Microcom 438 User Manual

MODEL 438

DIRECT THERMAL PRINTER

OPERATOR’S MANUAL

PART NUMBER 880052-0100

Revised: August 19, 2014 CPC

Copyright © 2014 by Microcom Corporation, Lewis Center, Ohio – All rights reserved.

Proprietary Statement

This manual contains information proprietary to Microcom Corporation. This information is
intended solely for the use of parties operating and maintaining such equipment described
herein.

Product Enhancements

Microcom Corporation is committed to the continual improvement of performance and
quality in our products. For this reason, specifications are subject to change without notice.

Liability Disclaimer

Microcom Corporation makes every effort to assure that all information and specifications
contained in this manual are accurate; however, mistakes are sometimes made. Microcom
Corporation shall not be liable for any damages resulting in the use or misuse of this
product. The exclusion or limitation involving consequential or incidental damage does not
apply to all states; therefore limitation mentioned above may or may not apply.

FCC Compliance Statement

This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if not installed and used in accordance with the instructions contained in this
manual, may cause harmful interference to radio communications.

HyperTerminal® and HyperAccess® are trademarks of Hilgraeve Inc.
Centronics

®

is a registered trademark of Data Computer Corporation.

HP® and LaserJet II® are trademarks of Hewlett-Packard Company.
Arial® is a registered trademark of The Monotype Corporation.
TrueType® is a registered trademark of Apple Computer, Inc.
Microsoft®, Windows®, Windows NT® are registered trademarks of Microsoft Corporation.
Other products and company names mentioned herein may be trademarks of their
respective owners.

Table of Contents

INTRODUCTION ...........................................................................................VII

CHAPTER 1:......................................................................... PRINTER SPECIFICATIONS

..................................................................................................................... 1-1

1.1 General Specifications ......................................................................................... 1-1

1.2 Printing Specifications.......................................................................................... 1-1

1.3 Media Specifications ............................................................................................ 1-2

CHAPTER 2: FEATURES AND OPTIONS ................................................ 2-1

2.1 Fonts .................................................................................................................... 2-1

2.2 Graphics............................................................................................................... 2-1

2.3 Bar codes............................................................................................................. 2-1

2.4 Special Features .................................................................................................. 2-2

2.5 Options................................................................................................................. 2-2

CHAPTER 3: GETTING STARTED............................................................ 3-1

3.1 Unpacking and Inspection.................................................................................... 3-1

3.2 Connecting the Printer ......................................................................................... 3-1

3.2.1 Printer Power ................................................................................................ 3-2

3.2.2 RS232 Serial Communication Interface ........................................................ 3-3

3.2.2.1 RS-232 Serial Cables ............................................................................ 3-3

3.2.3 USB Communication Interface...................................................................... 3-4

3.2.4 Optional Ethernet Communication Interface ................................................. 3-4

3.2.5 Optional Cutter Interface............................................................................... 3-4

3.3 Loading Media ..................................................................................................... 3-4

3.4 Print Button and Status Indicator Light................................................................. 3-5

3.4.1 Print Button ................................................................................................... 3-6

3.4.2 Status Indicator Light .................................................................................... 3-7

3.5 Printer Modes....................................................................................................... 3-7

3.5.1 Idle Mode: GREEN ...................................................................................... 3-7

3.5.2 Halted Mode: RED ....................................................................................... 3-8

3.5.2.1 Steps to clear the >STOCK OUT< error ............................................... 3-8

3.5.2.2 Steps to clear the >STOCK OUT< error with “E-Z Out function”............ 3-8

3.5.2.3 Automatic Stock Eject on >STOCK OUT<............................................. 3-8

3.5.3 Paused Mode: Solid or Flashing AMBER .................................................... 3-8

3.5.4 Diagnostic Mode ........................................................................................... 3-8

3.5.4.1 Entering Diagnostic Mode...................................................................... 3-9

3.5.4.2 Statistics Label....................................................................................... 3-9

CHAPTER 4: DESIGNING LABELS USING LDS...................................... 4-1

4.1 Control Characters ............................................................................................... 4-1

4.2 LDS Design Exercises ......................................................................................... 4-1

4.2.1 PC Connection (Serial) ................................................................................. 4-1

4.2.2 Format Creation ............................................................................................ 4-2

4.3 Label Design: An Overview.................................................................................. 4-3

438 Operator’s Manual - 880052-0100 i

4.4 Label Header........................................................................................................ 4-4

4.4.1 HFM (Number of Fields in Layout) ................................................................4-6

4.4.2 LSX (Print Head Size X)................................................................................ 4-6

4.4.3 LSY (Label Size Y)........................................................................................ 4-6

4.4.4 WEB (Web Size) ...........................................................................................4-6

4.4.5 GAP (GAP Size)............................................................................................ 4-6

4.4.6 DPS (Print Speed)......................................................................................... 4-6

4.4.7 LCB (Label Control Byte) .............................................................................. 4-7

4.4.7.1 Die-Cut and Blow-Hole Media (setting = 0) ............................................ 4-7

4.4.7.2 Continuous Media (setting = 2) .............................................................. 4-8

4.4.7.3 Black Line Media (Reflective) (setting = 3)............................................ 4-8

4.4.8 AGD (Activate Gap Detector)........................................................................ 4-8

4.4.9 SPG (Steps Past Gap).................................................................................. 4-8

4.4.10 OFX (Offset X Direction) ............................................................................. 4-10

4.4.11 OFY (Offset Y Direction) ............................................................................. 4-10

4.5 Sample Header .................................................................................................. 4-10

