Brady 2461 Users Manual J

2461 15b77aae-64f4-457e-a6b5-cd38ad37c98b Brady Printer 2461 User Guide |

2015-02-04

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Brady
Bradyprinter Models 2461, 3481, and 6441

Operator’s Manual

(TEMP COVER)
(DO NOT PRINT)

(DO NOT print this page)

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

Firmware (Software) Agreement
The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its
suppliers and is licensed for used only on a single printer in the user’s Trade or Business.
The User agrees not to, and not to authorize or permit any other person or party to
duplicate, or copy the Firmware or the information contained in the non-volatile or
programmable memory. The firmware (Software) is protected by applicable copyright
laws and Licensor retains all rights not expressly granted. In no event will Licensor or its
suppliers be liable for any damages or loss, including direct, incidental, economic,
special, or consequential damages, arising out of the use or inability to use the Firmware
(Software).
Information in this document is subject to change without notice and does not represent a
commitment on the part of Brady Worldwide, Inc. No part of this manual may be
reproduced or transmitted in any form or by any means, for any purpose other than the
purchaser's personal use, without the expressed written permission Brady Worldwide Inc.

All rights reserved. Printed in the United States of America.
© Copyright 2000 by Brady Worldwide, Inc.
Part Number: 88-2241-21
Revision: C

Agency Compliance and Approvals:
C

UL1950 Information Technology Equipment
C22.2 No. 950-M93

Listed

EN60950
For 230 Volt Operation (Europe): Use a cord set, marked “HAR,”
consisting of a min H05VV-F cord which has a minimum 0.75 square
mm diameter conductors, provided with an IEC 320 receptacle and a
male plug for the country of installation rated 6A, 250V
Für 230 Volt (Europa): Benützen Sie ein Kabel, das mit “HAR”
markiert ist, bestehend mindestens aus einem H05VV-F Kabel, das
mindestens 0,75 Quadratmillimeter Drahtdurchmesser hat; sowie eine
IEC320 Steckdose und einen für das Land geeigneten Stecker, 6A,
250 Volt.
As an Energy Star Partner, the manufacturer has determined that this
product meets the Energy Star guidelines for energy efficiency.
The manufacturer declares under sole responsibility that this product
conforms to the following standards or other normative documents:
EMC: EN 55022 (1993) Class B
EN 50024 (1998)
Safety: This product complies with the requirements of
EN 60950/All:1997
Gost-R

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

FCC: This device complies with FCC CFR 47 Part 15 Class A.
þ Note: This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy, and if not installed and used in accordance with the
instructions in this manual, it may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will be required to
correct the interference at his own expense.

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

This unit has been carefully designed to provide years of safe, reliable
performance. However, as with all electrical equipment, there are some basic
precautions that you follow to avoid personal injury or damage to the printer:
Ø Before using the printer, carefully read all the installation and operating
instructions.
Ø Observe all warning instruction labels on the printer.
Ø Install the printer on a flat, firm surface.
Ø Do not place the printer on or near a heat source.
Ø To protect your printer from overheating, make sure no openings on the
printer are blocked.
Ø Never insert anything into the ventilation slots and openings of the printer.
Ø Do not use the printer near water or spill liquid into it.
Ø Ensure that the AC power source matches the ratings listed for the printer.
(If unsure, check with your dealer or local utility provider.)
Ø Do not place the AC power cord where it can be stepped on. If the AC
power cord becomes damaged or frayed, replace it immediately.
Ø If the printer ever needs repair, consult only qualified, trained service
personnel. No user-serviceable parts are inside; do not remove the cover.

Printer Overview
1.0 About the Printer ...........................................................1
1.0.1 Standard Features...........................................2
1.0.2 Optional Features ...........................................2
1.1 Option Installation .........................................................5
1.2 Hardware Components .................................................6

Getting Started
2.0 Unpacking the Printer ...................................................7
2.0.1 Inspection ........................................................8
2.0.2 Additional Requirements .................................8
2.1 Media and Ribbon Selection .........................................9
2.1.1 Print Quality Controls.......................................9

Setting Up the Printer
3.0 Installation...................................................................11
3.0.1 Communications............................................12
3.1 Loading Media ............................................................14
3.1.1 Roll Media .....................................................15
3.1.2 Fan-Fold Media .............................................16
3.2 Media Sensor Adjustment...........................................17
3.3 Loading Ribbon...........................................................18
3.4 Quick Media Calibration..............................................20
3.5 Outputting Labels........................................................21
3.5.1 Rewinding......................................................21
3.5.2 On-Demand Dispensing ................................23
3.5.3 Cutting ...........................................................25

Using the Front Panel
4.0 Operation ....................................................................27
4.0.1 Ready Mode: Normal Operation ....................27
4.0.2 Menu Mode: Configuration ............................28
4.0.3 Quick Test Mode: Print Test Labels...............29
4.0.4 Indicator Lights ..............................................30
4.0.5 LCD ...............................................................30
4.0.6 Resetting the Printer......................................31
4.0.6.1 Soft Reset ........................................31
4.0.6.2 Level One Reset ..............................31
4.0.6.3 Level Two Reset ..............................31
4.1 The Menu System.......................................................32
4.1.1 Entrance and Exit Prompts ............................33
4.1.2 Media Settings...............................................34
4.1.3 Print Control ..................................................35
4.1.4 Printer Options...............................................37
4.1.5 System Settings.............................................39
4.1.6 Communications............................................47
4.1.7 Diagnostics ....................................................53
4.2 Display Messages.......................................................54
4.2.1 User Prompts and Condition Messages ........54
4.3 Quick Test Mode.........................................................56
4.3.1 Print Quality Label .........................................56
4.3.2 Configuration Label .......................................57
4.3.3 Quick Ribbon Test Label ...............................58
4.3.4 Dot Test Pattern Label...................................59
4.3.5 Validation Label .............................................60
4.3.6 User Defined Label........................................60

Maintenance and Adjustments
5.0 Media Sensor Calibration............................................61
5.0.1 Standard Calibration......................................61
5.0.2 Advanced Entry Calibration ...........................65
5.1 Printhead Adjustments................................................71
5.1.1 Leveling Cam Adjustment..............................71
5.1.2 Burn Line Adjustment ....................................72
ii

5.2 Printhead Replacement ..............................................73
5.3 Maintenance Schedule ...............................................74
5.3.1 Cleaning the Printhead ..................................75
5.3.2 Cleaning the Platen Roller.............................76
5.3.3 Cleaning Interior and Exterior Surfaces.........77
5.4 Application Version Updates.......................................77
5.4.1 Updating from Ready Mode...........................78
5.4.2 Updating from Download Mode .....................79
5.4.3 Possible Problems during an Update ............80
5.5 Boot Loader Program Updates ...................................81

Troubleshooting
6.0 Problem Resolution.....................................................83
6.1 Fault and Warning Messages .....................................87
6.2 Hex Dump Mode .........................................................93

Specifications
7.0 General Specifications ................................................95
7.1 Media and Ribbon Requirements................................97

Appendix A
ASCII Control Code Chart...................................................99

Appendix B
Available Fonts and Bar Codes.........................................101

Appendix C
Module Assignments.........................................................109
Print Resolutions and Maximum Label Widths..................109
Available Speeds and Default Settings .............................110

iii

Appendix D
GPIO Port Description ......................................................111

Appendix E
Menu System Multi-Language Support.............................113
Advance File Handling Information ...................................116

Appendix F
Saving a Configuration File...............................................119

Warranty Information ................................................121
Glossary ........................................................................125
Index ...............................................................................129

1.0 About the Printer
Congratulations on your purchase of a Bradyprinter Model 2461, 3481, and
6441 hereafter referred to as ‘the printer’, blends the rugged durability of diecast construction with state-of-the-art electronics and user-friendly features to
redefine the standard in industrial thermal printers.
This manual provides all the information necessary for everyday printer
operation. To begin printing labels, refer to the instructions provided with the
label-creation software you have chosen. If you wish to write custom label
programs, a copy of the Programmer’s Manual is included on the enclosed
Accessories CD.
To grow with all of your printing needs, the design of the printer allows most
upgrades to be performed easily by an operator; see Section 1.1. The following
subsections detail the standard features, available options and a hardware
overview.

1.0.1

Standard Features

This printer offers the following standard features:
Bradyprinter Standard Features Listing
Model
Feature
2461
3481
Printhead Density (Dots Per Inch)
203
300
Direct Thermal Printing
X
X
On-Demand and Batch Printing
X
X
Rotating Media Hub
X
X
Media Tear Bar
X
X
Fan-fold media capability
X
X
Flash memory
1MB
2MB
SDRAM
8MB
16MB
RS-232 interface port
X
X
IEEE 1284 Compliant parallel
X
X
interface port
Liquid Crystal Display
X
X
EFIGS (multi-language display
and configuration label support)
X
X
AGFA Scalable font engine
X
X

1.0.2

6441
600
X
X
X
X
X
2MB
16MB
X
X
X
X
X

Optional Features (available except as noted)

The printer offers the following optional features:

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

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

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

External Keyboard Support
An interface for the connection of the Passport™ keyboard.

