 12

If you encounter any problems while you are configuring or calibrating the
printer or printing a test label, refer to Troubleshooting, which starts on
page 75. Otherwise, refer to Establishing Communication on page 21 to set
up the communication parameters.

Brady X-PLUS Series User’s Guide 19

20 Brady X-PLUS Series User’s Guide

Establishing Communication

System Considerations

Interfaces

The method of interfacing this printer to a data source depends on the
communication options installed in the printer. The standard interfaces are
an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port.
The optional ZebraNet PrintServer II enables printers to be connected to
10 BaseT Ethernet networks. In addition, the IBM
option is available for those applications that require them.

Data Specifications

®

Twinax or IBM Coax

When communicating via an
asynchronous serial data port (refer
to Figure 13), the baud rate, number
of data and stop bits, parity, and
handshaking are user selectable.
Parity only applies to data
transmitted by the printer since the
parity of received data is ignored.

Printer

25

Male

25

Null modem adapter

(if using a standard

modem cable)

50’ maximum

Figure 13

Male

Computer

25

Female

9

Brady X-PLUS Series User’s Guide 21

When communicating via the parallel
port (refer to Figure 14), the
previously mentioned parameters are
not considered. Refer to page 53 to
configure the communication
parameters for the printer. The
values selected must be the same as
those used by the host equipment
connected to the printer.

For serial and parallel pinout and
technical information, refer to the
Appendix on page 93.

ComputerPrinter

36-pin

male

PC

25-pin

female

25-pin

male

10’ maximum

Cabling Requirements

Data cables must be fully shielded and fitted with metal or metalized
connector shells. Shielded cables and connectors are required to prevent
radiation and reception of electrical noise.

To minimize electrical noise pickup in the cable:

n

Keep data cables as short as possible.

n

Do not bundle the data cables tightly with the power cords.

n

Do not tie the data cables to power wire conduits.

NOTES: Brady X-PLUS printers comply with FCC “Rules and

Regulations”, Part 15, for Class B Equipment, using fully
shielded data cables. Use of unshielded cables may increase
radiated emissions above the Class B limits.

RS-422 and RS-485 applications should use twisted shielded

pairs as recommended in the Appendix of the TA/EA.-485
Specification.

Figure 14

22 Brady X-PLUS Series User’s Guide

Operator Controls

This section discusses the functions of the various controls and indicators
on the printer. The operator should become familiar with each of these
functions.

POWER Switch

This switch is located at the back of the printer above the power cord and
fuse. The POWER switch should be turned off before connecting or
disconnecting any cables.

External influences, such as lightning storms or noise on the power or data
cables, may cause erratic printer behavior. Turning the printer’s power off
and back on may re-establish proper printer operation.

Printer Basics

Brady X-PLUS Series User’s Guide 23

Front Panel Display

The front panel display communicates operational status and programming
modes and parameters.

Figure 15

24 Brady X-PLUS Series User’s Guide

Front Panel Keys

Key Function

Starts and stops the printing process.

• If the printer is not printing: no printing can occur.

• If the printer is printing: printing stops once the current label is complete.
Press to remove error messages from the display.
NOTE: Pause mode can also be activated via ZPL II (~PP, ^PP).

Forces the printer to feed one blank label each time the key is pressed.

• Printer not printing: one blank label immediately feeds.

• Printing: one blank label feeds after the current batch of labels is complete.
NOTE: Equivalent to the Slew to Home Position (~PH, ^PH) ZPL II instruction.

When in the pause mode, this key will cancel print jobs.

• Print job in queue: press once for each print job to be deleted.

• Press and hold for several seconds to cancel all print jobs in the printer’s
memory. The DATA light will turn off.

When in Pause mode, this key will calibrate the printer for:

• Media length.

• Media type (continuous or non-continuous).

• Print mode (direct thermal or thermal transfer).

• Sensor values.

NOTE: The keys below are used only when configuring the printer. Specific uses of these keys

are explained in Configuration, starting on page 43.

• Scrolls back to the previous parameter.

• Press and hold to quickly go backward through parameter sets.

• Scrolls forward to the next parameter. (Saves any changes you’ve made in the
configuration and calibration sequence.)

• Press and hold to quickly advance through parameter sets.

Enters and exits the configuration mode.

These keys change the parameter values. They are used in different ways
depending on the parameter displayed. Common uses are: to increase/decrease
a value, answer “yes” or “no,” indicate “on” or “off,” scroll through several
choices, input the password, or set up the printer for a firmware download.

Brady X-PLUS Series User’s Guide 25

Front Panel Lights

NOTE: If two operating conditions occur simultaneously (for example,

one that causes a light to be on constantly and one that causes the
same light to flash), the light will flash.

Light Status Indication

POWER

TAKE LABEL

ERROR

CHECK

RIBBON

PAPER OUT

PAUSE

DATA

Off The printer is off or power is not applied.

On The printer is on.

Off Normal operation.

Flashing

Off Normal operation — no printer errors.

Flashing

Off Normal operation — ribbon (if used) is properly loaded.

On

Off Normal operation — media is properly loaded.

On

Off Normal operation.

On

Off Normal operation. No data being received or processed.

On

Flashing

(Peel-off mode only.) The label is available. Printing is paused until
the label is removed.

A printer error exists. Check the display screen for more
information.

Printing is paused, the front panel displays a warning message, and
the PAUSE light is on.

• If the printer is in direct thermal mode: Ribbon is loaded.

• If the printer is in thermal transfer mode: No ribbon is loaded.

No media is under the media sensor. Printing is paused, the display
shows an error message, and the PAUSE light is on.

The printer has stopped all printing operations. Either the PAUSE
key was pressed, a pause command was included in the label
format, the on-line verifier detected an error, or a printer error was
detected. Refer to the display screen for more information.

Data processing or printing is taking place. No data is being
received.

The printer is receiving data from or sending status information to
the host computer. Flashing slows when the printer cannot accept
more data, but returns to normal once data is again being received.

26 Brady X-PLUS Series User’s Guide

Roll Media Loading

NOTE: A calibration must be performed when media and ribbon (if used)

are first installed in the printer, or when a different type of media
or ribbon is being used.

Tear-Off Mode

Refer to Figure 16.

1. Open the printhead.

2. Slide the media guide and media supply guide as far from the printer
frame as possible. Flip down the media supply guide.

3. Load media as shown.

4. Flip up the media supply guide. Slide in the media guide and media
supply guide so they just touch, but not restrict, the edge of the roll.

5. Close the printhead.

Printhead lever

Open

Closed

Media

guide

Figure 16

Media

supply

guide

Media

Brady X-PLUS Series User’s Guide 27

Peel-Off Mode

NOTE: Rewind option required.

Refer to Figure 17.

1. Remove the rewind plate from the front of the printer (if installed).
Store it on the two mounting screws on the inside of the front panel.

2. Open the printhead.

3. Slide the media guide and media supply guide as far from the printer
frame as possible. Flip down the media supply guide.

4. Load media as shown.

5. When loading media, allow approximately 36” (914 mm) of media to
extend past the tear-off/peel-off bar. Remove all labels from this
portion to create a leader.

6. Remove the hook from the rewind spindle. If you are using a core,
slide it onto the rewind spindle until it is flush against the guide plate.

7. Wind the label backing around either the 3” (76 mm) core or the rewind
spindle and reinstall the hook.

8. Flip up the media supply guide. Slide in the media guide and media
supply guide so they just touch, but not restrict, the edge of the roll.

Before closing the printhead, make sure:

n

The media is positioned against the inside guides.

n

The media is taut and parallel with itself and the pathway when wound
onto the rewind spindle/core.

9. Close the printhead.

10. To discard the label backing from the rewind spindle, refer to
“Removing the Label Backing Material” on page 38.

28 Brady X-PLUS Series User’s Guide

Label

Printhead lever

Open

Media
supply

guide

Media

Label

backing

Closed

Tear-off/

peel-off

Rewind

plate

bar

Hook

Media

guide

Figure 17

Rewind
spindle

Guide

plate

Brady X-PLUS Series User’s Guide 29

Rewind Mode (for Printers Without the Cutter Option)

NOTE: Rewind option required.

Refer to Figure 18.

1. Remove the rewind plate from its storage location in front of the print
mechanism inside the media compartment.

2. Invert the rewind plate so that the lip on the attached hook plate points
down.

3. Insert the hook plate lip a short distance (½"/13 mm) into the lower
opening in the side plate.

4. Align the upper end of the rewind plate with the corresponding opening
in the side plate. Slide in the rewind plate so that it stops against the
printer’s main frame.

5. Open the printhead.

6. Slide the media guide and media supply guide as far from the printer
frame as possible. Flip down the media supply guide.

7. Load media as shown.

8. When loading media, allow approximately 36” (914 mm) of media to
extend past the printhead. Remove all labels from this portion to create
a leader.

9. Remove the hook from the rewind spindle. If you are using a core,
slide it onto the rewind spindle until it is flush against the guide plate.

10. Wind the label backing around either the 3” (76 mm) core or the rewind
spindle and reinstall the hook.

11. Flip up the media supply guide. Slide in the media guide and media
supply guide so they just touch, but not restrict, the edge of the roll.

30 Brady X-PLUS Series User’s Guide

Before closing the printhead, make sure:

n

The media is positioned against the inside guides.

n

The media is taut and parallel with itself and the pathway when wound
onto the rewind spindle/core.

12. Close the printhead.

Printhead lever

Closed

Side

plate

Rewind

plate

Open

Hook

Media

guide

Figure 18

Media
supply

guide

Media

Rewind
spindle

Guide

plate

Brady X-PLUS Series User’s Guide 31

Cutter Mode

NOTE: Cutter option required.

Refer to Figure 19.