4.6 Label Format Fields............................................................................................4-10

4.6.1 TSN (Text String Number).......................................................................... 4-11

4.6.2 XB (X Beginning Coordinate) ......................................................................4-12

4.6.3 YB (Y Beginning Coordinate) ......................................................................4-12

4.6.4 CC (Character Count) .................................................................................4-12

4.6.5 TCI (Text Conversion Identifier).................................................................. 4-12

4.6.6 CGN (Character Generator Number) ..........................................................4-13

4.6.6.1 Embedded Fonts.................................................................................. 4-14

4.6.6.2 Downloadable Fonts and Graphics ...................................................... 4-14

4.6.6.3 Embedded Bar Codes.......................................................................... 4-15

4.6.7 FO (Field Orientation) ................................................................................. 4-16

4.6.8 FJ (Field Justification) ................................................................................4-16

4.6.9 CMX (Character Multiplier X Direction) ....................................................... 4-17

4.6.10 CMY (Character Multiplier Y Direction) ....................................................... 4-17

4.6.11 CS (Character Spacing) .............................................................................. 4-17

4.6.12 TSP (Text Starting Position)........................................................................4-18

4.6.13 ,,, (Reserved Spaces) ................................................................................ 4-18

4.6.14 AN (Attribute Number)................................................................................. 4-18

4.7 Line Draw ...........................................................................................................4-18

4.8 Reverse Video.................................................................................................... 4-20