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

Font Expansion Card (cannot be used with the I/O Expansion card)
A slide-in circuit card assembly with 8MB Flash memory expansion for
International Language Printing Capability (ILPC) and/or additional fonts and
graphics. ILPC consists of one of the following:
Ø
Ø
Ø
Ø

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

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

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

I/O Expansion Card (specify features at time of order)
Standard features* of this slide-in circuit card assembly include:
Ø General purpose (GPIO) interface for external printer and device control.
Ø Time and date calendar (Real Time Clock) function for label time stamping.
Optional feature:
Ø 8 MB Flash memory expansion for graphics and/or additional fonts
including International Language Printing Capability (ILPC).

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

*Item unavailable for the 2461 model

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

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

RS-422 Serial Interface*
Single-drop interface hardware to support greater distances from the host at
communication rates of up to 38,400 baud.

Thermal Transfer (specify configuration at time of order)
A printing method that uses ribbon to produce exceptional image clarity, as
compared to most direct thermal media types. This option must be specified for
use with either ‘coated side in’ ribbon or ‘coated side out’ ribbon.

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

*Item unavailable for the 2461 model.

1.1 Option Installation
The following table lists the available options and the recommended
qualification level of the installer. For detailed information concerning a specific
option, contact your dealer or Technical Support.
Suggested Experience Level for Option Installation
Option
Qualified Installer
Cutter Tray
Operator
Cutters: Light and Standard Duty
Operator
Passport External Keyboard
Operator
Font Expansion Card
Certified Technician
Internal Rewind
Operator
I/O Expansion Card
Certified Technician
LAN Interface
Certified Technician
Peel and Present Mechanism
Operator
Present Sensor
Operator
RS-422 Serial Interface
Certified Technician
Thermal Transfer Assembly
Operator
Twinax/Coax Interface
Certified Technician

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

2.0 Unpacking the Printer
Inspect the shipping container(s) for damage; if evident, immediately notify the
shipping company to report the nature and extent of the damage.
The printer has been carefully packaged to avoid damage during transit. In order
to operate the printer, you will need to remove the tape and foam placed there
for shipment. Complete the following steps prior to connecting power or
attempting to load media.
Œ With the arrow on the box pointing up,
open the box.

• Remove Accessories Box.

Ž Tilt the printer on its side and slide the
printer out of its box.

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

þ Note: It is a good idea to save the carton and packaging materials in the
event that future shipment is required.

2.0.1

Inspection

After removing the printer from the packaging material, check the contents of
the package. In addition to this manual, the following items should be included:
Ø Printer
Ø Power Cord
Ø Accessories CD
Ø Any special or additionally
purchased items.

2.0.2

Additional Requirements

The following items are necessary to produce labels. Contact your dealer or a
customer support representative for advice on which media and software may
best suit your needs.
Ø A serial or parallel interface cable; see Section 3.0.1
Ø Applicable media; see Section 2.1 for suggestions and Section 7.1 for
requirements.
Ø Applicable software

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

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

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

•

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

•

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

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

The label top coating and ribbon combinations affect image quality.

•

Ribbon backcoating is highly recommended. It provides protection for the
printhead, and may also provide an anti-static coating.

•

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

2.1.1

Print Quality Controls

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

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

•

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

•

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

•

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

You will find that printing barcodes and detailed images on less expensive direct
thermal and thermal transfer media at higher speeds can be tricky. At one heat
setting, the images will fade and at the next higher heat setting, the images will
bleed. This is because the reaction temperature of the media is so high that at
higher rates of speed, it cannot react fast enough. To print fine images at higher
speed, media with lower reaction or release temperatures are required. On the
slower end of the print rate settings, crisper images are possible because the
media is not being stretched beyond its limits.
The following table is intended for reference only (for specific application
information, consult your media specialist or a Media Representative).
Direct Thermal Media Type
Fasson 300 HD Direct Thermal Facesheet
Fasson 300 MD Direct Thermal Facesheet
Thermal Transfer
Media Type
Great Label TTL

Coated Paper,
Uncoated Paper, Tag
Stock, Some Films,
Some Synthetics
Coated Paper, Glossy
Paper, Tag Stock,
Some Synthetics, Films
Synthetics, Films

Print Speed*

Print Energy

10-12**

Medium

Ribbon
Print
Type
Speed*
10-12**
GPR Plus
MaxWax
IIMAK Versamark
Wax
2 - 10

Print
Image
Energy Durability
Medium Medium

Low

Wax/Resin

2-8

Medium

High

Resin

4-6

High

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

3.0 Installation
This section explains how to connect the printer, and load it with media and
ribbon.
þ Note: When connecting the AC Power Cord or interface cables to the printer,
ensure the Power On/Off Switch is in the ‘Off’ position.

Œ Place the printer on a firm, level surface.
• Turn ‘Off’ the Host Computer and ensure that the Power Switch on the
Printer is in the ‘Off’ position.
Ž Depending upon your interfacing requirements, connect the appropriate
interface cable between Host Computer and Printer; see Section 3.0.1.
• Connect the AC Power Cord to the receptacle on the back of the Printer,
and then plug the AC Power Cord into a properly grounded outlet. (The
power supply in the printer automatically detects, then adjusts to the applied
line voltage; see Section 7.0 for the acceptable voltage ranges.)

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

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

Parallel Port:
The parallel interface has two menu-selectable modes of operation: unidirectional or bi-directional. Uni-directional mode is forward channel
communication and requires a Centronics cable with a 36 pin male connector.
Bi-directional mode is IEEE 1284 Compliant, using forward and reverse channel
communications. In this mode, data can be sent to the host provided it is also
IEEE 1284 Compliant and has supporting software. This mode requires an IEEE
1284 cable with a Centronics 36 pin male connector.
NIC Adapter (optional):
The NIC Adapter has several menu-selectable modes; see Section 4.1.6 for
details. Refer to the information provided with the option for connection
requirements. The following items are accessible from the back of the printer:
•

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

•

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

•

The Ethernet Reset button will reset the
NIC Adapter.

þ Note: Following initialization, the printer will indicate ‘Ready’; however, the
NIC Adapter will not be ready to receive data until its ‘boot-up’ process
is completed. Depending upon the NIC Adapter configuration, this
process may take up to two minutes to complete.

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

Baud Rate (serial communication speed)
Word Length
Word Parity
Number of Stop Bits
Handshaking Protocol

In addition to the port settings, the serial interface cable wiring must have
specific connections (pin-outs) for proper data exchange between the host
and printer. The different serial cable pin-outs, suggested applications, and part
numbers are shown below (contact your reseller for ordering information).
Serial Interface Cable Listing (all models, except as noted)
Null Modem (MXM)
“PC” (DB9P) to Printer

Part Number 556000
For connection to other DCE equipment.
Flow control is only Xon/Xoff.

Part Number 556001
For connection to a PC compatible with
DB9P communication ports. Flow control
can be either Xon/Xoff or CTS/DTR.

RS-422 Connection*

“PC” (DB25P) to Printer

Part Number 556002
For connection to a PC compatible with
DB25 communication ports. Flow control
can be either Xon/Xoff or CTS/DTR.

Part Number N/A
Diagram provided only as a reference.
*

This optional interface is not available for
the 2461 model.

3.1 Loading Media
Begin loading as follows:
Œ Raise the Access Cover.
• Rotate the Printhead Latch forward and raise the Printhead Assembly.
Ž Slide the Media Guide out away from the frame and then lower it to the
down position.
• If using roll media, the Media Hub can accept 3.0-inch (76mm) and 1.5inch (38mm) cores. To use 1.5-inch cores, first slide off the 3 Inch Hub by
grasping and then pulling it firmly outward.
• Proceed according to the type of media you are using: either go to Section
3.1.1 for Roll Media or go to Section 3.1.2 for Fan-Fold Media.

3.1.1

Roll Media

This loading method is roll type media applications. To load:
Œ Slide the Roll Media
onto the Media Hub
until it rests against the
Backstop.
• Route the media as
shown:
under
the
Media Idler, through
the Media Sensor, then
out the front of the
printer.
Ž Raise and slide the
Media Guide over until
it rests lightly against the edge of the media.
• Position the Media Sensor; see Section 3.2.
• If your application uses thermal transfer media, load ribbon (see Section
3.3); otherwise continue.
‘ Lower the Printhead Assembly and rotate the Printhead Latch completely
back into the locked position. Close the Access Cover.

’ Turn ‘On’ the printer. After ‘Ready is displayed, press and hold the FEED
key until at least one label gap or mark is advanced; see Section 3.4.

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

3.1.2

Fan-Fold Media

This loading method is for tag and fan-fold type media applications. To load:
Œ Bring the media in through the Bottom or the Rear Media Slot. (If using
reflective stock, ensure that the mark is facedown.)
• Depending upon the entry point, route the media as shown: if through the
Rear Media Slot, route the media over the Media Hub; or, if through the
Bottom Media Slot, route the media over the Media Rewind Hub.
Ž Continue routing the media under the Media Idler, through the Media
Sensor and out the front of the printer.
• Raise and slide the Media Guide over until it rests lightly against the edge
of the media.
• Position the Media Sensor; see Section 3.2.
‘ If your application uses thermal transfer media, load ribbon (see Section
3.3); otherwise continue.
’ Lower the Printhead Assembly and rotate the Printhead Latch completely
back into the locked position. Close the Access Cover.