1. Open the printhead.

2. Slide the media guide and media supply guide as far from the printer

3. Load media as shown.

4. Flip up the media supply guide. Slide in the media guide and media

5. Close the printhead.

6. The printer will automatically feed out and cut one label when the

frame as possible. Flip down the media supply guide.

supply guide so they just touch, but not restrict, the edge of the roll.

printer is turned on.

32 Brady X-PLUS Series User’s Guide

Printhead lever

Open

Media
supply

guide

Media

Cutter

Closed

Media

guide

Figure 19

Brady X-PLUS Series User’s Guide 33

Rewind Mode (for Printers With the Cutter Option)

NOTE: Cutter and rewind options required.

Refer to Figure 20.

1. Remove the rewind plate from its storage location in front of the print
mechanism inside the media compartment.

2. Invert the rewind plate so that the lip on the attached hook plate points
down.

3. Insert the hook plate lip a short distance (½"/13 mm) into the lower
opening in the side plate. Slide in the rewind plate so that it stops
against the printer’s main frame.

4. Insert the two small tabs on the rewind plate into the corresponding
slots in the cutter support bracket. (The rewind plate should spring into
the proper position.)

5. Open the printhead.

6. Slide the media guide and media supply guide as far from the printer
frame as possible. Flip down the media supply guide.

7. Load media as shown.

8. When loading media, allow approximately 36” (914 mm) of media to
extend past the printhead. Remove all labels from this portion to create
a leader.

9. Remove the hook from the rewind spindle. If you are using a core,
slide it onto the rewind spindle until it is flush against the guide plate.

10. Wind the label backing around either the 3” (76 mm) core or the rewind
spindle and reinstall the hook.

11. Flip up the media supply guide. Slide in the media guide and media
supply guide so they just touch, but not restrict, the edge of the roll.

34 Brady X-PLUS Series User’s Guide

Before closing the printhead, make sure:

n

The media is positioned against the inside guides.

n

The media is taut and parallel with itself and the pathway when wound
onto the rewind spindle/core.

12. Close the printhead.

Cutter

Printhead lever

Closed

Side

plate

Rewind

plate

Open

Hook

Media

guide

Figure 20

Media

supply

guide

Media

Rewind
spindle

Guide

plate

Brady X-PLUS Series User’s Guide 35

Fanfold Media Loading

NOTE: A calibration must be performed when media and ribbon (if used)

are first installed in the printer, or when a different type of media
or ribbon is being used.

Fanfold media feeds through either the bottom or rear access slot from
outside the printer.

Refer to Figures 21 and 22.

1. Open the printhead.

2. Slide the media guide as far from the printer frame as possible.

3. Load media as shown. If in cutter mode, route media through the
cutter.

4. Slide in the media guide so it just touches, but not restricts, the edge of
the roll.

5. Close the printhead.

36 Brady X-PLUS Series User’s Guide

Printhead lever

Open

Bottom supply

Closed

Printhead lever

Open

Closed

Media

Media

guide

Figure 21

Rear supply

Media

guide

Media

Figure 22

Brady X-PLUS Series User’s Guide 37

Removing the Label Backing Material

Since the rewind spindle holds the backing from a standard-size media roll,
we recommend that you perform this procedure whenever you change the
media.

To remove the backing material from the rewind spindle, follow these steps
(you don’t need to turn off the printer for this procedure).

1. Unwind approximately 36” (914 mm) of backing from the rewind
spindle. Cut it off at the spindle.

2. Pull out the hook. Slide the backing material off of the rewind spindle
and discard.

3. Wind the media around the rewind spindle once or twice and reinstall
the hook. Continue winding to remove any slack in the media.

38 Brady X-PLUS Series User’s Guide

Ribbon Loading

To load ribbon, refer to Figure 23 (for the 300X-PLUS, 600X-PLUS, and
203X-PLUS) and Figure 24 (for the 360X-PLUS) and follow the procedure
below.

NOTE: Use ribbon that is at least as wide as the media. The smooth

backing of the ribbon protects the printhead from wear and
premature failure due to excessive abrasion. (For direct thermal

print mode, ribbon is not used and should
not be loaded in the printer.)

1. Align the segments of the ribbon supply spindle.

2. Place the ribbon roll on the ribbon supply spindle.

NOTE: Make sure that the core is pushed up against the stop on the ribbon

supply spindle and that the ribbon is aligned squarely with its core.
If this is not done, the ribbon may not cover the printhead entirely
on the inside, exposing print elements to potentially damaging
contact with the media.

3. Open the printhead.

4. (Optional) To make ribbon loading and
unloading easier, make a leader for your
ribbon roll if it doesn’t already have one.

Ribbon

Label

Strip of media

6-12” long

5. Tear off a strip of media (labels and
backing) about 6-12” (152-305 mm) long
from the roll. Peel off a label from this
strip. Apply half of this label to the end
of the strip and the other half to the end
of the ribbon. This acts as a ribbon
leader.

6. Thread the ribbon (with leader, if used) as shown without creasing or
wrinkling it.

Brady X-PLUS Series User’s Guide 39

7. Before wrapping the ribbon around the ribbon take-up spindle, ensure that
the arrow on the knob aligns with the indented notch (see Figure 25
inset).

NOTE: Do not tape the ribbon to the ribbon take-up spindle!

8. Place the ribbon (with leader, if used) around the ribbon take-up spindle
and wind counterclockwise for several turns.

9. Close the printhead.

Closed

Printhead

Closed

Printhead

lever

Open

lever

Open

Ribbon

take-up

spindle

Figure 23

Ribbon

take-up

spindle

Ribbon

supply

spindle

Ribbon

supply

spindle

Figure 24

40 Brady X-PLUS Series User’s Guide

Ribbon Removal

1. Break the ribbon as close to the ribbon take-up spindle as possible.

2. Refer to Figure 25. While holding the ribbon take-up spindle, turn the
knob (1) clockwise until it stops. This will cause the ribbon release bars
to pivot down (2), easing the spindle’s “grip” on the wound ribbon.

3. Slide the ribbon off of the ribbon take-up spindle. Once the spent
ribbon has been removed, ensure that the arrow on the knob aligns with
the indented notch in the ribbon take-up spindle (see Figure 25 inset).

4. Remove the empty core from the ribbon supply spindle.

5. Follow the ribbon loading procedure on page 39 to load the new ribbon.

2

1

Figure 25

Brady X-PLUS Series User’s Guide 41

42 Brady X-PLUS Series User’s Guide

Configuration

After you have installed the media and ribbon and the power-on self test
(POST) is complete, the front panel display will show “PRINTER READY.”
(If the printer fails its POST, refer to page 81.) You may now set printer
parameters for your application using the front panel display and the five keys
directly below it.

NOTE: Printers that are operating on an IP network can be quickly

configured via ZebraNet
PrintServer II required). For information, refer to ZebraNet
Networking: PrintServer II Installation and User’s Guide.

If it becomes necessary to restore the initial printer defaults, see “FEED
Key and PAUSE Key Self Test” on page 85.

NOTE: Unless otherwise noted, all parameters are listed in the order they

are displayed, starting with “DARKNESS.”

Entering the Setup Mode

To enter the programming mode, press the SETUP/EXIT key. Press either
the NEXT/SAVE key or PREVIOUS key to scroll to the parameter you
wish to set.

NOTE: You may also press and hold the NEXT/SAVE and PREVIOUS

keys to quickly advance through the configuration parameters.

Parameters in this section are shown in the order displayed when pressing
the NEXT/SAVE key. Throughout this process, press the NEXT/SAVE
key to continue to the next parameter, or press the PREVIOUS key to return
to the previous parameter in the cycle.



WebView(optional ZebraNet

An asterisk (*) in the upper left-hand corner of the display indicates that the
value displayed is different than the currently stored value.

Brady X-PLUS Series User’s Guide 43

Changing Password-Protected Parameters

Certain parameters are password-protected by factory default.

CAUTION: Do not change password-protected parameters unless

you are sure you know what you are doing! If they are
set incorrectly, these parameters could cause the
printer to function in an unpredictable way.

The first attempt to change one of these parameters (pressing one of the
BLACK OVAL keys) will require you to enter a four-digit password. This
is done via the “ENTER PASSWORD” display. The LEFT BLACK
OVAL key changes the selected digit position. The RIGHT BLACK
OVAL key increases the selected digit value. After entering the password,
press the NEXT/SAVE key. The parameter you wish to change will be
displayed. If the password was entered correctly, you can now change the
value.

The default password value is 1234. The password can be changed using
the ^KP (Define Password) ZPL II instruction or through ZebraNet
WebView (optional ZebraNet PrintServer II required).

NOTE: Once the password has been entered correctly, it will not have to

be entered again unless you leave and re-enter the programming
mode using the SETUP/EXIT key.

NOTE: You can disable the password protection feature so that it no

longer prompts you for a password by setting the password to
ØØØØ via the ^KPØ ZPL/ZPL II command. To re-enable the
password-protection feature, send the ZPL/ZPL II command ^KPx,
where “x” can be any number, one to four digits in length,
except Ø.

44 Brady X-PLUS Series User’s Guide

Leaving the Setup Mode

You can leave the program mode at any time by pressing the SETUP/EXIT
key. The “SAVE CHANGES” display will appear. There are five choices,
described below. Pressing the LEFT or RIGHT BLACK OVAL key
displays other choices and pressing the NEXT/SAVE key selects the
displayed choice.

n

PERMANENT - Permanently saves the changes. Values are stored in
the printer even when power is turned off.

n

TEMPORARY - Saves the changes until changed again or until power is
turned off.

n

CANCEL - Cancels all changes since pressing the SETUP/EXIT key
except the darkness and tear-off settings (if they were changed).

n

LOAD DEFAULTS - Loads factory defaults. The factory defaults are
shown on the following pages.

NOTE: Loading factory defaults will require printer calibration.

n

LOAD LAST SAVE - Loads values from the last permanent save.