4.8.1 Reverse Video............................................................................................. 4-20

4.8.2 True Reverse Video .................................................................................... 4-21

CHAPTER 5 PRINTER COMMANDS........................................................5-1

5.1 Special Printer Control Codes ..............................................................................5-1

5.1.1 Enquiry Responses....................................................................................... 5-3

5.2 Printer Configuration Commands .........................................................................5-5

5.2.1 Software Switches......................................................................................... 5-5

5.2.1.1 Software Switch #1 ................................................................................ 5-5

5.2.1.2 Software Switch #2 ................................................................................ 5-6

5.2.1.3 Software Switch #3 ................................................................................ 5-7

5.2.1.4 Software Switch #4 ................................................................................ 5-8

5.2.1.5 Software Switch #5 ................................................................................ 5-9

5.2.1.6 Software Switch #6 .............................................................................. 5-11

ii 438 Operator’s Manual - 880052-0100

5.2.1.7 Software Switch #7.............................................................................. 5-17

5.2.1.8 Software Switch #8.............................................................................. 5-18

5.2.2 Communication Port Configuration ............................................................. 5-20

5.2.2.1 Baud Rate............................................................................................ 5-20

5.2.2.2 Set Serial Port Source Command (Non-volatile- ^D108)..................... 5-21

5.2.2.3 Set Serial Port Source Command (Volatile - ^D109) ........................... 5-21

5.2.2.4 Ethernet Telnet Pass-Through Mode................................................... 5-21

5.2.3 Print Head Size Commands........................................................................ 5-23

5.3 General Purpose I/O .......................................................................................... 5-24

5.4 Specialized Print Modes..................................................................................... 5-26

5.4.1 Synchronous Print Mode............................................................................. 5-26

5.4.2 USB Image Print Mode ............................................................................... 5-27

5.4.3 Contrast Adjustment Commands ................................................................ 5-28

5.4.3.1 Adjust Contrast Window (Volatile - ^D35)............................................ 5-28

5.4.3.2 Adjust Contrast Base (Non-volatile - ^D36) ......................................... 5-28

5.4.4 Slice Buffer Size and Set Starting Slice Number Commands ..................... 5-29

5.4.5 Printer Restart / Reboot Commands........................................................... 5-29

5.4.6 Registration Commands ............................................................................. 5-30

5.4.7 Auto-size Commands.................................................................................. 5-31

5.4.8 AutoHeader Commands ............................................................................. 5-32

5.5 AutoLoad Media Commands.............................................................................. 5-33

5.5.1 AutoLoad + Form Feed............................................................................... 5-33

5.5.2 AutoLoad + Top-Of-Form............................................................................ 5-34

5.6 Printing Commands............................................................................................ 5-36

5.6.1 Basic Printing Commands........................................................................... 5-36

5.7 Label Header Parameter Override Commands.................................................. 5-37

5.7.1 Serial Number Commands.......................................................................... 5-37

5.8 Text String Commands ...................................................................................... 5-39

5.9 Cutter Configuration Commands........................................................................ 5-41

5.9.1 Cutter Type ................................................................................................. 5-41

5.9.2 Kiosk Cutter Commands ............................................................................. 5-41

5.9.2.1 Kiosk Cutter Mode ............................................................................... 5-41

5.9.2.2 Kiosk Cutter Advance Distance Command.......................................... 5-42

5.9.3 Volatile Cutter Operation............................................................................. 5-42

5.9.4 Cutter Hold-off............................................................................................. 5-43

5.10 Dispensing Commands ...................................................................................... 5-43

5.10.1 Tag/Tear Operation..................................................................................... 5-44

5.10.2 Peel-and-Dispense Operation..................................................................... 5-44

5.10.3 Load Advance/Retract Distance and Load Advance Delay......................... 5-44

5.11 View Printer Configuration and Statistics ........................................................... 5-44

5.12 Memory Commands........................................................................................... 5-45

5.13 Printer Code Update .......................................................................................... 5-50

5.14 Miscellaneous Commands ................................................................................. 5-51

CHAPTER 6: DOWNLOADABLE GRAPHICS........................................... 6-1

6.1 FLASH Data Types .............................................................................................. 6-1

6.2 RAM Data Types.................................................................................................. 6-1

6.3 Using the BMP2MIC.exe GRAPHIC Conversion Utility ........................................ 6-1

6.3.1 BMP2MIC.exe GRAPHIC Conversion Utility Procedure ............................... 6-2

6.4 Graphic Download Methods................................................................................. 6-3

438 Operator’s Manual - 880052-0100 iii

6.4.1 Uncompressed Graphic Downloads.............................................................. 6-3

6.4.2 Compressed Binary GRAPHIC Downloads................................................... 6-3

6.5 Advanced GRAPHIC Format Conversion for Programmers................................. 6-3

6.5.1 Save Compressed Graphics to RAM (D107).................................................6-4

6.5.2 Save Compressed Graphics to FLASH (D133) .............................................6-4

6.5.3 Binary Compression Algorithm...................................................................... 6-5

6.5.4 Uncompressed FONT to RAM (^D104)......................................................... 6-6

6.6 Graphic Image Data Format................................................................................. 6-7

6.7 Downloadable Graphics Commands .................................................................... 6-8

CHAPTER 7: DOWNLOADABLE FONTS ..................................................7-1

7.1 FLASH Data Types ..............................................................................................7-1

7.2 RAM Data Types ..................................................................................................7-1

7.3 Using the Font Conversion Utilities ...................................................................... 7-1

7.3.1 SFP2MIC.exe Program ................................................................................. 7-2

7.3.2 FONTCV16.exe Program ..............................................................................7-2

7.4 Font Download Methods ...................................................................................... 7-2

7.4.1 Compressed Binary Commands ...................................................................7-2

7.4.1.1 Save Compressed FONT to RAM (D127).............................................. 7-3

7.4.1.2 Save Compressed FONT to FLASH (D135) .......................................... 7-3

7.4.2 Uncompressed FONT to RAM (^D104)......................................................... 7-3

7.4.3 Save FONTS to FLASH (^D135)................................................................... 7-4

7.5 Font Structure....................................................................................................... 7-5

7.6 Downloadable Font Command Summary............................................................. 7-7

CHAPTER 8: BAR CODES ........................................................................8-1

8.1 Types of Bar Codes..............................................................................................8-1

8.1.1 Universal Product Code – Version A (UPC-A), TCI 12.................................. 8-1

8.1.2 Universal Product Code – Version E (UPC-E), TCI 13..................................8-1

8.1.3 Universal Product Code (UPC-E, send 6 digits), TCI 14............................... 8-2

8.1.4 Interleaved 2 of 5 (I2 of 5), TCI 15 ................................................................ 8-2

8.1.5 Code 3 of 9 (Code39), TCI 16 .......................................................................8-2

8.1.6 European Article Numbering System 13 (EAN-13), TCI 20...........................8-3

8.1.7 European Article Numbering System 8 (EAN-8), TCI 21............................... 8-3

8.1.8 Modified Plessey (MSI 1), TCI 24.................................................................. 8-3

8.1.9 Modified Plessey (MSI 2), TCI 25.................................................................. 8-3

8.1.10 Modified Plessey (MSI 3), TCI 26.................................................................. 8-3

8.1.11 GS1 Databar, TCI 35 ....................................................................................8-3

8.1.11.1 GS1 Databar Omni-Directional ..............................................................8-4

8.1.11.2 GS1 Databar Truncated......................................................................... 8-4

8.1.11.3 GS1 Databar Stacked ............................................................................8-4

8.1.11.4 GS1 Databar Stacked Omni-directional .................................................8-4

8.1.11.5 GS1 Databar Limited..............................................................................8-5

8.1.11.6 GS1 Databar Expanded......................................................................... 8-5

8.1.11.7 How to Print an GS1 Databar Barcode .................................................. 8-5

8.1.12 Postnet (ZIP+4), TCI 36 ................................................................................ 8-6

8.1.13 Postnet (ZIP+6), TCI 37 ................................................................................ 8-7

8.1.14 MaxiCode, TCI 38 ......................................................................................... 8-7

8.1.15 Code 128 (Automatic Compression), TCI 40................................................. 8-9

iv 438 Operator’s Manual - 880052-0100

8.1.16 Code 128 (Manual Compression), TCI 41 .................................................. 8-10

8.1.17 Codabar (Rationalized), TCI 42 .................................................................. 8-11

8.1.18 Code 93, TCI 43.......................................................................................... 8-11

8.1.19 PDF-417, TCI 46......................................................................................... 8-11

8.1.20 Datamatrix, TCI 47 ...................................................................................... 8-14

8.1.21 Intelligent Mail Barcode, TCI 48.................................................................. 8-19

8.1.22 Planet Code, TCI 49 ................................................................................... 8-21

8.1.23 UCC/EAN 128, TCI 50 ................................................................................ 8-22

8.1.24 UCC/EAN Text Information, TCI 51 ............................................................ 8-26

8.2 Bar Code Rotation ............................................................................................. 8-26

8.3 Bar Code Human Readable Text ....................................................................... 8-27

CHAPTER 9 CODE PAGE SWITCHING................................................... 9-1

9.1 What is Code Page Switching?............................................................................ 9-1

9.2 Character Sets ..................................................................................................... 9-1

9.3 Code Pages ......................................................................................................... 9-1

9.3.1 Code Pages .................................................................................................. 9-2

9.3.2 Danish Code Page........................................................................................ 9-3

9.3.3 860 Code Page............................................................................................. 9-4

9.3.4 Spanish Code Page...................................................................................... 9-5

9.3.5 850 Code Page............................................................................................. 9-6

9.3.6 German Code Page...................................................................................... 9-7

9.3.7 865 Code Page............................................................................................. 9-8

9.3.8 Swiss Code Page.......................................................................................... 9-9

9.3.9 852 Code Page........................................................................................... 9-10

9.3.10 French Code Page...................................................................................... 9-11

9.3.11 863 Code Page........................................................................................... 9-12