“ Turn ‘On’ the printer. After ‘Ready is displayed, press and hold the FEED
key until at least one label gap or mark is advanced; see Section 3.4.

+
16

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

3.2 Media Sensor Adjustment
The Media Sensor needs to be positioned so that the printer can detect the
presence of media and the top-of-form (except for continuous stock, where the
TOF is set through programming; see Label Length, Section 4.1.2). To adjust:
Œ With media loaded, as described in Section 3.1.1 or 3.1.2, grasp the Slide
Tab and move the Sensor Eye Mark into position over media according to
the table below.
• If loading media, return to the media loading instructions.

Media Type
Die-cut
Notched
Reflective
Continuous
*

Media Sensor Selection and Adjustment
Sensing Required*
Sensor Eye Mark Position
Near the middle of the label
Gap
Centered over the notch
Gap
Centered over the black mark
Reflective
Near the middle of the media
Continuous

See Section 4.1.2 for Sensor Type selection.

þ Note: Changes to the start of print position can be made using the Print
Control/Row Adjust or Row Offset (see Section 4.1.3).

3.3 Loading Ribbon
Ribbon is required with thermal transfer media. Depending upon the type of
Ribbon Supply Hub (see the next page for examples), the printer must use either
ribbons with the ‘coating side in’ or ribbons with the ‘coating side out’. To load:
þ Note: Using a ribbon that is slightly wider than your media (and liner, if any)
will help protect against printhead wear.

Œ With the access cover raised and the printhead assembly up, position the
ribbon to be dispensed in the direction appropriate for the Ribbon Supply
Hub.
• Slide the ribbon onto the Ribbon Supply Hub until it rests against the hub’s
flange.
Ž Route the ribbon under the Ribbon Idler, out the front of the printer and
then up around to the Ribbon Take-Up Hub, winding it several times in a
clockwise direction to secure it in place.
• If loading media, return to the media loading instructions. Otherwise, lower
the Printhead Assembly and rotate the Printhead Latch completely back into
the locked position. Close the Access Cover.

Removal:
When the supply is exhausted, pull the empty core from the Ribbon Supply
Hub and discard it. To remove used ribbon: grasp the Ribbon Take-Up Hub,
pull outward, then squeeze to collapse the hub and take off the ribbon.
18

þ Note: Directional Arrows near the Ribbon Supply Hub indicate the correct
ribbon route. Ribbon is available with the ink (coating) layer wound ‘in’
or ‘out’. These types are not interchangeable for use with the printer.

Ribbon Routing Diagrams

‘Coating Side In’ Ribbon Supply Hub

‘Coating Side Out’ Ribbon Supply Hub

3.4 Quick Media Calibration

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

At the factory, the printer is calibrated to sense a wide range of media types.
Quick Media Calibration fine-tunes the media sensor for your gap, notch or
reflective media application (this is not required for continuous media). Perform
this calibration during initial set-up or after changing your media type. To
calibrate:
Œ Ensure that media is loaded (see Section 3.1), that the Media Sensor is
adjusted (see Section 3.2), and that the printer is idle.
• Press and hold the FEED key. The printer will begin advancing media;
allow at least one label gap or mark to advance under the sensor during
this process.
Upon successful completion, the ‘Calibration Completed’ message will flash;
the printer will feed to the next label TOF and ‘Ready’ will be displayed. (A
‘Warning Low Backing’ message may appear if using notched media or media
on a transparent liner; however, the calibration was successful).
þ Note: Media containing large gaps may require a change in the ‘Paper Out
Distance’ setting; see Section 4.1.2.

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

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

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

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

If this method also fails, see Media Sensor Calibration, Section 5.0.
20

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

3.5.1

Rewinding

With the Internal Media Rewinder option, the printer can wind the printed labels
and backing material. To rewind labels:
þ Note: When winding labels, do not allow the outer diameter of the roll to
exceed 6 inches (154 mm) on the Media Rewind Hub.

Œ Remove the Front Fascia.

• Remove the Tear Plate by
first removing the
Thumbscrew.

Ž Position the Rewind Plate
on the printer and install and
tighten the Thumbscrew.

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

• Load media as described in Section 3.1, press the FEED key and advance
approximately 20 inches (51 cm) of media.
21

‘ Route the media back to the Media Rewind Hub, as shown below.
’ Insert the leading edge into a Slot on the Media Rewind Hub then insert the
Media Clip into a Slot to secure it in place.
“ Position the Rewind Retainer lightly against the edge of the media on the
Media Rewind Hub. Tighten the Thumbscrew to secure the retainer in
place.
” Manually rotate the Media Rewind Hub to remove any slack in the media.
Close the Access Cover.

Removal:
Remove the Rewind Retainer and Media Clip. Grasp the end of the hub. While
pulling outwardly, squeeze the hub together to collapse it and then slide off the
labels.
22

3.5.2

On-Demand Dispensing

When equipped with the Peel and Present option, labels are dispensed from the
printer one at a time, separated automatically from the liner for immediate
application.
Œ With the Peel and Present
Mechanism installed on the
printer, pull outward on the
Latch and allow the Roller
Bracket to swing forward.
• With media loaded as
described in Section 3.1, press
the FEED key to advance
approximately 20 inches (51
cm) of media. Remove all of
the labels from the backing
material.
Ž Route the backing material through the Roller Bracket as shown (the
backing should go under the top black roller, then out).

• Raise the Roller Bracket up to its latched position.

• If installed, remove the Media Clip and the Rewind Retainer from the
Media Rewind Hub. Route the Backing Material around the Media Rewind
Hub, as shown.
‘ Insert the leading edge into a Slot on the Media Rewind Hub then insert the
Media Clip into a Slot to secure it in place.
’ Position the Rewind Retainer lightly against the edge of the backing on the
Media Rewind Hub. Tighten the Thumbscrew to secure the retainer in
place.
“ Manually rotate the Media Rewind Hub to remove any slack in the media.
Close the Access Cover.

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

Removal:
Remove the Rewind Retainer and Media Clip. Grasp the hub. Pull the hub
outward then squeeze to collapse it and slide off the backing material.

3.5.3

Cutting

When equipped with one of the cutter options, cut labels are dispensed from the
printer.
Œ Ensure the leading edge of media is clean, straight and firmly attached to the
liner.
• Load media according to Section 3.1, except route the media out through the
Opening of the Cutter Assembly.

Ensure the Cutter has been enabled; see Section 4.1.4.

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

4.0.1

Ready Mode: Normal Operation (Ready Light ‘On’)
Œ
The PAUSE key temporarily suspends printing.
Pressing again will return the printer to normal
operation.
•
The FEED key advances one label, and clears any
corrected faults.
Pressing and holding cause the printer to perform
a Quick Media Calibration; see Section 3.4.
Ž
The CANCEL key ‘pauses’ the printer and then
prompts you for confirmation. If yes, the current
job is cancelled. The printer remains paused.
Pressing and holding four seconds will reset the
printer and clear temporary host settings (soft
reset).
•
The MENU key toggles between the Ready and
Menu Modes. In the Ready Mode, pressing and
holding four seconds will change the display
contrast.
•
The TEST key enters (or exits) the Quick Test
Menu.
27

4.0.2

Menu Mode: Configuration (Ready Light ‘Flashing’)
Œ
The DOWN ARROW key scrolls to the previous
menu item on the same menu level. It also
decrements numerical values in most menu
selections.
•
The UP ARROW key scrolls to the next menu
item. It also increments numerical values in most
menu selections.
Ž
The ENTER key selects the function, item or
displayed value. It also moves between selections
within multiple parameter fields.
•
The ESCAPE key moves to the previous menu
level, and finally back to the Ready Mode.

4.0.3

Quick Test Mode: Print Test Labels

þ Note: The Quick Test Mode functions are disabled while processing data
from communications interfaces until the Host Timeout value expires.

Œ
The DOWN ARROW key scrolls to the previous
test function.
•
The UP ARROW key scrolls to the next test
function.
Ž
The ENTER key will change the selected test label
quantity of 2, 100, 1000, or 9999 (except the
‘Configuration Label’, quantity of one). Holding
down the key scrolls quantities.
•
The ESCAPE key will exit the Quick Test Mode
without printing.
•
The TEST key will print the selected test label at
the selected quantity. During test label printing,
this key also functions as a cancel key (the printer
will prompt you for confirmation before
cancellation occurs).

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

4.0.4

Indicator Lights
Œ
‘On’ indicates that the printer is powered ‘On’
and, after initialization, it indicates the Ready
Mode.
‘Slow Flashing’ indicates the Menu Mode.
‘Fast Flashing’ indicates data is being received
and processed.

•
‘On’ indicates a ‘Paused’ condition.

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

4.0.5

LCD
Œ Liquid Crystal Display
The display provides several types of information:
• Following a brief power-up sequence
(initialization), the ‘Ready’ message.
• The time and date, if the printer has received it
from one of the following: the host, the front
panel setting, or the Time and Date option.
• A label counter during a batch print job.
• The Menu System when in the Menu Mode.
• Any prompt, condition, downloading, warning,
or fault message.