Brady X-PLUS Series User’s Guide 45

Configuration and Calibration Sequence

Press Display Shows Action/Explanation

---- PRINTER READY Normal printer operation.

Setting Print Parameters

Adjusting Print Darkness Press the RIGHT BLACK OVAL key to

increase darkness. Press the LEFT BLACK OVAL key to decrease
darkness.

Default: +10
Range: 0to+30

Darkness settings are dependent upon a variety of factors
including ribbon type, media, and the condition of the printhead.
You may adjust the darkness for consistent high-quality printing.

If printing is too light, or if there are voids in printed areas, you

DARKNESS

TEAR OFF

PRINT MODE

should increase the darkness. If printing is too dark, or if there is
spreading or bleeding of printed areas, you should decrease the
darkness.

The FEED key self test on page 84 can also be used to determine
the best darkness setting. Since the darkness setting takes effect
immediately, you can see the results on labels that are currently
printing.

CAUTION: Set the darkness to the lowest setting that provides

good print quality. Darkness set too high may cause
ink smearing and/or it may burn through the ribbon.

Darkness settings also may be changed by the driver or software
settings.

Adjusting the Tear-Off Position Press the RIGHT BLACK OVAL
key to increase the value, press the LEFT BLACK OVAL key to
decrease the value. Each press of the key adjusts the tear-off
position by four dot rows.

Default: +0
Range: -120 to +120

This parameter establishes the position of the media over the
tear-off/peel-off bar after printing. The label and backing can be
torn off or cut between labels.

Selecting Print Mode Press the RIGHT or LEFT BLACK OVAL key
to display other choices.

Default: Tear-off
Selections: Tear-off, peel-off, cutter, rewind, applicator*

Print mode settings tell the printer the method of media delivery
that you wish to use. Be sure to select a print mode that your
hardware configuration supports since some selections displayed
are for optional printer features.

* Option required

46 Brady X-PLUS Series User’s Guide

Press Display Shows Action/Explanation

Setting Media Type Press the RIGHT or LEFT BLACK OVAL key

to display other choices.

Default: Continuous
Selections: Continuous, non-continuous

MEDIA TYPE

SENSOR TYPE

PRINT METHOD

This parameter tells the printer the type of media you are using.
Selecting continuous media requires that you include a label
length instruction in your label format (^LLxxxx if you are using
ZPL or ZPL II).

When non-continuous media is selected, the printer feeds media
to calculate label length (the distance between two detections of
the inter-label gap, webbing, or alignment notch or hole).

Setting the Sensor Type Press the RIGHT or LEFT BLACK OVAL
key to display other choices.

Default: Web
Selections: Web, mark

This parameter tells the printer whether you are using media with
a web (gap/space between labels, notch, or hole) to indicate the
separations between labels or if you are using media with a black
mark printed on the back. If your media does not have black
marks on the back, leave your printer at the default (web).

Selecting Print Method Press the RIGHT BLACK OVAL key for
the next value; press the LEFT BLACK OVAL key for the previous
value.

Default: Thermal transfer
Selections: Thermal transfer, direct thermal

The print method parameter tells the printer the method of
printing you wish to use: direct thermal (no ribbon) or thermal
transfer (using thermal transfer media and ribbon).

NOTE: Selecting direct thermal when using thermal transfer

media and ribbon creates a warning condition, but
printing will continue.

Brady X-PLUS Series User’s Guide 47

Press Display Shows Action/Explanation

Setting Print Width Press the RIGHT BLACK OVAL key to

increase the value, press the LEFT BLACK OVAL key to decrease
the value. To change the unit of measurement, press the LEFT
BLACK OVAL key until the unit of measurement is active, then
press the RIGHT BLACK OVAL key to toggle to a different unit of

PRINT WIDTH

MAXIMUM
LENGTH

measure (inches, mm, or dots).
Default:, Range: The default and range of acceptable values vary

depending on what printer you have. Refer to “Printing
Specifications” on page 90 for further information about the
ranges available for your model.

Print width determines the printable area across the width of the
label.

Setting Maximum Length Press the LEFT BLACK OVAL key to
decrease the value, press the RIGHT BLACK OVAL key to
increase the value.

Default:, Range: The default and range of acceptable values vary
depending on your printer’s configuration. Values are adjustable
in 1” (25.4 mm) increments.

Maximum length is used in conjunction with the calibration
procedure. The value of this setting determines the maximum
label length that will be used during the media portion of the
calibration process. Only a few labels are required to set media
sensors. Always set the value that is closest to, but not lower
than, the length of the label you are using. For example, if the
length of the label is 14.5 inches (368 mm), set the parameter for

15.0 inches (381 mm).

48 Brady X-PLUS Series User’s Guide

Listing Printer Information

Press Display Shows Action/Explanation

List Fonts Press the RIGHT BLACK OVAL key to print a label

listing all of the available fonts.

LIST FONTS

LIST BAR CODES

LIST IMAGES

LIST FORMATS

LIST SETUP

LIST ALL

This selection is used to print a label that lists all of the fonts
currently available in the printer, including standard printer fonts
plus any optional fonts. Fonts may be stored in RAM, FLASH
memory, font EPROMs, or font cards.

List Bar Codes Press the RIGHT BLACK OVAL key to print a label
listing all of the available bar codes.

This selection is used to print a label that lists all of the bar codes
currently available in the printer.

List Images Press the RIGHT BLACK OVAL key to print a label
listing all of the available images.

This selection is used to print a label that lists all of the images
currently stored in the printer’s RAM, FLASH memory, optional
EPROM, or optional memory card.

List Formats Press the RIGHT BLACK OVAL key to print a label
listing all of the available formats.

This selection is used to print a label that lists all of the formats
currently stored in the printer’s RAM, FLASH memory, optional
EPROM, or optional memory card.

List Setup Press the RIGHT BLACK OVAL key to print a label
listing the current printer configuration.

This selection is used to print a label that lists the current printer
configuration information. (Same as CANCEL key self test.)

List All Press the RIGHT BLACK OVAL key to print a label listing
all of the available fonts, bar codes, images, formats, and the
current printer configuration.

This selection is used to print a label that lists the five previous
selections, as described.

Brady X-PLUS Series User’s Guide 49

Press Display Shows Action/Explanation

Initialize Memory Card
CAUTION: Perform this operation only when it is necessary to

erase all previously stored information from the optional memory
card. Press the NEXT//SAVE key to bypass this function.

1. Press the RIGHT BLACK OVAL key to select “YES.”

If your printer is set to require a password, you will
now be prompted to enter the password. Enter the
password and then press the NEXT/SAVE key.

2. The display will ask “INITIALIZE CARD?”. Press the RIGHT

BLACK OVAL key “YES.”

3. The front panel LCD will ask “ARE YOU SURE?”.

INITIALIZE CARD

INIT FLASH MEM

4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.

or

Press the LEFT BLACK OVAL key “NO” to cancel the request
and return to the “INITIALIZE CARD” prompt.

5. Press the SETUP/EXIT key followed by the NEXT/SAVE key.
If initialization is still in process, the front panel display
will flash back and forth between the two phrases
“CHECKING B: MEMORY” and “PRINTER IDLE.”

When initialization is complete, the printer will
automatically exit the configuration mode and the
front panel will display “PRINTER READY.”

NOTE: Depending on the amount of memory in the memory

card, initialization may take up to five minutes to
complete.

Initialize Flash Memory
CAUTION: Perform this operation only when it is necessary to

erase all previously stored information from the FLASH memory.
Press the NEXT//SAVE key to bypass this function.

1. Press the RIGHT BLACK OVAL key to select “YES.”

If your printer is set to require a password, you will
now be prompted to enter the password. Enter the
password and then press the NEXT/SAVE key.

2. The display will ask “INITIALIZE FLASH?”. Press the RIGHT
BLACK OVAL key “YES.”

3. The front panel LCD will ask “ARE YOU SURE?”.

4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.

or

Press the LEFT BLACK OVAL key “NO” to cancel the request
and return to the “INITIALIZE FLASH” prompt.

5. Press the SETUP/EXIT key followed by the NEXT/SAVE key.
If initialization is still in process, the front panel display
will flash back and forth between the two phrases
“CHECKING E: MEMORY” and “PRINTER IDLE.”

When initialization is complete, the printer will
automatically exit the configuration mode and the
front panel will display “PRINTER READY.”

NOTE: Depending on the amount of free FLASH memory,

initialization may take up to one minute to complete.

50 Brady X-PLUS Series User’s Guide

Media and Ribbon Sensor Calibration
NOTE: Before you begin this procedure, make sure that the maximum length is set to a value

equal to or greater than the length of the labels you are using. If the maximum length is set to a
lower value, the calibration process will assume that continuous media is in the printer. See
page 48 for more information.

There are two different types of calibration that can be performed by the printer:

1) Standard Calibration. Pressing the CALIBRATE key on the printer’s front panel causes the
printer to feed media and ribbon and set the values it detects for media, media backing material
(the spaces between labels), media out, and ribbon or no ribbon (which determines the print
mode — thermal transfer or direct thermal). This type of calibration also occurs as part of the
sensor profile and media and ribbon calibration procedures.

2) Media and Ribbon Sensor Sensitivity Calibration. Performing the media and ribbon
calibration procedure first resets the sensitivity of the sensors to better detect the media and
ribbon you are using. With the sensors at their new sensitivity, the printer then performs the
standard calibration described above. Changing the type of ribbon and/or media may require
resetting the sensitivity of the media and ribbon sensors. Indications that the sensitivity may
need to be reset would be a CHECK RIBBON light on with the ribbon properly installed or
non-continuous media being treated as continuous media.