9.3.12 Swedish Code Page ................................................................................... 9-13

9.3.13 437 Code Page........................................................................................... 9-14

9.3.14 Italian Code Page ....................................................................................... 9-15

9.3.15 British Code Page....................................................................................... 9-16

9.3.16 USA Code Page.......................................................................................... 9-17

CHAPTER 10 PRINTER MAINTENANCE................................................ 10-1

10.1 Maintenance Schedule....................................................................................... 10-1

10.2 Thermal Printer Card.......................................................................................... 10-1

10.3 Internal Cleaning................................................................................................ 10-4

10.4 Print head Maintenance ..................................................................................... 10-5

10.5 Cleaning the Drive Roller ................................................................................... 10-6

10.6 Exterior Cleaning ............................................................................................... 10-6

CHAPTER 11: TROUBLESHOOTING ..................................................... 11-1

11.1 Troubleshooting Tips.......................................................................................... 11-1

INDEX ....................................................................................................... 12-1

General Index........................................................................................................ 12-1

List of Figures........................................................................................................ 12-7

List of Tables ......................................................................................................... 12-9

438 Operator’s Manual - 880052-0100 v

APPENDIX.................................................................................................13-1

Appendix A: Limited Warranty.................................................................................. 13-1

Appendix B: RMA Procedure ................................................................................... 13-3

Appendix C: ^D Command Summary .......................................................................13-5

Glossary...................................................................................................................... 13-23

Appendix D: User Notes ......................................................................................... 13-27

vi 438 Operator’s Manual - 880052-0100

Introduction

This manual covers the 438 printer. The 438 printer uses a 4.1 inch (104mm) print head.
Both printers are offered with a standard resolution of either 203 dpi (8 dots/mm) or an
optional 300 dpi (12 dots/mm).

Figure 1-1 Printer Models

438 Operator’s Manual - 880052-0100 vii

Chapter 1: Printer Specifications

1.1 General Specifications

224* 424*
Width* 6.5” (165 mm) 8.5” (216 mm)
Height* 6.9” (175 mm) 6.9” (175 mm)
Depth* 4.8” (122 mm) 4.8” (122 mm)
Weight* 7.1 lbs. (3.2 kg) 7.8 lbs. (3.5 kg)
Electrical Voltage: Auto-sensing; 100–240 VAC; 50–60 Hz
Current 4 Amps maximum
Temperature 40 – 104° F (5 – 40° C), operating
Humidity 10 – 85%, non-condensing
SRAM Memory 512 K
Code Flash Memory 512 K
User Flash Memory 8 MB
Agency Approvals Designed to meet CUL, CE, and FCC Class A

Interface Communications

Flow Control XON, XOFF, and CTS
Baud Rate 110 to 115200
Parity Odd, Even, and None
Data Bits 7 or 8
Protocols TCP/IP

* NOTE: Listed specifications are based on a standard print mechanism and may vary

Table 1-1 General Specifications

RS-232 (9 pin D-Sub connector (DCE)), USB (version

1.1 supported), and optional 10/100BASE-T Ethernet

based on final configuration.

1.2 Printing Specifications

Print Type Direct Thermal

Print Resolution

Maximum Print Speed 8”/sec. (203 mm/sec.)

Maximum Print Width

Maximum Print Length 50” (1,270 mm) with 203 dpi

Table 1-2 Printing Specifications

438 Operator’s Manual - 880052-0100 1-1

203 DPI (8 dots/mm = 0.0049” per dot)
300 DPI (12 dots/mm = 0.0032” per dot)

224 - 203DPI = 2.1” (53 mm)
424 - 203DPI = 4.098” (104 mm)

Printer Specifications Chapter 1

1.3 Media Specifications

Media Types

Maximum Media Thickness .0075” (.19 mm)*

Maximum Media Width

Continuous, die-cut, preprinted and tag stock either rolled
or fanfold

224 = 2.5” (63.5 mm)**
424 = 4.5” (114.3 mm)***

Table 1-3 Media Specifications

*NOTE: The printers may print on thicker media types depending on the pliability of the
material; however, this requires testing and evaluation. Contact your authorized Microcom
Corporation representative for additional information regarding testing and evaluation of
thicker or rigid media types.

**NOTE: The 224 printer’s media path has a maximum width of 2.5” while the actual
printable width is 2.1” for the 203 DPI print head.

***NOTE: The 424 printer’s media path has a maximum width of 4.5” while the actual
printable width is 4.095” for the 203 DPI print head.

The printers may be optimally configured with fixed media guides to assist in the installation
of media.

1-2 438 Operator’s Manual - 880052-0100

2.1 Fonts

 7 resident fonts including OCR-A and OCR-B.

 Downloadable font support.

 All bitmapped fonts expandable in height and width.

 Rotated: 0 º, 90 º, 180 º, and 270 º.

2.2 Graphics

 Resident Lines feature.

 Storage of fonts, label formats and graphics in both volatile RAM and non-

Chapter 2: Features and Options

volatile FLASH memory.

 All BMP files may be converted using a Microcom utility program.

 Rotated: 0 º, 90 º, 180 º, and 270 º.

2.3 Bar codes

 One-dimensional

 Code 39

 Interleaved 2 of 5

 Code 128 (A, B, C and

Auto)

 Code 93

 Codabar

 Modified Plessey

 UPC-A

 UPC-E

 EAN 8

 EAN 13

 UCC/EAN 128

 Postnet

 Two-dimensional

 GS1 Databar

Omni-directional

Truncated

Stacked

Stacked

Omni directional

Limited

Expanded

 PDF-417
 Maxicode.

 Rotated: 0 º, 90 º, 180 º, and

270 º.

 Expandable in height and

width.