4.0.6

Resetting the Printer

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

4.0.6.1

Soft Reset

To reset the printer and clear any temporary host settings:
With the printer ‘On’, press and hold the CANCEL key for approximately four
seconds.

4.0.6.2

Level One Reset

To return the printer to the factory default settings or, if saved, to restore the
Factory Setting File:
Œ Turn ‘Off’ the printer.
• Press and hold the PAUSE and CANCEL keys while turning ‘On’ the
printer; continue to depress the keys until the ‘SYSTEM RESET’ message
flashes.
þ Note: This reset has the same effect as the System Settings/Set
Factory Defaults selection in the menu system. (See Section 4.1
for a listing of the factory default settings and Section 4.1.5 for
information about the Factory Setting File.)

4.0.6.3

Level Two Reset

To return the printer to the factory default settings, and clear all the calibration
and adjustment parameters:
Œ Turn ‘Off’ the printer.
• Press and hold the PAUSE, FEED, and CANCEL keys while turning ‘On’
the printer; continue to depress the keys until the ‘SYSTEM RESET’
message flashes.
þ Note: After executing a Level 2 Reset, the media calibration must be
performed; see Section 5.0. A listing of the factory default
settings can be found in Section 4.1.

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

Media Settings
Print Control
Printer Options
System Settings
Communications
Diagnostics

While in the menu system, the current selection will be indicated with the ‘*’
symbol next to the displayed item on the LCD, and selections designated with
the ‘§’ symbol will require a printer reset before becoming effective. Changes
made can be saved so that, in the event that power is lost or removed, the new
settings will be retained. A reset will be automatically invoked when exiting the
menu system and answering ‘Yes’ to the ‘Save Changes’ prompt.
The same functional commands from the host computer may, in some cases,
override the printer’s menu settings. In addition, as a security feature for the
prevention of accidental or unauthorized changes, the menu system has a
password protection feature.

þ Note: In the following subsections, the factory default settings are denoted
with the ‘²’ symbol. Selections denoted with the ‘♦’ symbol can only
be changed through the menu system - all other selections can be
overridden by host software commands. Consult the Programmer’s
Manual for specific information.

4.1.1

Entrance and Exit Prompts

With ‘Ready’ displayed on the LCD, press the
Mode.

key to enter the Menu

þ Note: While in the Menu Mode, the printer will stop processing new DPL
(or bitmapped) data.

MENU MODE

ENTER PASSWORD
0000

KEEP HOST CHANGES?
ENTER = YES

SAVE CHANGES?
ENTER = YES

Depending upon the configuration of the
printer, the following Entrance and Exit
Prompts may be displayed when accessing
or leaving the Menu System.
You are attempting to enter the Menu Mode.
Security has been enabled and now the
correct user-definable password is required
for access the Menu Mode functions.
You are now entering the Menu Mode.
Existing Host commands have affected the
configuration of the printer. Pressing
ENTER will save these changes; otherwise,
the printer will revert to previously saved
settings.
You are now exiting the Menu Mode, but
have made changes to the printer’s settings.
Pressing ENTER will reconfigure your
printer according to these changes;
otherwise, the printer will revert to
previously saved settings.
þ Note: If changes have been made that
require a reset, the printer will
automatically invoke that reset.

4.1.2

Media Settings

MEDIA TYPE

Selects the printing method.

DIRECT THERMAL

For use with heat sensitive media.

²THERMAL TRANSFER

For use with media requiring a ribbon to
create an image.

SENSOR TYPE
²GAP
CONTINUOUS
REFLECTIVE

LABEL LENGTH
²04.00in (0-99.99)

Selects the top-of-form (TOF) sensing
method for the media.
The printer recognizes the TOF by sensing
gaps in the media.
No TOF sensing. The LABEL LENGTH
setting determines the length.
The printer recognizes the TOF by sensing
reflective (black) marks on the media.
When the Sensor Type is set to Continuous,
this value is used to determine the TOF.

MAXIMUM LABEL LENGTH Sets the maximum length between TOF
marks (gap or reflective). If this limit is
²16.00in (0-99.99)
exceeded, a top of form fault is declared.
PAPER OUT DISTANCE
²00.25in (0-99.99)

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

LABEL WIDTH

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

SENSOR CALIBRATION ♦

Adjusts the printer to sense your media.

PERFORM CALIBRATION

ADVANCED ENTRY
SENSOR LEVELS

SENSOR GAIN

The user follows steps to allow the printer to
calculate the empty, gap (or mark), and
paper values to set the media sensor.
The user directly inputs the best values to
adjust the media sensor.
Sets threshold values for the media sensor
parameters. Manual entry for paper, gap (or
mark), and empty thresholds.
Observe A/D reading and set SENSOR
GAIN. Adjusts the sensitivity of the sensor for
custom label stock.

4.1.3

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

HEAT
²10 (0-30)

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

PRINT SPEED

Controls the rate of label movement during
the printing process; see Appendix C.

FEED SPEED

Controls the rate of label movement between
printing areas; see Appendix C.

REVERSE SPEED

Controls the rate of label movement during
backup positioning for start of print, cutting
or present distance; see Appendix C.

ROW OFFSET
²00.00in (0-99.99)

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

COLUMN OFFSET
²00.00 in (0-99.99)

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

PRESENT DISTANCE
²0.00 in (0-4.00)

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

Print Control (continued)
CUSTOM ADJUSTMENTS ♦ These factory adjustments independently
change the listed parameters to finely tune the
printer and compensate for slight mechanical
differences sometimes evident when multiple
printers share label formats. In addition, each
of the following adjustments has no factory
default setting and restoring factory defaults
will NOT affect these settings.
DARKNESS
Controls the printhead strobe time to fineXX
(1-64)
tune the HEAT setting.
ROW ADJUST
Shifts the vertical start of print position
XXX DOTS (0-128)
upward in dots to fine-tune the ROW
OFFSET setting; see Appendix C.
COLUMN ADJUST
Shifts both the horizontal start of print
XXX DOTS (0-128)
position and the LABEL WIDTH termination
point to the right in dots to fine-tune the
COLUMN OFFSET setting; see Appendix C.
PRESENT ADJUST
Adjusts the label stopping position in dots to
XXX DOTS (0-128)
fine-tune the PRESENT DISTANCE setting;
see Appendix C.

4.1.4

Printer Options

MODULES

PRINT DIRECTORY

PRINT FILE
FORMAT MODULE

DELETE FILE

PACK MODULE

PRESENT SENSOR

Memory available for user storage of
graphics, fonts and label formats. (The
physical presence of the respective memory
module must be detected to show the function
selections for that module in the menu
system.) See Appendix C for a listing of all
possible modules.
Prints a label directory of selected, or of all
available modules, the available space on
these modules, the files present, and the type
of module and files.
The user may select from a list of available
files for sample printing.
The user may select from a list of available
modules for formatting – all data will be
erased.
The user may select from a list of available
files for deleting (protected modules will not
appear). Bytes will NOT be retrieved until the
module that contained the deleted file is
packed.
Packing the module removes files marked as
deleted and defragments existing file
structures to recover space.

ENABLED

Used for on-demand label dispensing, where
a printed label blocking the sensor will
inhibit further printing until removed. (The
physical presence of the Present Sensor must
be detected to show the ENABLE/DISABLE
selections.)
Enables the sensor for on-demand printing.

²DISABLED

Disables the sensor.

NOT INSTALLED

No sensor is detected.

Printer Options (continued)
CUTTER

ENABLED

Used to cut media into separate labels. (The
physical presence of a cutter must be
detected to show the ENABLE/DISABLE
selections.)
Enables label cutting.

²DISABLED

Disables the cutter.

NOT INSTALLED

No cutter is detected.

GPIO PORT

ENABLED

Model dependant option used to interface the
printer to an external controlling device (see
Appendix D).
Input control signal is required to print a
label.
Enables external signal control.

²DISABLED

Disables the GPIO.

GPIO

END OF PRINT
ACTIVE LOW
ACTIVE HIGH
LOW PULSE
HIGH PULSE

Programmable signal output.

4.1.5

System Settings

CONFIGURATION FILE
RESTORE AS CURRENT

SAVE SETTING AS

DELETE FILE

Options for storage and recall of printer
configuration files. See Appendix F for
details.
Provides a list of available configuration
files. Selecting a file from the list causes a
printer reset; afterward, the printer is
configured according to the activated file.
Saves the entire effective configuration of
the printer to a file. Unique names with up
to nineteen characters are possible.
Provides a list of available configuration
files. Files selected are immediately
removed, freeing the module.
þ Note: A currently activated file cannot
be deleted.

FACTORY SETTING FILE

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

INTERNAL MODULE
²1024 KB

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

DEFAULT MODULE
²D

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

SCALEABLE FONT CACHE Sets the number of 1K blocks allocated for
the scaleable font engine. Available memory
²312 KB
dependent upon model; see Appendix C.
SINGLE BYTE SYMBOLS
²PC_850 MULTILINGUAL

Selects the code page used to print single
byte fonts unless otherwise specified in
DPL.
61 selectable sets are standard; see the
Programmer’s Manual for details.