Press Display Shows Action/Explanation

Sensor Profile Press NEXT/SAVE to skip this standard calibration

procedure and continue with the media and ribbon calibration
parameter which follows. Press the RIGHT BLACK OVAL key to
initiate this standard calibration procedure and print a media
sensor profile.

SENSOR PROFILE

See Figure 26. The media sensor profile may be used to
troubleshoot registration problems that may be caused when the
media sensor detects preprinted areas on the media or
experiences difficulty in determining web location. If the
sensitivity of the media and/or ribbon sensors MUST be adjusted,
use the media and ribbon sensor sensitivity procedure.

Figure 26

Brady X-PLUS Series User’s Guide 51

Press Display Shows Action/Explanation

Media and Ribbon Sensor Sensitivity Press NEXT/SAVE to skip

the calibration procedure and continue with the host port
selection parameters that follow. Press the RIGHT BLACK OVAL

MEDIA AND
RIBBON
CALIBRATE

Media and Ribbon Calibration Procedure

LOAD BACKING

REMOVE RIBBON

CALIBRATING
PLEASE WAIT

---- RELOAD ALL

MEDIA AND
RIBBON
CALIBRATE

key to start the calibration procedure.
This procedure is used to adjust the sensitivity of the media and

ribbon sensors.
NOTE: The procedure must be followed exactly as presented.

All steps must be performed even if only one of the
sensors requires adjustment.

Press the LEFT BLACK OVAL key to cancel the operation, or do
the following:

1) Open the printhead.

2) Remove approximately 8” (203 mm) of labels from the media

roll, enough so that only the backing material is threaded
between the media sensors when the media is loaded.

Press the LEFT BLACK OVAL key to cancel the operation or do
the following:

1) Remove the ribbon (sliding it as far to the right as possible will

have the same effect as removing it).

2) Close the printhead.

The printer automatically adjusts the scale (gain) of the signals it
receives from the media and ribbon sensors based on the
specific media and ribbon combination you are using. On the
sensor profile, this essentially corresponds to moving the graph
up or down to optimize the readings for your application.

When “RELOAD ALL” is displayed:

1) Open the printhead and pull the media forward until a label is

positioned under the media sensor.

2) Move the ribbon back to its proper position.

3) Close the printhead.

Now that the scale has changed, the printer performs a
calibration equivalent to pressing the CALIBRATE key. During
this process, the printer checks the readings for the media and
ribbon based on the new scale you have established, determines
the label length, and determines whether you are in direct
thermal or thermal transfer print mode. The process is now
complete! To see the new readings on the new scale, print a
sensor profile.

52 Brady X-PLUS Series User’s Guide

Setting Communication Parameters

Communication parameters must be set correctly for the printer to communicate with the host.
These parameters make sure that the printer and host are “speaking the same language.” All
communications parameters are password protected.

Press Display Shows Action/Explanation

Setting Parallel Communications Press the RIGHT or LEFT

BLACK OVAL key to display other choices.
PARALLEL
COMM

SERIAL COMM

BAUD

DATA BITS

Default: Parallel

Selections: Parallel, twinax/coax

Select the communications port that matches the one being used

by the host computer.

Setting Serial Communications Press the RIGHT or LEFT

BLACK OVAL key to display other choices.

Default: RS232

Selections: RS232, RS422/485, RS485 multidrop

Select the communications port that matches the one being used

by the host computer.

Setting Baud Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: 9600

Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200,

28800, 38400, 57600

The baud setting of the printer must match the baud setting of

the host for accurate communications to take place. Select the

value that matches the one being used by the host.

Setting Data Bits Press the RIGHT or LEFT BLACK OVAL key

to display other choices.

Default: 7-bits

Selections: 7-bits, 8-bits

The data bits of the printer must match the data bits of the host

for accurate communications to take place. Set the data bits to

match the setting being used by the host.

NOTE: Must be set to 8 data bits to use Code Page 850.

Brady X-PLUS Series User’s Guide 53

Press Display Shows Action/Explanation

Setting Parity Press the RIGHT or LEFT BLACK OVAL key to

display other choices.
Default: Even

PARITY

STOP BITS

HOST
HANDSHAKE

PROTOCOL

Selections: Even, odd, none
The parity of the printer must match the parity of the host for

accurate communications to take place. Select the parity that
matches the one being used by the host.

Setting Stop Bits Press the RIGHT or LEFT BLACK OVAL key
to display other choices.

Default: 1 stop bit
Selections: 1 stop bit, 2 stop bits

The stop bits of the printer must match the stop bits of the host
for accurate communications to take place. Select the stop bits
that match the one being used by the host.

Setting Host Handshake Press the RIGHT or LEFT BLACK
OVAL key to display other choices.

Default: XON/XOFF
Selections: XON/XOFF, DTR/DSR

The handshake protocol of the printer must match the handshake
protocol of the host for communications to take place. Select the
handshake protocol that matches the one being used by the host.

Setting Protocol Press the RIGHT or LEFT BLACK OVAL key
to display other choices.

Default: None
Selections: None, Zebra, ACK/NACK

Protocol is a type of error checking system. Depending on the
selection, an indicator may be sent from the printer to the host
signifying that data has been received. Select the protocol that is
requested by the host. Further details on protocol can be found
in the ZPL II Programming Guide Volume I.

NOTE: Zebra is the same as ACK/NACK except that with Zebra

the response messages are sequenced.

NOTE: If Zebra is selected, printer must use “DTR/DSR” host

handshake protocol.

54 Brady X-PLUS Series User’s Guide

Press Display Shows Action/Explanation

Setting Network ID Press the LEFT BLACK OVAL key to

move to the next digit position, press the RIGHT BLACK OVAL

key to increase the value of the digit.

Default: 000

NETWORK ID

COMMUNI­CATIONS

Range: 000 - 999

Network ID is used to assign a unique number to a printer used in

an RS-422/RS-485 network. This gives the host the means to

address a specific printer. If the printer is used in a network, you

must select a network ID number. This does not affect TCP/IP or

IPX networks.

Setting Communications Mode Press the RIGHT or LEFT

BLACK OVAL key to display other choices.

Default: Normal mode

Selections: Normal mode, diagnostics

The communication diagnostics mode is a troubleshooting tool

for checking the interconnection between the printer and the

host. When “diagnostics” is selected, all data sent from the host

to the printer will be printed as straight ASCII hex characters. The

printer prints all characters received including control codes, like

CR (carriage return). A sample printout is shown in Figure 36 on

page 85.

NOTES on diagnostic printouts:

• An FE indicates a framing error.

• An OE indicates an overrun error.

• A PE indicates a parity error.

• An NE indicates noise.

For any errors, check that your communication parameters are

correct. Set the print width equal to or less than the label width

used for the test. See page 48 for more information.

Brady X-PLUS Series User’s Guide 55

Selecting Prefix and Delimiter Characters

Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to
the printer. The printer uses the last prefix and delimiter characters sent to it, whether from a
ZPL II instruction or from the front panel.

NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The

printer needs to see different characters to function properly.

Press Display Shows Action/Explanation

Control Prefix Character Press the LEFT BLACK OVAL key to

move to the next digit position, press the RIGHT BLACK OVAL
key to increase the value of the digit.

CONTROL PREFIX

FORMAT
PREFIX

DELIMITER CHAR

Default: 7E (tilde - displayed as a black square)
Range: 00-FF

The printer looks for this 2-digit hex character to indicate the start
of a ZPL/ZPL II control instruction.

Format Prefix Character Press the LEFT BLACK OVAL key to
move to the next digit position, press the RIGHT BLACK OVAL
key to increase the value of the digit.

Default: 5E (caret)
Range: 00-FF

The printer looks for this 2-digit hex character to indicate the start
of a ZPL/ZPL II format instruction.

Delimiter Character Press the LEFT BLACK OVAL key to
move to the next digit position, press the RIGHT BLACK OVAL
key to increase the value of the digit.

Default: 2C (comma)
Range: 00-FF

The delimiter character is a 2-digit hex value used as a parameter
place marker in ZPL/ZPL II format instructions. Refer to the ZPL II
Programming Guide Volume I for more information.

56 Brady X-PLUS Series User’s Guide

Selecting ZPL Mode

Press Display Shows Action/Explanation

Selecting ZPL Mode Press the RIGHT or LEFT BLACK OVAL

key to display other choices.

Default: ZPL II

Selections: ZPL II, ZPL

ZPL MODE

Power-Up and Head Close Parameters

MEDIA POWER
UP

HEAD CLOSE

The printer will remain in the selected mode until it is changed by

this front panel instruction or by using a ZPL/ZPL II command. The

printer accepts label formats written in either ZPL or ZPL II. This

eliminates the need to rewrite any ZPL formats you already have.

Refer to the ZPL II Programming Guide Volume II for more

information on the differences between ZPL and ZPL II .

Media Power-Up Press the RIGHT or LEFT BLACK OVAL key

to display other choices.

Default: Feed

Selections: Feed, calibration, length, and no motion

This parameter establishes the action of the media when the

printer is turned on.

• Calibration: Recalibrates the media and ribbon sensors.

• Feed: Feeds the label to the first web.

• Length: Determines the length of the label.

• No Motion: Media does not move.

Head Close Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: Feed

Selections: Feed, calibration, length, no motion

Determines the action of the media after the printhead has been

opened and then closed.

• Calibration: Recalibrates the media and ribbon sensors.

• Feed: Feeds the label to the first web.

• Length: Determines the length of the label.

• No Motion: Media does not move.

Brady X-PLUS Series User’s Guide 57

Label Positioning Parameters

Press Display Shows Action/Explanation

Backfeed Sequence Press the RIGHT or LEFT BLACK OVAL

key to display other choices.
Default: Default (90%)

BACKFEED

LABEL TOP

LEFT POSITION

Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%,

This parameter establishes when and how much label backfeed
occurs after a label is removed or cut in the peel-off, cutter, and
applicator modes. It has no effect in rewind or tear-off modes.
This parameter setting can be superseded by the ~JS instruction
when received as part of a label format (refer to the ZPL II
Programming Guide Volume I).