438 Operator’s Manual - 880052-0100 2-1

Features and Options Chapter 2

2.4 Special Features

 3 Serial Data inputs

 RS-232D, up to 115,200 baud

 USB 1.1

 Rotating head mechanism for easy print head cleaning

 Adjustable media guides for easy label centering or custom fixed guide

brackets

 Software controlled contrast adjustment

 Detects label gap, black line, and blow-hole using reflective and

transmissive sensors

 Field incrementing, decrementing, and serialization

 Downloadable fonts and graphics (with data compression)

 Internal statistical counters for inches and labels printed

 Remote printer interrogation

 On-site programmable flash memory updates

 Supports 203 dpi and 300 dpi print heads

 Automatic stock eject on paper-out

2.5 Options

 Cutter – Full and partial

 Label Present Detector (LPD) reflective sensor with indicator light and

 10/100BASE-T Ethernet communications port

 Catch Tray

 External label roll rack (8” O.D. max)

 Cleaning kit

adjustable range

2-2 438 Operator’s Manual - 880052-0100

Chapter 3: Getting Started

3.1 Unpacking and Inspection

The printer has been packaged in protective foam to help reduce the damage during
shipment. Inspect the shipping container(s) for signs of damage. If damage is evident,
contact the shipping company immediately to file a damage claim.

After the printer is removed from the container(s), verify that all the items on the packing list
are present and in good condition. The picture below (See Figure 3-1) shows a 424 printer,
operator's manual, and optional power cord. Your shipment may contain different items.

The foam and shipping container(s) should be kept and used if the printer is to be shipped
at a later time. Additional shipping materials can be ordered by contacting the Microcom
Corporation Service Department.

Figure 3-1 Typical Printer Accessories

3.2 Connecting the Printer

The printer’s may be interfaced to PC’s, mini-computers, main frames, and special purpose
machines using the available communications ports described in the following sections.

438 Operator’s Manual - 880052-0100 3-1

Getting Started Chapter 3

3.2.1 Printer Power

The 438 printer has a universal auto-sensing internal power supply that operates in the 100­240 VAC; 50-60 Hertz range. The three-prong female end of the power cord plugs into the
mating connector located on the back of the printer.

Figure 3-2 AC Power Connection

Note: Verify that printer’s ON/OFF switch is switched to OFF before the power cord into an

electrical outlet.

Plug the printer in and turn the power switch “ON.” Once powered up, the Front Panel LED

should be solid green.

Front Panel
and LED
(Status Light)

Figure 3-3 Front Panel LED

On/Off Switch

AC Power Connection

3-2 438 Operator’s Manual - 880052-0100

Chapter 3 Getting Started

3.2.2 RS232 Serial Communication Interface

The printer provides a 9-pin female D-Sub connector, on the rear panel, for RS-232D serial
communication. The printer is configured as DCE (Data Circuit-terminating Equipment) so a
NULL modem cable is not necessary. A serial data cable is required to use serial
communications, refer to Table 3-1 below for correct cable configurations.

The factory settings, unless otherwise requested, are set at 115200 baud, 8 data bits, 1 stop
bit and no parity with both hardware and software handshaking enabled. The baud rate is
user selectable from 110 to 115,200 and uses software XON/XOFF flow control and/or
hardware CTS handshaking.

If XON/XOFF handshaking is used, the only signals that the printer requires are the RXD,
TXD, and GND signals. If the hardware handshaking is used, then the CTS and RTS signals
are required. The other signals are offered in the event that the host computer would
require them.

3.2.2.1 RS-232 Serial Cables

The printer uses a standard through serial cable, typically referred to as a modem cable,
which may be purchased through Microcom Corporation or a local computer supply
company. A NULL-modem cable is not required because the printer is configured as DCE.

For a 25-pin serial communication port – Use a 25-pin female to 9-pin male cable.

For a 9-pin serial communication port – Use a 9-pin female to 9-pin male cable.

9 to 9 Pin Cable 9 to 25 Pin Cable

DE-9

State

XX 1 DCD

XX 2 TXD

XX 3 RXD

HI 4 DTR

LO 5 GND

HI 6 DSR

DC 7 RTS

XX 8 CTS

HI 9 +5V

Pin #

Signals /

Directions

PC

DE-9

Pin #

DCD

RXD 2 XX 2 TXD

TXD 3 XX 3 RXD

DSR 4 HI 4 DTR

GND

DTR 6 HI 6 DSR

CTS 7 DC 7 RTS

RTS 8 XX 8 CTS

+5V 9 HI 9 +5V -

1 HI 1 DCD

5 LO 5 GND

State

DE-9
Pin #

Signals /

Directions

DCD 8

RXD 3

TXD 2

DSR 20

GND 7

DTR 6

CTS 4

RTS 5

PC

DB-25

Pin #

DC = DO NOT CARE XX = INDETERMINATE

Table 3-1 RS-232 Cable Configurations

CAUTION: Connection of a serial port to a parallel port may
result in damage to the printer and/or computer.

438 Operator’s Manual - 880052-0100 3-3

Getting Started Chapter 3

3.2.3 USB Communication Interface

A standard USB 1.1 connector is provided on the rear panel of the printer. The USB port
operates as a virtual serial communications port and requires the installation of the
Microcom Corporation supplied USB driver for proper operation. The USB cable must be
connected to a host PC that is already powered on before the printer is turned on. The
^D108 command is used to select the USB port and requires a power cycle to take affect.

3.2.4 Optional Ethernet Communication Interface

The Model 224 and 424 printers provide an optional 10/100BASE-T Ethernet connector on
the rear panel of the printer. The ^D108 command is used to select the Ethernet port at
power-up.