System Settings (continued)
DOUBLE BYTE SYMBOLS

JIS

When equipped with the ILPC option, this
selects the code page used to print double
byte fonts unless otherwise specified in
DPL; see the Programmer’s Manual for
details.
Japanese Industry Standard

SHIFT JIS

Shift Japanese Industry Standard

EUC

Extended UNIX Code

²UNICODE

Unicode (including Korean)

Government Bureau Industry Standard;
Chinese (PRC)
Taiwan encoded

BIG 5

TIME AND DATE

Allows the user to set Time and Date.

MEDIA COUNTERS

Internal record of inches printed and time of
use.
Shows the number of inches printed since
being set at the factory. Not resettable by the
user.
The number of inches printed since the last
reset. User may reset.
Resets the resettable counters to zero.

ABSOLUTE COUNTER

RESETTABLE COUNTER
RESET COUNTER

PRINT CONFIGURATION

Prints the effective configuration of the
system. In addition, if settings were changed
that require a reset to become effective, this
will be indicated with the ‘§’ symbol.
A ‘•’ symbol next to the printed item
indicates that it was changed via the host
but not saved in non-volatile memory.

System Settings (continued)
CONFIGURATION LEVEL

PRINTER KEY

To upgrade the application program
(resident software) version of the printer,
the hardware and software compatibility
levels must match for the update to be
accepted. This information is displayed
here; it is also printed on a configuration
label.
Each printer has a unique KEY number in
the following form:
vvvv-wwxx-yyyyyy-zzz
Where:
vvvv – represents the model number of
the application loaded
wwxx – represents the hardware /
software feature level, where:
ww – represents the hardware
feature level of the main
board:
PA = PCB 51-2178-xx
TB = PCB 51-2301-xx
xx – represents the software
feature level:
10 = Standard DPL
11 = 2461
20 = Internal CG Times
Font
The printer will accept
software feature levels up to
the ‘xx’ value. (This feature
level requires authorization
to upgrade.)
yyyyyy – is a manufacturing date code
zzz – is a unique time stamp

UPGRADE PRINTER CODE This function is used to upgrade the

software feature level of the printer,
authorization is required.

System Settings (continued)
SET FACTORY DEFAULTS Parameters in this menu listing with the ‘²’
symbol are the designated defaults.
SET FACTORY DEFAULTS Overwrite the current settings with the
factory default settings or, if selected, will
restore the Factory Setting File.
þ Note: The reset will be automatic. If no
Factory Setting File is used, all menu
settings will be restored except CUSTOM
ADJUSTMENTS, and the media and ribbon
sensor calibrations.

FORMAT ATTRIBUTES

TRANSPARENT

²XOR
OPAQUE

IMAGING MODE ♦

Affects the manner in which overlapping text
and graphics are treated as the label is
printed. Consult the Programmer’s Manual
for details.
Intersecting text strings, images, and bar
codes will not be printed. (An odd number of
overlapping objects will print.)
Intersecting text strings, images, and bar
codes print on top of one another.
Interacting text strings, images, and bar
codes are obliterated by those formatted
last. Each character cell is treated as
opaque.
Instructs the printer whether to pre-image
the label format.
þ Note: This selection can affect the
accuracy of time-stamped labels and label
throughput.

²MULTIPLE LABEL

SINGLE LABEL

The printer images multiple labels as
memory permits, achieving the fastest
throughput; however, if time-stamping, the
time will reflect the moment the label is
imaged rather than when actually printed.
The printer images the next label only after
the previous label has been successfully
printed. Single processing provides timestamps that are more accurate, but it slows
label throughput time.

System Settings (continued)
PAUSE MODE
ENABLED
²DISABLED

SECURITY ♦

When enabled, Pause Mode suspends
printing between each label until the
PAUSE key is pressed.
Printer requires operator to press the
PAUSE key after each label.
Printer completes label batch without
pausing between labels.

ENABLED

Provides the user with the ability to
password protect all printer settings made
through the operator panel.
Enable or disable the menu system’s
security feature.
Password protected.

²DISABLED

No protection.

SELECT SECURITY

MODIFY PASSWORD

UNITS OF MEASURE
METRIC
²IMPERIAL

Modify the password required to access the
menu system when security is enabled.
Selects the measurement system in which
the system’s settings are represented in the
menu system and on configuration labels.
Metric standard: Lengths in millimeters and
Counters in centimeters.
Inch standard: Lengths and Counters given
in inches.

System Settings (continued)
þ Note: As indicated, the following menu selections will only appear
according to the model of your printer.

PLUS EMULATION

ENABLED

ALLEGRO EMULATION

ENABLED
²DISABLED

This instructs the firmware to process
specific DPL data as would the
Allegro® printer without all of the
variations.
The row position is calculated based on
194 DPI.
The above exception is disabled.

2461 Model

²DISABLED

This instructs the firmware to process
specific DPL data as would the Prodigy
Plus® printer without all of the
variations.
This list of exceptions will be updated
with new firmware releases:
• Data Terminator – I 2 of 5 Barcodes
(IDs D, J, and L), the first nonnumeric character processed will
terminate the barcode data field.
• Bar Size – I 2 of 5 Barcode (ID L),
when the bar size is specified greater
than P (25), the size is automatically
decreased to 10.
• Human Readable Fonts – The EAN
and UPC barcodes (IDs B, C, F, G,
M, and N) print a fixed font size.
• The column position, bar code
height, line width, and column offset
commands are interpreted as 200
DPI calculations.
The above exceptions are disabled.

System Settings (continued)

þ Note: As indicted, the following menu selections will only appear according
to the model of your printer.

DPI EMULATION

300 DOTS PER INCH
203 DOTS PER INCH

6441 Model

²DISABLED

For users who want to print DPL files
intended for a 203 or 300 DPI printer.
Label formats interpreted as intended
for 600 DPI.
Label formats interpreted as intended
for 300 DPI.
Label formats interpreted as intended
for 203 DPI.

System Settings (continued)
SOP EMULATION

110 (PRODPLUS)

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

220 (ALLEGRO)

Emulates the Allegro® printer.

250 (PRODIGY)

Emulates the Prodigy™ printer.

²DISABLED

No emulation, natural start of print position.

BACK AFTER PRINT

ENABLED

²DISABLED

MENU LANGUAGE ♦

When the present distance is set with the
cutter, present sensor or GPIO option
enabled, this setting determines the timing
of the label back up.
Commands the printer to immediately back
up the label after the cut operation, the
GPIO start of print signal is received, or the
present sensor is clear. It provides the
advantage of faster throughput.
The printer will not initiate repositioning
until the next label is ready to print. May
help prevent the curling of the label edge.

²ENGLISH

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

FRENCH

French

ITALIAN

Italian

GERMAN

German

SPANISH

Spanish

USER DEFINED

User defined, downloaded language(s).

4.1.6 Communications
SERIAL PORT A♦
BAUD RATE
38400
28800
19200
²9600
4800
2400
1200
PROTOCOL

Controls the communications settings for
Serial Port A.
Determines the serial communication rate.

²BOTH
SOFTWARE
HARDWARE
NONE
PARITY

38400 bits per second
28800 bits per second
19200 bits per second
9600 bits per second
4800 bits per second
2400 bits per second
1200 bits per second
Sets the data flow control (handshaking)
method.
Uses both handshaking methods.
XON/XOFF
CTS/DTR
No flow control is used.
Sets Word parity

²NONE
ODD
EVEN
DATA BITS

No parity
Odd parity
Even parity
Sets Word length

7
²8
STOP BITS

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

²1
2

SERIAL PORT B♦

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

PARALLEL PORT A♦

Controls the communications settings for
Parallel Port A.
PORT DIRECTION
Determines if messages are sent from the
printer to the host via the parallel port.
²UNI-DIRECTIONAL One-way printer communication.
BI-DIRECTIONAL

Enables IEEE 1284 back-channel operation.

Communications (continued)
PARALLEL PORT B♦

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

þ Note: If the ‘LOCKED’ message appears when attempting to access the NIC
ADAPTER menu, the printer may have active print requests or multiple
users may be trying to access these parameters (for example, during
simultaneous telenet sessions).

NIC ADAPTER♦

Network Interface Card Adapter (optional).
If not present, this displays ‘NOT
INSTALLED’ when accessed.
NIC
Adapter
firmware
version
V3.6/5(010212) DM or later is required to
support the described functionality.
After making changes to these parameters,
save the changes, exit the menu system, and
cycle the printer’s power ‘Off’ and ‘On’ for
the changes to take effect.
þ Note: With the NIC Adapter installed, a
boot process (taking up to two minutes,
depending upon the configuration) must
be
completed
before
the
printer
recognizes the option as ‘installed’. During
this time, the NIC Adapter will not be
accessible
or
configurable;
"NOT
INSTALLED" will be indicated when in the
menu system or on a Configuration Label.
After the process, you will be able to
configure the options provided using the
menu system.

IP ADDRESS
SUBNET MASK
DEFALUT GATEWAY

The static IP address of the NIC Adapter.
This is in standard dotted-decimal format.
The static subnet assigned to the NIC
Adapter.
The network gateway address the NIC
Adapter should use.