NOTE: The difference between the value entered and 100%

Adjusting Label Top Position Press the RIGHT BLACK OVAL key

to increase the value, press the LEFT BLACK OVAL key to
decrease the value. The displayed value represents dots.

Default: +0
Range: -120 to +120 dot rows

The label top position adjusts the print position vertically on the
label. Positive numbers adjust the label top position further down
the label (away from the printhead), negative numbers adjust the
position up the label (toward the printhead).

Adjusting Left Position Press the LEFT BLACK OVAL key to
move to the next position, press the RIGHT BLACK OVAL key to
change between + and - and to increase the value of the digit.
The displayed value represents dots.

Default: 0000
Range: -9999 to +9999
NOTE: For a negative value, enter the value before changing to

This parameter establishes how far from the left edge of a label
the format will begin to print by adjusting horizontal positioning
on the label. Positive numbers adjust the printing to the left by
the number of dots selected, negative numbers shift printing to
the right.

60%, 70%, 80%, off

establishes how much backfeed occurs before the next
label is printed. For example, a value of 40 means that
40% of the backfeed takes place after the label is
removed or cut. The remaining 60% takes place before
the next label is printed. A value of “before” means that
all backfeed will take place before the next label is
printed.

the minus sign.

58 Brady X-PLUS Series User’s Guide

Press Display Shows Action/Explanation

Setting the Head Test Count Press the LEFT BLACK OVAL

key to move to the next digit position, press the RIGHT BLACK

OVAL key to change the value of the digit.

HEAD TEST
COUNT

HEAD RESISTOR

VERIFIER PORT

Default: 0000 (disables the test)

Range: 0000 to 9999

The printer periodically performs a test of the printhead

functionality, called a “printhead test” or “head test.” This

parameter establishes how many labels are printed between

these internal tests.

Setting the Head Resistor Value Press the LEFT BLACK

OVAL key to move to the next digit position, press the RIGHT

BLACK OVAL key to increase the value of the digit.

CAUTION: This parameter should only be changed by qualified

personnel!

Initial Value: Factory-set to match the printhead shipped with

your printer.

Default Value: 0500

Range: 0500 to 1175

This value has been pre-set at the factory to match the resistance

value of the printhead. It will not need to be changed unless the

printhead is replaced.

CAUTION: DO NOT set the value higher than that shown on the

printhead. Setting a higher value may damage the
printhead!

Before replacing a printhead, look on the bottom of the printhead

element for the label that shows the resistance value (ohm value).

Setting the Verifier Port Press the RIGHT or LEFT BLACK

OVAL key to display other choices.

Default: Off

Selections: Off, 1 VER-RPRNT, 2 VER-THRUPUT

The auxiliary port is used to determine how the printer will react

to the on-line verifier. There are currently three operating

conditions for this port:

• Off: The verifier port is off.

• 1 VER-RPRNT ERR: Label reprinted if verifier detects an error.

If a bar code is near the upper edge of the label, the label will be

fed out far enough to be verified and then backfed to allow the

next label to be printed and verified.

• 2 VER-THRUPUT: Allows greatest throughput but may not

indicate a verification error immediately upon detection. May

print from one to three labels before an error is recognized and

printing stops.

For more information on the operation of the optional verifier,

refer to the documentation provided with that option.

Brady X-PLUS Series User’s Guide 59

Press Display Shows Action/Explanation

Setting the Applicator Port Press the RIGHT or LEFT BLACK

OVAL key to display other choices.

Default: Off
Selections: Off, mode 1, mode 2, mode 3, mode 4

Determines the action of the verifier port.

• Off: The applicator port is off.

APPLICATOR
PORT

WEB S.

MEDIA S.

RIBBON S.

• Mode 1: Asserts the ~END_PRINT signal low while the printer
is moving the label forward.

• Mode 2: Asserts the ~END_PRINT signal high while the printer
is moving the label forward.

• Mode 3: Asserts the ~END_PRINT signal low for 20
milliseconds when a label has been completed and positioned.
Not asserted during continuous printing modes.

• Mode 4: Asserts the ~END_PRINT signal high for 20
milliseconds when a label has been completed and positioned.
Not asserted during continuous printing modes.

MARK S.

MARK MED S.

MEDIA LED

RIBBON LED

MARK LED

These parameters are automatically set during the calibration
procedure. They should only be changed by a qualified service
technician. Refer to the maintenance manual for more
information on these parameters.

Press the NEXT/SAVE key repeatedly to skip these parameters.

60 Brady X-PLUS Series User’s Guide

Press Display Shows Action/Explanation

LCD Display Adjustment Press the LEFT BLACK OVAL key to

decrease the value (reduce brightness), press the RIGHT BLACK

LCD ADJUST

FORMAT
CONVERT

IDLE DISPLAY*

RTC DATE*

RTC TIME*

OVAL key to increase the value (increase brightness).

Range: 00 to 19

This parameter allows you to adjust the brightness of your

display if your display is difficult to read.

Format Convert Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: None

Selections: None, 150 → 300, 150 → 600, 200 → 600, 300 → 600

Selects the bitmap scaling factor. The first number is the original

dots per inch (d.p.i.) value; the second, the d.p.i. to which you

would like to scale.

Idle Display Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: Firmware version

Selections: mm/dd/yy (24 hour), mm/dd/yy (12 hour),

dd/mm/yy (24 hour), dd/mm/yy (12 hour)

This parameter selects the LCD display options for the real time

clock (if installed).

NOTE: If the default value is not selected, pressing either BLACK

OVAL key will briefly display the firmware version of the
printer.

RTC Date Press the LEFT BLACK OVAL key to move to the

next digit position, press the RIGHT BLACK OVAL key to increase

the value of the digit.

This parameter allows you to set the date following the

convention selected in “IDLE DISPLAY.”

RTC Time Press the LEFT BLACK OVAL key to move to the

next digit position, press the RIGHT BLACK OVAL key to increase

the value of the digit.

This parameter allows you to set the time following the

convention selected in “IDLE DISPLAY.”

* Option required

Brady X-PLUS Series User’s Guide 61

Press Display Shows Action/Explanation

IP Resolution Press the RIGHT or LEFT BLACK OVAL key to

display other choices.
Default: Dynamic

IP RESOLUTION*

IP PROTOCOLS*

IP ADDRESS*

SUBNET MASK*

DEFAULT
GATEWAY*

Selections: Dynamic, permanent
Depending on the selection, allows either the user (”permanent”)

or the server (”dynamic”) to select the IP address. For more
information, refer to ZebraNet Networking: PrintServer II
Installation and User’s Guide.

IP Protocols Press the RIGHT or LEFT BLACK OVAL key to
display other choices.

Default: All
Selections: All, gleaning only, RARP, BOOTP, DHCP,

DHCP/BOOTP

If “dynamic” was chosen in the previous parameter, this selection
determines the method(s) by which the PrintServer II will receive
the IP address from the server. For more information, refer to

ZebraNet Networking: PrintServer II Installation and User’s
Guide.

IP Address Press the LEFT BLACK OVAL key to move to the
next digit position, press the RIGHT BLACK OVAL key to increase
the value of the digit.

This parameter allows you to select the IP address if “permanent”
was chosen in “IP RESOLUTION.” (If “dynamic” was chosen, the
user cannot select the address.) For more information, refer to

ZebraNet Networking: PrintServer II Installation and User’s
Guide.

Subnet Mask Press the RIGHT or LEFT BLACK OVAL key to
display other choices.

Default: Permanent (user must set)
Selections: Dynamic (user may set, but server can assign),

permanent

This parameter selects the part of the IP address that is
considered to be part of the local network It can be reached
without going through the default gateway.

Default Gateway Press the LEFT BLACK OVAL key to move
to the next digit position, press the RIGHT BLACK OVAL key to
increase the value of the digit.

This parameter allows you to select the IP address that the
network traffic is routed through if the destination address is not
part of the local network.

* Option required

62 Brady X-PLUS Series User’s Guide

Press Display Shows Action/Explanation

Selecting the Display Language Press the RIGHT or LEFT BLACK

OVAL key to display other choices.

Default: English

LANGUAGE

You have now completed the entire configuration and calibration sequence. You may either
press the NEXT/SAVE key or the SETUP/EXIT key.

Selections: English, Spanish, French, German, Italian,

Norwegian, Portuguese, Swedish, Danish,
Spanish 2, Dutch, Finnish, Custom

This parameter allows you to change the language used on the

front panel display.

You are now back at the first parameter in the configuration

sequence.

DARKNESS

SAVE SETTINGS

PRINTER READY

NOTE: If you pressed the NEXT/SAVE key but are through

programming the printer configuration, you may press
the SETUP/EXIT key and continue with the “SAVE
SETTINGS” function.

Save Settings Press the RIGHT or LEFT BLACK OVAL key to

display other choices.

Default: Permanent

Selections: Permanent, temporary, cancel, load defaults,

load last save.

This display appears when you attempt to exit the configuration

mode.

• Permanent: Permanently saves the changes, even when printer

power is turned off.

• Temporary: Saves the changes until changed again or until

power is turned off.

• Cancel: Cancels all changes since you entered the

configuration mode except for darkness and tear-off position (if

they were changed).

• Load defaults: Loads factory defaults.

NOTE: Loading factory defaults will require calibration and

resetting the head resistor value.

• Load last save: Loads the values from the last permanent save.

Press the NEXT/SAVE key to activate the displayed choice.

You have exited the configuration and calibration sequence and

are now ready for normal printer operation

Brady X-PLUS Series User’s Guide 63

64 Brady X-PLUS Series User’s Guide

Routine Care and Adjustment

Cleaning

The following table provides a brief cleaning schedule. Specific cleaning
procedures are provided on the following pages.