3.2.5 Optional Cutter Interface

The printer is fitted with a connector on the rear panel for the optional cutter interface. Use
this connector when a cutter is to be installed on the printer. To prevent damage to the
printer and/or cutter, connect the cutter when the printer power is off. The cutter type is set
by the user using the ^D115 command and will be reported on the Statistics Label.

3.3 Loading Media

The easy- to-release print head makes loading media into the Model 438 printer an easy
process. Follow the instructions below to properly load the media.

1. Feed the media into the paper path, located on the back of the printer, until you feel
resistance.

2. Push and hold the Print Button to feed the media through the printer.

3. Once the media exits the front of the printer, release the Print Button.

The printer is also equipped with an Auto-Load feature. This feature allows the printer to
automatically sense new media as it is inserted into the printer, and automatically feed the
media to provide proper registration of the first label/tag to either the leading edge or a
registration mark. For more details on this feature, please refer to Chapter 5, Auto-Load
Commands.

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Figure 3-4 Loading Media

3.4 Print Button and Status Indicator Light

The Print Button and the Status Indicator Light are used to identify and perform many
functions. This section provides a description to familiarize you with the basic function of
the Print Button and the Status Indicator Light.

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Front Panel
and LED
(Status Light)

Figure 3-5 Print Button and Status Indicator Light

3.4.1 Print Button

Operation Description

Press the Print Button while the printer is IDLE or PAUSED to

Printing a label

reprint the last label.
A power up label will print after a power ON cycle when the Print
Button is pressed.

Pause printing

Feeding labels

(Line feed)

Press the Print Button briefly while the printer is printing to enter
the PAUSED mode.
Press the Print Button again to continue printing.

Press & hold the Print Button while the printer is IDLE to advance
label media. The printer will continue advancing label media until
the Print Button is released.

Table 3-2 Print Button Description

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3.4.2 Status Indicator Light

Light Color Description

Solid Green

Solid Red

Solid Amber

Flashing Red

Indicates that the power is on and the printer is in a ready state.

Indicates an error has occurred. The printer will remain in this
state until the condition is removed. If an unexplained error
persists, contact your Service Representative.

The printer is in the Tag/Tear or Peel-and-Dispense mode and is
waiting for the label/tag to be taken.
OR
Indicates that the printer is in the Boot Loader mode (MCB) and is
not running the printer application program.

A cutter error has occurred.
OR
A memory download operation was not successful.
OR
Power Spike or low voltage on the AC line. (The printer will
remain in this mode until the condition is removed and the printer
power is cycled.)

Flashing Amber Printer is PAUSED,

Table 3-3 Status Indicator Light Description

3.5 Printer Modes

The printer has four primary modes of operation. The different types of modes have an
impact on how the Print Button and the Status Indicator Light operate. This section is
intended to provide the user with an explanation of these different modes.

3.5.1 Idle Mode: GREEN

The printer is in the IDLE Mode when it is not printing and/or has no pending activity. The
indicator light is GREEN, which indicates that the printer is ready to receive label formats
and/or commands.

In IDLE Mode the Print Button has several different functions:

a) Pressing the button quickly will reprint the last label
b) If the printer was just turned ON and no formats were sent to the

printer, pressing quickly will print the power-up label,

c) Holding the button depressed: Form Feed labels until the button is

released.

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3.5.2 Halted Mode: RED

The printer is in the HALTED Mode when it has stopped due to an error condition. The
Status Indicator Light will be solid red in color when the printer has entered the HALTED
Mode. The printer will remain in this mode until the error has been corrected and cleared.
Once the error has been cleared, the printer will attempt to execute the previous format
and/or commands.

3.5.2.1 Steps to clear the >STOCK OUT< error

a) Load new label media.
b) Press the Print Button quickly to start printing.
c) Press the Print Button until label is properly registering on media.
d) Press the Print Button again during printing to resume batch printing.

3.5.2.2 Steps to clear the >STOCK OUT< error with “E-Z Out function”

If Soft Switch #5, Bit #1 is set to “1”, then a single quick press of the Print
Button will clear the >STOCK OUT< error once the printer has more label
media loaded.

3.5.2.3 Automatic Stock Eject on >STOCK OUT<

The printer performs an Automatic Stock Eject operation whenever it runs out
of label media. As soon as the >STOCK OUT< condition is detected, the
printer feeds the label media forward to clear the drive roller.

The feed distance is just enough to eject the last of the label media past the
drive roller and then stop. This happens automatically, the user doesn’t have
to hit the Print Button.

3.5.3 Paused Mode: Solid or Flashing AMBER

There are several ways that the operator can control the output of the printer. The printer
will display either solid or flashing AMBER depending upon the mode of operation. Also,
the printer will display a solid AMBER during a FLASH operation.

Solid AMBER A printed tag/label is waiting to be taken by the operator when the

printer is in a Tag/Tear (^D97) or Peel-and-Dispense (^D98) mode.

The printer is in the FLASH mode.

Flashing AMBER Pressing the Print Button during tag/label printing will pause printing. It

will resume printing by pressing the Print Button again.

3.5.4 Diagnostic Mode

The Diagnostic Mode temporarily powers up the printer using factory default parameters.
Also, the printer’s current user configuration parameters and statistical information are
printed out on a Status Label. This provides useful information to help diagnose and
troubleshoot problems. The printer will use the factory default parameters until the printer
has been reset using a soft reset or by cycling power. The printer will then return to the
configuration shown on the Status Label.

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3.5.4.1 Entering Diagnostic Mode

To enter the Diagnostic Mode, press and hold the Print Button “IN” while turning the printer
“ON.” Release the Print Button after printer begins to print the Status Label. The printer will
enter the DIAGNOSTICS Mode, and print the Statistics label and a print test pattern.