Communications (continued)
PROTOCOL
IP
LAT

²ENABLED

The network protocols recognized by the
NIC Adapter.
This protocol is always supported.
Local Area Transport is a DEC VMS
network protocol that requires a LAT
license number.
Protocol is enabled by default.

DISABLED

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

²ENABLED

Enables the DEC MOP protocol.

DISABLED

Ignore the MOP protocol. Select this option
if MOP is not needed.

MOP

APPLETALK
²ENABLED
DISABLED
NETWARE
²ENABLED
DISABLED
LAN MANAGER
²ENABLED
DISABLED

The AppleTalk protocol is enabled by
default.
Ignore the AppleTalk protocol. Select this
option if AppleTalk is not needed.
Allow the printer to be driven from an NDS
Novell Print Queue.
Netware is enabled by default.
Ignore the Netware protocol. Select this
option if Netware is not needed.
Enable DLC/LAN Manager protocol.
Ignore LAN Manager protocol.

Communications (continued)
DISCOVERY

This is the address discovery method used
by the NIC Adapter if a static address is not
utilized. If no server for any of the discovery
methods is found, the static value specified
above is used.
þ Note: For faster NIC Adapter boot times,
disable any discovery methods not used.

DHCP

²ENABLED

Dynamic
Host
Control
Protocol.
Automatically assign IP address from a
DHCP Server.
DHCP is enabled by default.
WARNING! An IP Address assigned by a
DHCP has precedence over any static IP
Address stored in the NIC Adapter.

DISABLED

Disable DHCP.
þ Note: Select this option to insure any

static IP stored is used by the NIC Adapter.
BOOTP
²ENABLED

A UNIX based automatic IP address
assignment controlled by a BOOTP server.
BOOTP is enabled by default.

DISABLED

Disable BOOTP.

RARP
²ENABLED
DISABLED

Reverse Address Resolution Protocol.
RARP is enabled by default.
Disable RARP. This should be selected if
RARP is not needed.

Communications (continued)
HOST SETTINGS

ENABLED

Settings which affect all communications
with a host.
The number of seconds a communications
port must be idle before the printer may
process data from a different port. This
value is also used to “timeout” an image /
label format download.
Allows the operator to change the prefix of
the software commands interpreted by the
printer.
Hex 01 = SOH command; Hex 02 = STX
command; count-by = ^; Hex 1B = ESC;
Hex 0x0D = Carriage Return
Hex 5E = SOH command; Hex 7E = STX
command; count-by = @; Hex 1B = ESC;
Hex 0x0D = Carriage Return
Hex 5E = SOH command; Hex 7E = STX
command; count-by = @; Hex 1B = ESC;
Hex 0x7C = Carriage Return
Hex 5E = SOH command; Hex 23 = STX
command; count-by = @; Hex 1B = ESC;
Hex 0x0D = Carriage Return
Returns a Hex 1E, [RS], after each label
successfully prints, and a Hex 1F, [US],
after each batch of labels is printed.
Feedback characters are sent to the host.

²DISABLED

No feedback characters are sent.

HOST TIMEOUT
SEC (1-60)

²10

CONTROL CODES ♦

²STANDARD CODES

ALTERNATE CODES

ALTERNATE CODES 2

ALTERNATE CODES 3

FEEDBACK CHARACTERS

ESC SEQUENCES
²ENABLED
DISABLED

Allows data containing invalid ESC control
code sequences to be processed.
Normal printer operating mode.
ESC sequences are ignored and the data is
processed. Bitmapped font downloads are
disabled in this mode.

Communications (continued)
HEAT COMMAND

²ENABLED
DISABLED

DPL Heat Commands are ignored. The heat
value is controlled via the menu setting; see
Print Control, Section 4.1.3.

SPEED COMMANDS

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

²ENABLED
DISABLED

Allows the user to disable the DPL Heat
Command, providing compatibility with
other printers.
Normal printer operating mode.

DPL speed commands are ignored. The
print, feed and reverse speeds are controlled
via the menu setting; see Print Control,
Section 4.1.3.

4.1.7

Diagnostics

HEX DUMP MODE

Most commonly used for troubleshooting.
Prints data and instructions received from
the host rather than interpreting them as
label formats; see Section 6.2.
Prints raw ASCII data received from the
host rather than executing the commands.
Executes and prints label formats (normal
operating mode).

ENABLE
²DISABLE

OPTIONS TESTING

Tests currently installed options

TEST PRESENT SENSOR
TEST CUTTER
PERFORM TEST
1 TIME

Performs a functional test of the Present
Sensor circuitry.
Performs a functional test of the optional
cutter mechanism and circuitry.
The cutter will cycle 1, 10 or 100 times
(selectable). The results of each attempt
will be displayed.

MONITOR GPIO INPUT
TEST GPIO OUTPUTS

PRINT TEST RATE
²0
(0-120)

(MIN)

SENSOR READINGS
THR TRAN RIBM 24V à
255 255 255 255

ß PS HD RANK
255 255 255

The number of minutes to delay between
the printing of batches of labels in Quick
Test Mode.
Analog Sensor readings are displayed.
Live sensor values are displayed. View
can be toggled with forward and reverse
keys. Maximum values are shown in this
example: thermistor sensor, transmissive
(gap) media sensor (TRAN is replaced
with REFL when the SENSOR TYPE is set
to ‘reflective’), ribbon sensor, 24 volt
power supply sensor.
Present sensor, head down sensor,
printhead ranking resistor.

RIBBON SENSOR LIMITS

Displays ribbon sensor ADC low and high
values used for motion detection.
RIBBON ADC LOW HIGH Approximate default values are shown
070 164 here (actual values will vary).

4.2 Display Messages
The printer displays several different types of information (if not in the menu
system or Quick Test Mode):
Ø User Prompts and Condition Messages (also see Section 4.1.1 for a listing
of the Enter/Exit Prompts)
Ø Application and Boot Loader Updating Messages (see Section 5.4 and 5.5)
Ø Fault and Warning Messages (see Section 6.1)

4.2.1

User Prompts and Condition Messages

User Prompts alert the operator to a required action. Condition Messages are
used to indicate an operational state.
User Prompts and Condition Messages
Displayed Message
Description
Condition(s)
The printer is trying to Occurs when the FEED key
clear a fault condition. is pressed after the
correction of a fault.
A media calibration is
being performed.

The FEED key was pressed
and held.

The CANCEL or
The current print batch will
TEST key was pressed be cancelled if ENTER is
during a batch job.
pressed; the remaining
labels will not be printed.

The printer is paused
or offline.

The printer is in a paused
condition.

A label is awaiting
removal.

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

User Prompts and Condition Messages (continued)
Displayed Message

Description

Condition(s)

Normal power-up and Follows the ‘SYSTEM
soft reset condition.
RESET IN PROGRESS’
message after a reset or
power-up.
Normal power-up and Occurs when the user
soft reset condition.
resets the printer via the
host or Front Panel.
The media calibration Perform calibration; see
is not set.
Section 5.0.
The print job is being Batch status indication,
processed.
updated with each label
printed.

4.3 Quick Test Mode
This section explains the functions of the resident Quick Tests, accessible by
pressing the
key on the Front Panel.
þ Notes: (1) With the exception of the Configuration Label, all Quick Test
labels require 4-inch (102mm) wide media to print the entire format. If
using narrower media, change the Label Width setting (Section
4.1.2) to match your media’s width to avoid printing on the platen.
(2) During any Quick Test, press the
key to stop printing.

key or the

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

4.3.1

Print Quality Label

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

key.

• Use the
key to
scroll to ‘Print Quality
Label’.
Ž Use the
key to
select a quantity; see Section
4.0.3.
• Press the
start printing.

key to

4.3.2

Configuration Label

The Configuration Label provides valuable printer database information, as
detailed in Section 4.1.
þ Note: The Configuration Label content can vary with the application version
and printer model. To print all information, the media cannot be less
than 2 inches wide (51mm) and the Label Width setting must match the
width of the media being used (see Section 4.1.2).

To print a Configuration Label:
Œ Press the

key.

• Use the
key to scroll
to ‘Print Configuration’.
Ž Press the
start printing.

key to

4.3.3

Quick Ribbon Test Label

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

key.

• Use the

key to scroll to ‘Ribbon Test Label’.

Ž Use the

key to select a quantity; see Section 4.0.3.

• Press the

key to start printing.

4.3.4

Dot Test Pattern Label

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

key.

• Use the

key to scroll to ‘Dot Test Pattern’.

Ž Use the

key to select a quantity; see Section 4.0.3.

• Press the

key to start printing.

Good Test Pattern Label:
Even pattern consistency
indicates correct printhead
is operation.

Faulty Test Pattern Label:
Streaks indicate a dirty or
faulty
printhead.
See
Section 5.3.1 for cleaning
instructions.

4.3.5

Validation Label

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

key.

• Use the

key to scroll to ‘Validation Label’.

Ž Use the

key to select a quantity; see Section 4.0.3.

• Press the

4.3.6

key to start printing.

User Defined Label

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

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

5.0.1

Standard Calibration

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

Empty:

•

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

•

Paper:

No media in the sensor.

The label (with the liner attached) in the sensor.

To perform a Standard Calibration:
Step

Operator Action

(Media should be loaded
and the appropriate
Sensor Type selected.)
Turn ‘On’ the printer.