Area Method Interval

Printhead Solvent*

Platen roller Solvent*

Transmissive sensor Air blow

Black mark sensor Air blow

Media path Solvent*

Ribbon sensor Air blow

Label available sensors Air blow Monthly

Tear-off/peel-off bar Solvent*

Cutter Solvent*

* Brady recommends using a solvent containing 90% isopropyl alcohol.

Direct thermal print mode:
After every roll of media (or
500’/152 m of fanfold media).

Thermal transfer print mode:
After every roll of ribbon.

As neededSnap plate Solvent*

CAUTION: Use only the cleaning agents indicated.

Brady USA, Inc. will not be responsible for any other
fluids being used on this printer.

Brady X-PLUS Series User’s Guide 65

Cleaning the Exterior

The exterior surfaces of the printer may be cleaned with a lint-free cloth.
Do not use harsh or abrasive cleaning agents or solvents. If necessary, a
mild detergent solution or desktop cleaner may be used sparingly.

Cleaning the Interior

Inspect this area after every four rolls of media. Remove any dirt and lint
from the interior of the printer using a soft bristle brush and/or vacuum
cleaner.

Cleaning the Printhead and Platen Roller

Inconsistent print quality, such as voids in the bar code or graphics, may
indicate a dirty printhead. For best results, perform the following cleaning
procedure after every roll of ribbon.

NOTE: You do not need to turn off the printer before cleaning the

printhead. If power is turned off, all label formats and images, as
well as any temporarily saved parameter settings stored in the
printer’s internal memory, will be lost. When power is turned back
on, you will need to reload these items.

To clean the printhead, refer to Figure 27 and follow these steps:

1. Open the printhead.

2. Remove the media and ribbon (if loaded).

3. Moisten an applicator tip with Brady-recommended solvent and wipe
along the print elements from end to end. (The print elements are on
the brown strip just behind the chrome strip on the printhead.) Allow a
few seconds for the solvent to evaporate.

66 Brady X-PLUS Series User’s Guide

4. Rotate the platen roller and clean thoroughly with solvent and an
applicator.

5. Brush/vacuum any accumulated paper lint and dust away from the
rollers.

6. Reload ribbon and/or media, and close and the printhead.

Printhead

lever

Printhead

Black

mark

sensor

Ribbon

sensor

Label

available

sensors

Platen

roller

Tear-off/peel-off

bar

Figure 27

Cleaning the Sensors

The media, ribbon, and label available sensors should be cleaned on a
regular basis to ensure proper operation of the printer. To locate these
sensors, refer to Figure 27, Figure 6 on page 11, and Figure 7 on page 12.
Brush/vacuum any accumulated paper lint and dust off of these sensors.

Brady X-PLUS Series User’s Guide 67

Cleaning the Snap Plate

Clean the snap plate to remove label adhesive or a label that has adhered to
the underside of the snap plate.

Refer to Figure 28.

1. Insert a small-blade screwdriver or similar tool into the loop on the left
side of the snap plate. Lift the snap plate.

CAUTION: Use care to not bend, twist, or otherwise deform the

loops!

2. Repeat step one on the right side of the snap plate.

3. Remove the snap plate from the printer.

4. Clean the snap plate with cleaning solvent and a soft cloth.

Refer to Figure 29.

5. To reinstall the snap plate, insert the two tabs on the bottom of the snap
plate into the two slots of the media pathway.

6. Slide the snap plate toward you.

7. Press down on the loops to lock the snap plate into place.

68 Brady X-PLUS Series User’s Guide

Loop

Loop

Loop

Snap

plate

Figure 28

Slot

Ta b

Loop

Slot

Ta b

Figure 29

Brady X-PLUS Series User’s Guide 69

Cleaning the Cutter Module

(For printers equipped with the optional cutter.)

If labels are not being cut properly or if the cutter jams with labels, turn off
the printer power and unplug the printer. Then, clean the stationary cutter
blade with cleaning solvent. This will remove label adhesive and/or paper
debris. If further cutter cleaning is necessary, or if the cutter continues to
perform unsatisfactorily, contact an authorized service technician.

Lubrication

CAUTION! No lubricating agents of any kind should be used on

this printer! Some commercially available lubricants
will damage the finish and the mechanical parts if
used.

Fuse Replacement

The printer uses a metric-style fuse (5 X 20 mm IEC) rated at F5A, 250V.
The end caps of the fuse must bear the certification mark of a known
international safety organization (see Figure 37 on page 92). The printer
comes with two approved fuses: one in the circuit and one in the “spare
fuse” holder.

1. Turn off the printer power and unplug the power cord from the back of
the printer. See Figure 30.

2. Using a small-blade screwdriver or similar tool, remove the fuse holder
from the printer.

3. Remove the faulty fuse and install a new fuse of the correct type. Refer
to Figure 31. The fuse that goes into the printer first is the one that is
“in-circuit.” If you use the spare fuse, be sure to order a replacement
fuse (fuses can be ordered from your Brady distributor).

70 Brady X-PLUS Series User’s Guide

4. Snap the fuse holder back into position.

5. Reconnect the power cord.

If the new fuse fails right away, the printer has an internal component
failure and must be repaired.

Fuse

holder

Small blade
screwdriver

In-circuit

fuse

Fuse

holder

AC power

entry

module

Figure 30

Spare

fuse

Figure 31

Brady X-PLUS Series User’s Guide 71

Adjustments

Toggle Positioning

Both toggles should be positioned so that they provide even pressure on the
media. The toggles are positioned by sliding them to the desired location.
On media too narrow to accommodate both toggles, position one toggle
over the center of the media and decrease the pressure on the unused toggle.
If you are using a 300X-PLUS or 600X-PLUS printer, position the toggle
over the center of the media.

NOTE: Make sure that the toggle pressure is even across the width of the

media. Otherwise, the media and/or ribbon may “drift.”

Label

available

sensors

Adjusting

nuts

Figure 32

72 Brady X-PLUS Series User’s Guide

Printhead Pressure Adjustment

This adjustment may be necessary if printing is too light on one side or if
thick media is used. Refer to Figure 32.

1. Perform the toggle positioning procedure. If the problem is solved, you
may stop here; otherwise, continue with the rest of this procedure.

2. Print some labels at 2.4"/61 mm per second (1”/25.4 mm for the
600 X-PLUS) by running the PAUSE key self test (see page 83).

3. While printing labels, lower the darkness setting until a gray level of
printing is seen.

4. Loosen the knurled (upper) locking nuts at the top of the toggle
assembly/assemblies.

5. Increase or decrease spring pressure using the knurled (lower) adjusting
nuts on the shafts of the toggle(s) until the left and right edges of
printed area are equally dark.

NOTE: Printhead life can be maximized by using the lowest pressure that

produces the desired print quality.

6. Increase darkness to the optimum level for the media being used.

7. Retighten locking nuts.

Media Sensor Position Adjustment

See “Positioning the Media Sensors” on page 10.

Brady X-PLUS Series User’s Guide 73

74 Brady X-PLUS Series User’s Guide

Troubleshooting

LED Error Conditions and Warnings

Error Condition Ribbon Out

Problem Solution

In thermal transfer mode, the ribbon is
not loaded or loaded incorrectly.

In thermal transfer mode, the ribbon
sensor is not sensing correctly loaded
ribbon.

In direct thermal mode, when ribbon is
not used:

Error Condition Paper Out

Problem Solution

The media is not loaded or loaded
incorrectly.

The media sensor is not adjusted
properly.

The printer is set for non-continuous
media, but continuous media is loaded.

The incorrect media sensor is being
used.

Load the ribbon correctly. See “Ribbon Loading” on
page 39.

Perform the media and ribbon sensor calibration (see
page 17).

Put the printer in direct thermal mode via the front
panel and remove ribbon (if loaded).

Ensure that the printer driver or software settings are
correctly set (if applicable).

Reload the media. Refer to “Roll Media Loading” on
page 27.

Check the position of the upper and lower media
sensors. See “Positioning the Media Sensors” on
page 10.

Either load the correct media or set the printer for the
correct media type via the front panel.

Ensure that the printer driver or software settings are
correctly set (if applicable).

Calibrate the printer (see page 17).

Via the front panel, check the sensor type to ensure
that the correct one is used for the media loaded. See
page 16. Calibrate the printer (see page 17).

Brady X-PLUS Series User’s Guide 75

Error Condition Head Open

Problem Solution

The printhead is not fully closed. Close the printhead.

Error Condition Head Element Bad

Problem Solution

One or more of the printhead elements
have failed the printhead element test.

If the failed elements impact your printing application,
replace the printhead. To override this error, disable
the head test count feature on the front panel by
defaulting the value to “0000.” See page 59.

Warning Ribbon In

Problem Solution

Remove the ribbon and set the printer to direct thermal

The ribbon is loaded.

mode.

Ensure that the printer driver and/or software settings
are correctly set (if applicable).

Warning Head Too Hot

Problem Solution

The printhead is over temperature.

76 Brady X-PLUS Series User’s Guide

Allow the printer to cool. Printing automatically
resumes when the printhead elements cool to an
acceptable operating temperature.

Warning Head Cold

Problem Solution

The printhead is under temperature.

Warning Cutter Jammed

Problem Solution

Cutter blade is in the media path.

Out of Memory*

Problem Solution

*There is not enough memory to
perform the function shown on the
second line of the error message.

Continue printing while the printhead reaches the
correct operating temperature. If the error remains,
the environment may be too cold for proper printing.
Relocate the printer to a warmer area.

Turn off the printer power and unplug the printer.
Inspect the cutter module for debris and clean as
needed following the cleaning instructions on page 70.

Insufficient DRAM for the label length, downloaded
fonts/graphics, and images.