In the DIAGNOSTICS Mode, the printer is forced to use the RS-232 port at 115,200 baud.
The normal Soft Switch settings are ignored, and factory default settings are loaded into the
printer. These default settings will remain in effect until the printer power is cycled or a Soft
RESET command is issued (^D32). These are the only 2 ways to get out of the
DIAGNOSTICS mode.

3.5.4.2 Statistics Label

The Statistics Label may be printed either by entering the DIAGNOSTICS Mode or sending
the Printing Statistics Command.

PRINTER SERIAL #: 00516645051

PRINTED LABELS: 303

PRINTED INCHES: 1533

TOTAL INCHES: 1571

POWER ON HOURS: 32.8

CUTTER TYPE: Guillotine

CUTTER ENABLED?: YES

CUTTER COUNTS: 1789

KIOSK CUT MODE: Disabled

KIOSK DISTANCE: 0
SWITCH BANK 1: 10001010
SWITCH BANK 2: 01010001
SWITCH BANK 3: 00000000
SWITCH BANK 4: 00000000
SWITCH BANK 5: 00000000
SWITCH BANK 6: 00000001

CURRENT COMM PORT: Autoselect USB/RS232

RS232 PARAMETERS: 115200-N-8-1

PRINT HEAD SIZE: 1280

PRINT HEAD DPI: 300

% CONTRAST: 100

D91 GAP VALUE: 30

TOF DISTANCE: 179

STOCK OUT VALUE: 100

PRINTER CODE REV: 02.12.050719A

BOOTLOADER CODE REV: 02.12.050719A

CODE ASSY PN. 071001-0212

PRINTER SERIAL #: 00516645051

PRINTED LABELS: 303

PRINTED INCHES: 1533

TOTAL INCHES: 1571

POWER ON HOURS: 32.8

CUTTER TYPE: None

KIOSK CUT MODE: Disabled

KIOSK DISTANCE: 0
SWITCH BANK 1: 10001010
SWITCH BANK 2: 01010001
SWITCH BANK 3: 00000000
SWITCH BANK 4: 00000000
SWITCH BANK 5: 00000000
SWITCH BANK 6: 01110010

CURRENT COMM PORT: Autoselect USB/RS232

RS232 PARAMETERS: 115200-N-8-1

PRINT HEAD SIZE: 1280

PRINT HEAD DPI: 300

% CONTRAST: 100

D91 GAP VALUE: 30

TOF DISTANCE: 160

STOCK OUT VALUE: 100

PRINTER CODE REV: 02.12.050719A

BOOTLOADER CODE REV: 02.12.050719A

CODE ASSY PN. 071001-0212

Figure 3-6 Status Label (Examples)

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Chapter 4: Designing Labels Using LDS

Label Design Software (LDS) refers to the control language resident in the printer used to
create labels. All bitmapped fonts, character sets and bar codes are resident in the printer.
Additional fonts and graphic images may be sent from a host and stored in the printer’s
memory.

A label format is produced by a series of 5 steps:

1. Control commands to define printer operation.

2. A format header to define the label height, width, print speed, etc…

3. Field data that defines the placement of text, bar codes, graphics or lines.

4. Actual text data to place in the Field data strings.

5. Control commands to initiate printing.

4.1 Control Characters

Throughout this manual there are references to control characters. In order to print them in
this manual, they have been written using standard characters and icons. Escape
characters are represented by <ESC> and a carriage return is represented by <CR>. It is
important to note that all printer functions, unless otherwise noted, must be followed or
terminated with a carriage return (<CR> or HEX OD).

Note: Control codes are ignored when the printer is configured to accept binary
compressed files (^D23).

4.2 LDS Design Exercises

There are many different machines capable of sending information to the printer including
main frames, mini-computers, special purpose computers and PC’s. For the purpose of
simplicity, the design exercises contained in this manual will use one of the easiest methods
by using an IBM compatible PC and a VT-100 terminal emulation software program. This
method of connection will allow two-way, serial communication with the printer.

Items required:

- A computer with at least one unused serial communication port (COM1, COM2…).

- A serial interface cable.

- A VT-100 terminal emulation program such as HyperTerminal™.

- A text editor that does not add formatting characters such as Microsoft® Notepad.

4.2.1 PC Connection (Serial)

The printer is shipped with serial communication parameters set to 115200 bits per second,
no parity, 8 data bits, and 1 stop bit (115200-N-8-1). This means that for proper
communication, the PC’s communication port must be set to these parameters. If a terminal
program is not available, it is possible to send files to the printer using the DOS COPY (for
example: C:\>COPY FILENAME COM1) command. When using DOS, it is a good idea to
set the communications port up using the DOS MODE (for example: C:\>MODE
COM1:9600,n,8,1,p) command before copying the files to the port. Create a text file, enter
“^D3” <CR> (carriage return) and save it as “D3.txt”. Send the file to the printer by either
using the DOS COPY (C:\>copy d3.txt com1) command or by using a terminal program.

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Designing Labels Using LDS Chapter 4

Figure 4-1 HyperTerminal™ Window Example

4.2.2 Format Creation

Special Control code functions (see Chapter 5, Special Control Codes) and/or label formats
may be entered directly through the keyboard but this is not the most efficient method if
entering a large amount of data or numerous commands. Large formats and/or numerous
commands should be entered in an ASCII text editor and then uploaded to the printer.
Microsoft® Notepad has been used for the creation of label designs in this manual because
it is simple to use and does not add formatting characters.

The LDS programming language uses thermal dots as the unit of measure. All commands
and parameters, unless noted otherwise, should be entered using dots. The 224 and 424
printers may be fitted with either a standard density 203dpi head, or a higher density 300dpi
print head.