Press the

key.

Displayed Message

Comment
Wait until the
printer initializes
(about six
seconds).
You are entering
Menu Mode.

Raise the printhead
assembly.

Standard Calibration (continued)
Step

Operator Action

Press the
key to
enter the Media Settings
menu.

See Section 4.1.2
for menu layout.

Press the
key
and scroll to ‘Sensor
Calibration’.

Press the
key to abort this
procedure.

Press the

key.

You are beginning
the standard
calibration
procedure.

Press the

key.

This sets the
parameter for the
‘empty’ value.

Remove the media from
the Media Sensor then
press any key.

Displayed Message

Comment

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

Standard Calibration (continued)
Step
7

Operator Action

Displayed Message

Proceed according to
your media type:
Die-cut stock: strip the
Or, for reflective media:
media from the backing
and then reinsert it into
the sensor; adjust the
Sensor Eye Mark over
the center of the backing.
Notched stock: adjust
the Sensor Eye Mark
over the center of the
notch.
Reflective stock: Adjust
the Sensor Eye Mark
over the center of the
facedown black mark.
Continuous stock: go to
Step 8.

Comment
This sets the
parameter for the
‘gap’ or ‘mark’
value.
Where ‘yyy’ is a
numerical value
representing the
current sensor
reading: useful in
locating the best
sensor position.
þ Note: Never
position the
sensor over a
perforation when
recording a
sensor reading.

Press any key to
continue.
þ Note: Do not move the position of the Media Sensor after it has been
adjusted.

Position the label (and
backing, if any) under
the Sensor Eye Mark.

This sets the
parameter for the
‘paper’ value.

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

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

Press any key to
continue.

Standard Calibration (continued)
Step
9

Operator Action

Displayed Message

Observe the display.

Comment
The calibration
was successful.

Or, for reflective media:

See note below if
another message
was displayed.

Or, for continuous media:

10 Exit upon successful
calibration: Back out of
the menu tree by
repeatedly pressing the
key.
If using gap or reflective
media, press and hold
the FEED key. The
printer will begin
advancing media; allow
at least one label gap (or
mark) to advance under
the sensor.

The printer is now
ready to begin
printing.
If this calibration
was not successful,
go to Section 5.0.2.

þ Note: A ‘Warning Low Backing’ message indicates that the calibration was
successful with notched media or media on a transparent liner; see
Section 6.1 for details on this and other possible messages.

5.0.2

Advanced Entry Calibration

Advanced Entry Calibration is the alternate method for special-case media
types. The procedure has two parts:
1) Using different sampling algorithms, displayed sensor readings have to be
listed for each label and TOF value.
2) From this data, the best algorithm is chosen; then those values are manually
entered for the ‘Paper’, ‘Gap’ (or ‘Mark’), and ‘Empty’ variables.

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

To perform an Advanced Entry Calibration:
Step

Operator Action

(Media should be loaded
and the appropriate
Sensor Type selected.)
Turn ‘On’ the printer.

Press the

key.

Displayed Message

Comment
Wait until the
printer initializes
(about six
seconds).
You are entering
Menu Mode.

Raise the printhead
assembly.
3

Press the
key to
enter the Media Settings
menu.

See Section 4.1.2
for menu layout.

Press the
key
and scroll to ‘Sensor
Calibration’.

Press the
key to abort this
procedure.

Press the

You are entering
the calibration
submenu.

key.

Advanced Entry Calibration (continued)
Step

Operator Action

Displayed Message

Comment

Press the
key
to scroll to ‘Advanced
Entry’.

You are entering
Advanced Entry
Calibration.

Press the

key.

Press the
key to abort this
procedure.

Press the

key.

You are beginning
the Advanced
Entry Calibration.

Press the

key.
-OR-

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

-OR-

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

Place the label under the
Sensor Eye Mark and
lower the printhead
assembly.

10 Press the
key
to select the setting
(denoted by an ‘*’) and
then record the sensor
reading (the ‘yyy’ value)
in a table similar to the
one shown after Step 12,
as a Label Value.
Next, press the
key to increment the
Gain Number.
Repeat this step for each
of the Gain Numbers
(00-32).

þ Note: Never
position the
sensor over a
perforation when
recording a
sensor reading.

Advanced Entry Calibration (continued)
Step

Operator Action

Displayed Message

11 Proceed according to
your media type:
Die-cut stock: strip the
media from the backing
and then reinsert it into
the sensor; adjust the
Sensor Eye Mark over
the center of the backing.
Notched stock: adjust
the Sensor Eye Mark
over the center of the
notch.
Reflective stock: Adjust
the Sensor Eye Mark
over the center of the
facedown black mark.

Or, for reflective media:

Comment
Where ‘yyy’ is a
numerical value
representing the
current sensor
reading: useful in
locating the best
sensor position.
þ Note: Never
position the
sensor over a
perforation when
recording a
sensor reading.

Press the
key
to select the setting and
then record the sensor
reading in a table similar
to the one shown after
Step 12, as a TOF
Value.
Next, press the
key to increment the
Gain Number.
Repeat for each of the
Gain Numbers (00-32).

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

Advanced Entry Calibration (continued)
Step

Operator Action

Displayed Message

12 From the data collected in
Steps 10 and 11, where
both the sensor readings are
above 20, subtract each
Label Value from the
corresponding TOF Value.
These are the Difference
Values.

Comment
Both sensor
readings must
be above 20.

Or, for reflective media:

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

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

Gain
Number

Label
Value

TOF
Value

Difference
Value

00
01
02
03
04
05
06
07
08
09
10
11
12
…
31
32

255
251
241
231
219
212
200
189
178
167
156
146
136
…
116
112

254
240
213
182
150
119
88
58
32
19
17
16
15
…
14
14

1
11
28
49
69
93
112
131
146
N/A
N/A
N/A
N/A
…
N/A
N/A

Advanced Entry Calibration (continued)
Step

Operator Action

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

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

Displayed Message

Comment
Selection is
denoted with an
‘*’.

Or, for reflective media:

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

Ž Remove all media.
Record the sensor
reading and label it ‘E’
(Empty).
15 Press the
Then press the
key.

key.

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

Advanced Entry Calibration (continued)
Step

Operator Action

16 Press the

Displayed Message

key.

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

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

Or, for reflective media:

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

17 After all entries have been
made, press the
key to back out of the menu
and then press the
key to save the settings and
return to the Ready Mode.

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

þ Note: If the Advanced Entry Calibration fails, try the following procedure.
Re-enter Media Settings / Calibration / Advanced Entry / Sensor Gain
and lower the selected Gain Setting number by one (to make the
sensor less sensitive). Select the new Gain Setting, save the changes,
exit the menu, and then test your media. Repeat the procedure until a
usable media setting is obtained.

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

5.1.1

Leveling Cam Adjustment

When printing on less than full width media,
use the Leveling Cam to adjust the right side of
the Printhead Assembly for even pressure
distribution. To adjust the Leveling Cam:
Œ With media loaded in the printer, download your label format (or use a
Quick Test format) and begin batch printing.
• While observing the printed labels, rotate the Leveling Cam counterclockwise to an over-adjusted position (see Example 1, below).
Ž Next, rotate the Leveling Cam clockwise, one click at a time, until the
printed labels contain a complete, even image (see Example 2).

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

Example 1 – Over adjustment:
Too much adjustment produces an image
that fades across the label. To correct this,
decrease the setting of the Printhead
Leveling Cam.

Example 2 – Correct adjustment:
The proper adjustment produces a
complete image with even print contrast
across the label (see note below).

þ Note: Under-adjustment of the Leveling Cam: Problems can include ribbon
wrinkling, label tracking, and platen roller and printhead wear.

5.1.2

Burn Line Adjustment

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

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

To adjust the Burn Line:
Œ Load the printer with your media
(and ribbon, if required), lower the
printhead assembly and rotate the
printhead latch back into the locked
position.
• Loosen the two Locking Screws
approximately ¼ turn counterclockwise.
Ž Turn the Adjustment Screws counter-clockwise until the burn line is past
the platen roller vertex. Print a Validation Label from the Quick Test menu;
see Section 4.3.5. The label should look light and uneven.
• Tighten the Locking Screws just until they are ‘snug’ (tight enough to
remove any play in the printhead assembly, yet loose enough to allow the
Adjustment Screws to move the printhead).
• Turn each Adjustment Screw clockwise about a ¼ turn (or an 1/8 turn for
finer adjustments, see note below). Print another Validation Label and
examine the print quality. Repeat this step until the labels are produced with
even print contrast (darkness) and acceptable print quality are produced.
þ Note: When the Locking Screws are ‘snug’, turning the Adjustment Screws
counter-clockwise will not move the printhead outward; if you have
adjusted the printhead too far inward, restart the entire procedure.

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

5.2 Printhead Replacement
þ Note: The printhead is fragile; use extreme care when handling and never
use a sharp object on the surface. If you have any questions or
concerns regarding this procedure, contact a qualified technician or
Technical Support before proceeding.