Ensure that the device, such as FLASH memory or
PCMCIA card, is installed and not write protected or
full.

Ensure that the data is not directed to a device that is
not installed or available.

Brady X-PLUS Series User’s Guide 77

Print Quality Problems

General Print Quality Issues

Problem Solution

You are using an incorrect media and
ribbon combination for your application.

The printer is set at the incorrect print
speed.

The printer is set at the incorrect
darkness level.

The printhead is dirty.

There is light printing (or no printing) on
the left or right side of the label or the
printed image is not sharp.

Gray lines on blank labels with no consistent pattern

Problem Solution

The printhead is dirty.

Consult your authorized Brady reseller/distributor for
information and advice.

For optimal print quality, set the print speed to the
lowest possible setting via ZPL II, the driver, or the
software.

For optimal print quality, set the darkness to the lowest
possible setting via the front panel, the driver, or the
software.

Clean the printhead according to the instructions on
page 66.

The toggle pressure needs to be adjusted. Follow the
printhead pressure adjustment instructions on
page 73.

Clean the printhead according to the instructions on
page 66.

Light, consistent vertical lines running through all of the labels

Problem Solution

The printhead or platen roller is dirty.

Clean the printhead, platen roller, or both according to
the instructions on page 66.

Intermittent creases on the left and right edges of the labels

Problem Solution

There is too much toggle pressure on
the printhead.

78 Brady X-PLUS Series User’s Guide

Reduce the toggle pressure. Refer to the printhead
pressure adjustment on page 73.

Wrinkled Ribbon

Problem Solution

The ribbon is not loaded correctly.

The darkness setting is incorrect.

Incorrect printhead pressure or balance.

The media is not feeding correctly. It is
“walking” from side to side.

Load the ribbon correctly. See “Ribbon Loading” on
page 39.

Set the darkness to the lowest possible setting for
good print quality. See “Darkness” on page 46.

Set the pressure to the minimum required for good
print quality. See “Printhead Pressure Adjustment” on
page 73.

Make sure that the media guide and media supply
guide touch the edge of the media.

Communications

A label format was sent to the printer but not recognized. The
DATA light does not flash.

Problem Solution

Check the printer driver or software communications
settings (if applicable).

Check the printer host port setting via the front panel
(see page 53). Select the port that matches the one
being used by the host.

The communication parameters are
incorrect.

Are you using the correct communication cable? See
page 22 for the requirements.

Via the front panel, check the protocol setting. It
should be set to “none.” See page 54.

Ensure that the correct driver is being used, if
applicable.

Brady X-PLUS Series User’s Guide 79

A label format was sent to the printer. Several labels print, then the
printer skips, misplaces, misses, or distorts the image on the label.

Problem Solution

The host is set to EPP parallel
communications.

The serial communication settings are
incorrect.

Change the settings on the computer host to standard
parallel communications.

Ensure that the flow control settings match.

Check the communication cable length. See page 22
for requirements.

Check the printer driver or software communications
settings (if applicable).

A label format was sent to the printer but not recognized. The
DATA light flashes but no printing occurs.

Problem Solution

The prefix and delimeter characters set
in the printer do not match the ones in
the label format.

Incorrect data is being sent to the
printer.

Verify the prefix and delimeter characters. See
page 56.

Ensure that ZPL is being used.

Check the communication settings on the computer.
Ensure that they match the printer settings.

80 Brady X-PLUS Series User’s Guide

Printer Diagnostics

Power-On Self Test

A power-on self test (POST) is performed automatically each time the
printer is turned on. During this test sequence, the front panel lights and
liquid crystal display monitor the progress of the POST. If the printer fails
any of these tests, the word “FAILED” will be added to the display. If this
occurs, notify an authorized Brady distributor.

Additional Printer Self Tests

These self tests produce sample printouts and provide specific information
that help determine the operating conditions for the printer.

Each self test is enabled by pressing a specific front panel key or
combination of keys while turning the POWER switch on. Keep the key(s)
depressed until the DATA light turns off. When the power-on self test is
complete, the selected self test starts automatically.

NOTES: When performing self tests, avoid sending a label format to the

printer. In the case of a remote host, disconnect all data interface
cables from the printer.

When canceling a self test prior to its actual completion, always

turn the printer power off and then back on to reset the printer.

When performing these self tests while in the peel-off mode,

you must remove the labels as they become available.

If your media is not wide enough or long enough, unexpected
and/or undesired results may occur. Make sure that your print
width is set correctly for the media you are using before you
run any self tests, otherwise the test may print out on the platen
roller. See page 48 for information on setting the print width.

Brady X-PLUS Series User’s Guide 81

CANCEL Key Self Test

This self test prints a listing of the
configuration parameters currently
stored in the printer’s memory. See
Figure 33 (depending on the options
ordered, your label may look
different).

1. Turn the printer off.

2. Press and hold the CANCEL key
while turning on the power.

The configuration may be changed
either temporarily (for specific label
formats or ribbon and label stock) or
permanently (by saving the new
parameters in memory). Saving new
parameters occurs whenever a
calibration procedure is performed.
Refer to page 15 for further
information about the configuration
procedure.

Figure 33

82 Brady X-PLUS Series User’s Guide

PAUSE Key Self Test

This self test can be used to provide the test labels required when making
adjustments to the printer’s mechanical assemblies. See the sample printout
in Figure 34.

1. Turn off the printer.

2. Press and hold the PAUSE key while turning on the power.

n

The initial self test prints 15 labels at 2.4"/61 mm per second
(1”/25.4 mm for the 600X-PLUS) per second, then automatically pauses
the printer. Each time the PAUSE key is pressed, an additional 15 labels
print.

n

While the printer is paused, pressing the CANCEL key alters the self
test. Now each time the PAUSE key is pressed the printer prints 15
labels at 6"/152 mm per second (4”/102 mm for the 600X-PLUS).

n

While the printer is paused, pressing the CANCEL key again alters the
self test again. Each time the PAUSE key is pressed the printer prints 50
labels at 2.4”/61 mm per second (1”/25.4 mm for the 600X-PLUS).

n

While the printer is paused, pressing the CANCEL key again alters the
self test a third time. Now each time the PAUSE key is pressed the
printer prints 50 labels at 6”/152 mm per second (4”/102 mm for the
600X-PLUS).

n

While the printer is paused, pressing the CANCEL key again alters the
self test a fourth time. Each time the PAUSE key is pressed the printer
prints 15 labels at the printer’s maximum speed.

n

To exit this self test at any time, press and hold the CANCEL key.

Figure 34

Brady X-PLUS Series User’s Guide 83

FEED Key Self Test

See Figure 35.

1. Turn off the printer.

2. Press and hold the
FEED key while
turning on the power.

The FEED key self test
prints out at various
darkness settings above
and below that of the
darkness value shown on
the configuration label.
Look at these labels and
determine which one has
the best darkness setting
for your application. This
value can be entered into
the printer by setting the
darkness during the
configuration procedure.
Refer to page 46 for more
information.

Figure 35

The value printed on that label is added to (plus) or subtracted from (minus)
the darkness value specified on the configuration label. The resulting
numeric value (0 to 30) is the best darkness value for that specific
media/ribbon combination.

84 Brady X-PLUS Series User’s Guide

FEED Key and PAUSE Key Self Test

1. Turn off the printer.

2. Press and hold the FEED and PAUSE keys while turning on the power.

Performing this self test temporarily resets the printer configuration to the
factory default values. These values will be active only until power is
turned off unless you save them permanently in memory.

Communications Diagnostics Test

This test is controlled from the front panel display. Refer to page 55. A
typical printout from this test is shown in Figure 36. Turn off the power to
exit this self test.

NOTE: This label will be inverted when printed.

Figure 36

Additional Printer Diagnostics

Additional diagnostic tests are available for this printer, however they are
beyond the scope of this user’s guide. Refer to the maintenance manual for
information about these additional tests.

Brady X-PLUS Series User’s Guide 85

86 Brady X-PLUS Series User’s Guide

NOTE: Printer specifications are subject to change without notice.

Media Handling

n

Tear-off mode: Labels are produced in strips.

n

Peel-off mode: Labels are dispensed and peeled from the liner as
needed.

n

Cutter mode: Labels are printed and individually cut.

n

Rewind mode: Labels are rewound internally.

Options

n

Cutter

n

Rewind

n

Cutter-rewind

n

Cutter tray

n

Media supply spindle
(1.6”/40 mm core)

n

Media supply spindle
(3”/76 mm core)

n

Double-hinged media door with
clear panel

n

Applicator interface

n

Real time clock

n

Advance counter

Specifications

n

IBM twinax interface

n

IBM coax interface

n

ZebraNet PrintServer II, including
Ethernet interface (10Base-T),
WebView graphical setup and printer
control, and Alert unsolicited error
notification

n

RS-485 interface

n

Font cards

n

DRAM memory expandable to 12 MB

n

Memory cards

n

Printer drivers for Windows
operating systems

™

Brady X-PLUS Series User’s Guide 87

Zebra Programming Language (ZPL II®)

n

Downloadable graphics, scalable and
bitmap fonts, and label formats

n

Object copying between memory areas
(RAM, memory card, and internal
FLASH)

n

Code Page 850 character set

n

Adjustable print cache

n

Data compression

n

Automatic virtual input buffer
management

n

Automatic memory allocation

n

Format inversion

n

Mirror image printing

n

Four-position field rotation (0º, 90º,
180º, and 270º)