These are the conversion values for each print head:

Print head Dots/mm Dots/inch Inch/Dot

203 8 203 0.0049
300 12 300 0.0033

EXAMPLE: To enter the width of a label that is 2” wide when using a 203dpi head, the
value entered would be 406 (2” x 203 dots/in. = 406).

The printer can accept either the one-character control code (“Ctrl + E” (HEX05)) or the two­character caret (^) plus alpha character (“^E”). In other words, for a PC keyboard, the same
command can be generated either by holding down the “Ctrl” key and pressing the alpha
character or by entering the two characters; the “^” (the character generated when you
press the “Shift” key and the “6”) plus the alpha character. See Chapter 5 for additional
information regarding control codes and printer commands.

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Chapter 4 Designing Labels with LDS

There are some special features offered by the printer that assist in label design. For
example, the auto-size command (^A2^D39 <CR>) provides most of the header format
information needed to define the different properties of the media being used. The current
state of the printer is accessed through the enquiry command (^D5 <CR>, Ctrl E, or 5 NULL
characters + 01 (HEX 00 00 00 00 00 01) if binary compression has been enabled). The
statistical information of the printer is made available through the use of the ^A0^D29 <CR>
or more simply ^D29 <CR> command.

The following sections of this chapter are intended to provide the user an overview of the
LDS language. The overview will include information regarding the label format, header
definition, and list the different types of field information available. The combination of these
sections and Chapter 5 should provide the user with the information required for easy format
creation and printing. Once some understanding of these basic concepts has been
achieved, use the Quick Reference Guide in Appendix C for expedient label design.

4.3 Label Design: An Overview

A label format consists of a header record and field records, followed by the text data to be
printed. The records describe how the label is to be printed. The header contains
information about the label itself such as label height, width, print speed, etc. The field
records refer to the data section and contain information about positioning coordinates, and
the type of character generation such as text, graphics, bar codes, etc. The number of
fields is limited only by the amount of free memory available.

Below is a sample label format created for the Model 424 with a 300 DPI print head. We will
refer to this format as we break down the steps and components to produce the format.
Refer to Figure 4-2 for a printed representation.

^D57 <CR> A label format is coming.
5,1280,900,20,40,7,0,1,405,0,0 <CR> Header Information.
1,640,650,8,1,5,0,4,2,2,,,,,0 <CR> Field #1 format information.
2,640,591,11,1,5,0,4,2,2,,,,,0 <CR> Field #2 format information.
3,640,443,26,1,5,0,4 <CR> Field #3 format information.
4,640,296,6,1,5,0,4 <CR> Field #4 format information.
4,640,148,6,16,3,,4,3,75 <CR> Field #4 format information.
^D56 <CR> Signals the end of the label field definition .
^D2 <CR> Text data is coming.
Microcom <CR> Text data string #1.
Corporation <CR> Text data string #2.
Thermal Printing Solutions <CR> Text data string #3.
012345 <CR> Text data string #4.
^D3 <CR> Print label.

The command ^D57<CR> on the first line informs the printer that a format is coming and
causes the printer to enter the format entry mode.

The next line is the header information that sets the label size and other pertinent
information.

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Designing Labels Using LDS Chapter 4

The next five lines are layout and configuration for each data field in the format.
The command ^D56<CR> selects the user’s layout or more simply the end of the formatting
information.

The command ^D2<CR> instructs the printer to start accepting data for each of the defined
field’s strings that are entered into the previous format received (between the ^D57 and
^D56 commands). Field #1 defines the placement and configuration for Text Data String
#1; Field #2 defines the placement and configuration for Text Data String #2, etc… The
label is printed from the bottom left corner to the top of the label.

The next three lines are the text data for the associated field format lines.

Text Data String #4 is being accessed twice. The format places the Text “012345” on the
label and then is accessed again placing a Code39 symbol representing “012345” on the
label.

The command ^D3<CR> instructs the printer to print.

Thermal Printing Solutions

Figure 4-2 3x3 Sample Label

Microcom

Corporation

012345

4.4 Label Header

The label header consists of eleven parameters that control the media layout as well as
printer configuration. A comma (,) delimiter is used to separate the parameters and a
carriage return is required to terminate the header.

The values for header elements requiring measurements are expressed as thermal dots or
pixels. Dot or pixel size varies depending upon the print resolution of the print head. Two
print resolutions are currently available for the 224 and 424 printers (203 DPI and 300 DPI).
The dot size of a 203 dots per inch head (8 dots/mm) is 0.0049”. The dot size of a 300 dots
per inch head (12 dots/mm) is 0.0032”. The dot size is the same in both the horizontal and
vertical direction. For example, a 4” X 6” label printed with a 203 DPI print head would be

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This is the

3.0” or 900 Dots

812 (4 X 203) dots in the horizontal or “X” direction, and 1218 (6 X 203) dots in the “Y”
direction.

While the maximum number of dots in the horizontal or “X” direction is limited by print head
size, it is virtually unlimited in the vertical or “Y” direction. Vertical dot rows are “stepped” by
the drive roller motor.

This is a list of the header element mnemonics for the sample label in Figure 4-2:

HFM, LSX, LSY, WEB, GAP, DPS, LCB, AGD, SPG, OFX, OFY
5 1280 900 20 40 7 0 1 730 0 0

Feed Direction

4” PRINT HEAD

Web Value
.0625” or
20 Dots

Thermal Printing Solutions

Microcom

Corporation

LSY

012345

X beginning

origin; 1,1

Y beginning

Gap Value
.125” or 40 Dots

LSX

4.266” or 1280 Dots

(Total Print Head Dots)

Figure 4-3 Header Elements

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