Bar Codes

n

Bar code ratios - 2:1, 7:3, 5:2, & 3:1

n

Codabar (supports ratios of 2:1 up to
3:1)

n

CODABLOCK

n

Code 11

n

Code 39 (supports ratios of 2:1 up to
3:1)

n

Code 49 (2-dimensional bar code)

n

Code 93

n

Code 128 (with subsets A, B, and C
and UCC case C codes)

n

Data Matrix

n

EAN-8, EAN-13, EAN extensions

n

Industrial 2 of 5

n

Interleaved 2 of 5 (supports ratios of
2:1 up to 3:1, Modulus 10 Check
Digit)

n

Slew command

n

Programmable quantity with print,
pause, and cut control

n

Communicates in printable ASCII
characters

n

Error-checking protocol

n

Controlled via mainframe, mini­computer, PC, portable data terminal

n

Serialized fields

n

In-spec OCR-A and OCR-B

n

UPC/EAN

n

User-programmable password

n

Status message to host upon request

n

ISBT-128

n

LOGMARS

n

MaxiCode

n

Micro PDF

n

MSI

n

PDF-417 (2-dimensional bar code)

n

Plessey

n

POSTNET

n

QR-Code

n

Standard 2 of 5

n

UPC-A, UPC-E, UPC extensions

n

Check digit calculation where
applicable

88 Brady X-PLUS Series User’s Guide

General Specifications

General Specifications 300/600X-PLUS 203X-PLUS 360X-PLUS

Height 15.5" 393.7 mm 15.5" 393.7 mm 15.5" 393.7 mm

Width 9.15" 232.4 mm 11.15" 283.2 mm 13.15" 334.4 mm

Depth 19.5" 495.3 mm 19.5" 495.3 mm 19.5" 495.3 mm

Weight (without options) 50 lb 22.7 kg 55 lb 25 kg 67 lb 30.5 kg

Electrical

Temperature

Relative
humidity

General (auto adjusting)

Printing PAUSE test

Power
consumption

Compliance

Operating
environment

Storage

Operating environment

Storage

label at
slowest speed

Printer idle 20 W 19 W 19 W

Thermal transfer

Direct thermal

90-264 VAC;

48-62 Hz

121 W 180 W 220 W

Complies with FCC class “B” and Canadian Doc. class “A” rules.

41º to

104º F

32º to
104º F

-40º
to

140º F

20 to 85%

non-condensing

5to85%

non-condensing

Carries the CE mark of compliance.

5º to

40º C

0º to

40º C

-40º
to

60º C

90-264 VAC;

48-62 Hz

41º to

104º F

32º to
104º F

-40º to
140º F

20 to 85%

non-condensing

5to85%

non-condensing

5º to

40º C

0º to

40º C

-40º
to

60º C

90-264 VAC;

48-62 Hz

41º to
104º F

32º to
104º F

-40º to
140º F

20 to 85%

non-condensing

5to85%

non-condensing

5º to

40º C

0º to

40º C

-40º
to

60º C

Brady X-PLUS Series User’s Guide 89

Printing Specifications

Printing Specifications 300X-PLUS 600X-PLUS 203X-PLUS 360X-PLUS

Resolution

Dot size (width x length)

First dot location
from inside media edge

Maximum print width 3.4” (86 mm) 3.2” (81 mm) 5.04” (128 mm) 6.6” (168 mm)

Non­continuous

Print
length
(max.)

Bar code
modulus
(“X”)
dim.

Thin-film printhead with Element
Energy Equalizer (E3)

printing

Continuous
printing

Ladder (rotated) orientation 3.9 mil to 39 mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.9 mil to 39 mil

Picket fence (non-rotated) 3.33 mil to 33 mil 1.6 mil to 16 mil 4.9 mil to 49 mil 3.33 mil to 33 mil

With standard
memory

With 12 MB
memory

With standard
memory

With 12 MB
memory

®

300 dots/inch
(12 dots/mm)

0.0033” x 0.0039”
(.084 x .100 mm)

0.12" ± .035"
(3 mm ±

.89 mm)

39” (991 mm) 20” (508 mm) 39” (991 mm) 39” (991 mm)

39” (991 mm) 39” (991 mm) 39” (991 mm) 39” (991 mm)

80” (2032 mm) 20” (508 mm) 121” (3073 mm) 41” (1041 mm)

100” (2540 mm) 52” (1321 mm) 150” (3810 mm) 100” (2540 mm)

Yes Yes Yes Yes

600 dots/inch

(23.5 dots/mm)

0.0016” x 0.0016”
(.042 x .042 mm)

0.12" ± .035"
(3 mm ±

.89 mm)

203 dots/inch

(8 dots/mm)

0.0049” x 0.0049”
(.125 x .125 mm)

0.10" ± .035"
(2.5 mm ±

.89 mm)

300 dots/inch
(12 dots/mm)

0.0033” x 0.0039”
(.084 x .100 mm)

0.10" ± .035"
(2.5 mm ±

.89 mm)

Ribbon Specification

Ribbon Specifications 300/600X-PLUS 203X-PLUS 360X-PLUS

Ribbon must be wound with the coated side out.

Ribbon width (Brady recom­mends using ribbon at least as
wide as the media to protect
the printhead from wear.)

Standard
lengths

Ribbon core inside diameter 1.0” (25.4 mm) 1.0” (25.4 mm) 1.0” (25.4 mm)

Maximum ribbon roll outside diameter 3.2” (81.3 mm) 3.2” (81.3 mm) 3.2” (81.3 mm)

2:1 media to ribbon roll ratio 984 ft. (300 m) 984 ft. (300 m) 984 ft. (300 m)

3:1 media to ribbon roll ratio 1476 ft. (450 m) 1476 ft. (450 m) 1476 ft. (450 m)

Minimum 0.79” (20 mm) 1.57” (40 mm) 2.0” (51 mm)

Maximum 3.40” (87 mm) 5.10” (130 mm) 6.7” (170 mm)

90 Brady X-PLUS Series User’s Guide

Media Specifications

Media Specifications 300/600X-PLUS 203X-PLUS 360X-PLUS

Tear-off 0.7" (18 mm) 0.7" (18 mm) 0.7" (18 mm)

Minimum label length*

Total media width
(label + liner, if any)

Total thickness
(includes liner, if any)

Cutter maximum full-width media
thickness

Roll media core inside diameter 3” (76 mm) 3” (76 mm) 3” (76 mm)

Maximum roll diameter 8.0” (203 mm) 8.0” (203 mm) 8.0” (203 mm)

Inter-label gap

Maximum internal fanfold media pack size
(label + liner)LxWxH

Ticket/tag sensing notchLxW

Ticket/tag sensing hole diameter 0.125" (3 mm) 0.125" (3 mm) 0.125" (3 mm)

Effective leading edge
registration accuracy*

Mark length
(measuring
parallel to
label/tag edge)

Mark width

Additional
specs. for
black mark
sensing

(measuring
perpendicular to
label/tag edge

Mark location Marks must be located within .040" (1 mm) of the inside media edge.

Mark density

Maximum density of the back of
the media on which the black
mark is printed

Peel-off 0.5" (13 mm) 0.5" (13 mm) 0.5" (13 mm)

Cutter 1.5" (38 mm) 1.5" (38 mm) 1.5" (38 mm)

Rewind 0.25" (6 mm) 0.25" (6 mm) 0.25" (6 mm)

Minimum 0.79" (20 mm) 1.57” (40 mm) 2.00” (51 mm)

Maximum 3.54" (90 mm) 5.51” (140 mm) 7.1” (180 mm)

Minimum 0.003” (0.076 mm) 0.003” (0.076 mm) 0.003” (0.076 mm)

Maximum 0.012” (0.305 mm) 0.012” (0.305 mm) 0.012” (0.305 mm)

.014" (.35 mm) .009" (.23 mm) .007" (.18 mm)

Minimum 0.079” (2 mm) 0.079” (2 mm) 0.079” (2 mm)

Preferred 0.118” (3 mm) 0.118” (3 mm) 0.118” (3 mm)

Maximum

Vertical ±0.060” (±1.5 mm) ±0.070” (±1.8 mm) ±0.060” (±1.5 mm)

Horizontal ±0.060” (±1.5 mm) ±0.070” (±1.8 mm) ±0.060” (±1.5 mm)

Minimum 0.12” (3 mm) 0.12” (3 mm) 0.12” (3 mm)

Maximum 0.43” (11 mm) 0.43” (11 mm) 0.43” (11 mm)

Minimum 0.43” (11 mm) 0.43” (11 mm) 0.43” (11 mm)

Maximum Full media width Full media width Full media width

2 x (label length for which you have calibrated the printer) + 1”

8.0” x 3.54” x 4.5”
(203x90x114 mm)

0.12" x .25"

(3 mm) x (6 mm)

> 1.0 ODU

(Optical Density Unit)

0.5 ODU 0.5 ODU 0.5 ODU

Maximum inter-label gap =

8.0” x 5.51” x 4.5”

(203x140x114 mm)

0.12" x .25"

(3 mm) x (6 mm)

> 1.0 ODU

(Optical Density Unit)

8.0” x 7.1” x 4.5”

(203x180x114 mm)

0.12" x .25"

(3 mm) x (6 mm)

> 1.0 ODU

(Optical Density Unit)

* Media registration and minimum label length are affected by media type and width, ribbon type,

print speed, and printer mode of operation. Performance improves as these factors are optimized.
Brady recommends always qualifying any application with thorough testing.

Brady X-PLUS Series User’s Guide 91

Power Line Cord Specifications

n

The overall length must be less than 9.8 feet (3.0 meters).

n

It must be rated for at least 5 A, 250 V.

n

The chassis ground (earth) MUST be connected to assure safety and
reduce electromagnetic interference. The ground connection is handled
by the third wire (earth) in the power line cord. See Figure 37.

n

The AC power plug and IEC 320 connector must bear the certification
mark of at least one of the known international safety organizations
shown in Figure 38.

AC power

your country

R

plug for

+

3 conductor

<HAR> cable

Figure 37

Figure 38

IEC 320

connector

Contact

view

Neutral

Earth

Live

92 Brady X-PLUS Series User’s Guide