If the printhead must be replaced, Locating Pins eliminate the need for printhead
alignment after the installation. To replace the printhead:
Œ Touch a bare metal part of the printer’s
frame to discharge any static electricity
that may be present.
• Turn ‘Off’ and unplug the printer. Open
the access cover, if ribbon is installed,
remove it.
Ž With the printhead locked in the down position, loosen the Printhead
Mounting Screw (it will remain captivated in the assembly).
• Rotate the printhead latch forward. While holding the Printhead, raise the
assembly. Disconnect the two Cables and then remove the old Printhead.
• While
carefully
holding
the
new
Printhead,
connect
both Cables.
‘ Position the Printhead
onto the Locating
Pins in the Printhead
Assembly and secure
in place with the
Printhead Mounting
Screw. (Do not overtighten this screw.)
’ Clean the Printhead; see Section 5.3.1.
“ Reload ribbon (if removed), lower the printhead assembly, and rotate the
printhead latch back, into the locked position. Plug in and turn ‘On’ the
printer. Print a Validation Label from the Quick Test menu; see Section
4.3.5. If necessary, adjust the print darkness to match that of the previous
printhead using the Print Control/Custom Adjustments/Darkness setting in
the menu; see Section 4.1.3.
73

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

Isopropyl alcohol
Cotton swabs
A clean, lint-free cloth
Soft-bristle brush
Soapy water/mild detergent
Compressed air

CAUTION
Area
Printhead

Platen
Roller

For your safety and to avoid damaging the printer, turn ‘Off’ and
unplug the printer before cleaning; and take proper precautions
when using isopropyl alcohol, a flammable liquid.

Recommended Cleaning Schedule
Method
Interval
Using a cotton swab dampened with isopropyl Clean after
alcohol, clean the printhead from end to end, each roll or
removing all build-up. See Section 5.3.1.
box of labels,
WARNING! Before cleaning, allow time for the or after each
roll of ribbon.
printhead to cool.
Using a cotton swab dampened with isopropyl Clean after
alcohol, rotate the platen and remove all build- each roll or
up. See Section 5.3.2.
box of labels,
or after each
roll of ribbon.

Media
Compressed air / soft-bristle brush and isopropyl As needed,
Path / Tear alcohol. Remove all build-up along the path that based on a
Plate
the ribbon and paper follow through the printer. weekly visual
inspection.
Media
Sensor

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

Interior

Soft-brush or compressed air. Remove all build- As needed.
up. See Section 5.3.3.

Exterior

Mild detergent. Remove all build-up. See As needed.
Section 5.3.3.

Cutter

Refer to the documentation supplied with the As directed.
option.

5.3.1

Cleaning the Printhead

If print quality declines (symptoms include non-compliant bar codes, print
dropouts, streaks; see Section 4.3.4), the typical cause is debris build-up on the
printhead. Furthermore, when the build-up is not removed it may lead to element
failure, greatly reducing the life of the printhead. To clean the printhead:
Œ Turn ‘Off’ and unplug the printer.
• Open the access cover. Unlock the Printhead Latch and raise the Printhead
Assembly. Move media and ribbon away from the printhead as necessary.
Ž Using a cotton swab moistened, not soaked, with isopropyl alcohol gently
wipe away any build-up on the Printhead surface, paying close attention to
the Burn Line. Allow the printhead to dry.
• Replace the ribbon and media. Lower the Printhead Assembly and rotate the
Printhead Latch completely back, to the locked position.
• Close the cover. Plug in and turn ‘On’ the printer. Feed several labels to
normalize tracking.

NEVER use a sharp object to clean the Printhead.

CAUTION
75

5.3.2

Cleaning the Platen Roller

A platen roller contaminated with grit, label adhesive, or ink can cause a decline
in print quality and, in extreme cases, cause labels to stick and wrap around the
roller. To clean the platen roller:
Œ Turn ‘Off’ and unplug the printer.
• Open the access cover. Unlock the Printhead Latch and raise the Printhead
Assembly. Remove media and ribbon.
Ž Using a Cotton Swab dampened with isopropyl alcohol, clean the Platen
Roller; manually rotate the roller and repeat, cleaning the entire surface.
Allow the Platen Roller to dry.
• Replace ribbon and media.
• Lower the Printhead Assembly and rotate the Printhead Latch completely
back, to the locked position.
‘ Close the access cover. Plug in and turn ‘On’ the printer. Feed several labels
to normalize tracking.

NEVER use a sharp object to clean the Platen Roller.

CAUTION
76

5.3.3

Cleaning Interior and Exterior Surfaces

Interior Surfaces: During operation, dust particles from the media build-up
inside the printer. Then, as the media is pulled through the printer, the particles
can become attached and cause voids on the printed labels. To prevent this, turn
‘Off’ and unplug the printer. Remove all media. Using a soft bristle brush or
compressed air, clean out the interior of the printer.
Exterior Surfaces: The outer surfaces of the printer should be cleaned using a
general-purpose cleanser. Never use abrasive cleansers or solvents. To clean,
turn ‘Off’ and unplug the printer. Using a soft cloth or sponge dampened with
the cleanser, wipe the exterior surfaces until clean.

5.4 Application Version Updates
The printer stores its application program in Flash memory on the Main PCB. A
feature is included that allows updates to this program through any printer
interface port. Updates can be found at our web site.
There are two modes in which the firmware of the printer can be updated: (1)
the Ready Mode, or (2) the Download Mode. Before beginning an update,
identify the current version of the printer’s application program by printing a
Configuration Label (see Section 4.3.2). Compare that version string to those
filenames available from our web site and then download the desired file onto
your computer’s hard drive.
Proceed with the printer update accordingly:
Ÿ

If the current application version is 2.091 or greater, refer to Section 5.4.1
or Section 5.4.2.

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

Should an error occur during the download (see Section 5.4.3),
the update is aborted. If this process did not reach ‘Erasing Flash’
or ‘Updating Software’, the previous program is left intact;
WARNING otherwise, a successful download must be completed before the
printer is operable.
þ Note: Users desiring a foreign language menu: After updating from 2.xx to
3.xx firmware for the first time, you must also download the EFIGS
menu language file. Go to the EFIGS ftp directory and copy
832296.01C (or most current version) to lpt1: /b (the DOS Copy
command requires the /b parameter because this file contains binary
code).

5.4.1

Updating from Ready Mode
Update Procedure for Application Version 2.091 or greater

Step Displayed Message
1

Operator Action

Comment(s)

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

As an example, this would be
entered as:
copy 4212tb~1.zs lpt1
(Where ‘lpt1’ is the host
computer’s port; however,
this selection can differ to
include a serial or other port,
as the printer is equipped.)

copy filename lpt1: The Ready Indicator will
flash as data is received.
2

No action required. The new application program
is being stored and verified.

No action required. The printer has reset
automatically and is now
displaying the new firmware
version.

No action required.

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

5.4.2 Updating from Download Mode
Required Update Procedure for Application Version 2.08 or earlier*
Step

Displayed Message

Operator Action

Comment(s)

Press and hold the The Boot Loader version
PAUSE and TEST is displayed.
keys while turning þ Note: This information
‘On’ the printer to
will vary with the printer
enter the Download model and Boot Loader
version.
Mode.

Using the DOS
copy command,
copy the filename
to the printer (see
Step 2 in Section
5.4.1).

The printer is ready to
accept the new application
version.
þ Note: The parallel port
(LPT1) must be used to
write to the printer.

No action required. The printer is receiving
the new image (program).

No action required. The program has been
received and verified;
now memory is being
cleared of the previous
application.

No action required. The new program is being
written into Flash
memory. Upon
completion, the printer
will automatically reset
and start the new
application.
þ Note: If ‘Uncalibrated’
is displayed, the printer
must be calibrated (see
Section 5.0).

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

5.4.3

Possible Problems during an Update

The following is list of possible error messages when downloading:
þ Note: If experiencing trouble when attempting to download the file to the
printer, try the following alternate methods:
1) Use Download Mode (see Section 5.4.2).
2) Windows users – try restarting the computer in MS-DOS mode.
3) Use the Windows Driver by Seagull Scientific™ – Device Setting /
Send File to Printer function.

Application Update Error Messages
Displayed Message
Descriptions / Causes / Solutions
The printer detected an error during the
decompression and transfer of file data from
cache storage into the Flash memory. Confirm the
version and retry in Download Mode; however, if
the problem continues call for service.
The printer could not successfully erase Flash
memory. The possible cause is defective Flash
memory. Try the download again; however, if the
problem continues call for service.
The printer could not successfully write the
program into Flash memory. A possible cause is
defective Flash memory. Try the download again;
however, if the problem continues call for service.
Application Firmware downloaded was not
compatible with the printer’s Main PCB. The
firmware used was for a different model and not
supported by this boot loader version. See
Configuration Level, Section 4.1.5.
The printer detected an error in the download. The
possible causes include:
• An invalid or corrupted file was downloading.
Try saving the file to the host and then
download again.
• A communications error. Recheck cabling and
port setting.
Software level not authorized for this printer (See
Section 4.1.5, Configuration Level/Printer Key.)
80

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

WARNING

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

þ Note: Only printers with an Application Version of 2.09 or greater can
update the Boot Loader Program.

Before beginning the Boot Loader update, identify the printer’s current version.
Print a Configuration Label (see Section 4.3.2) and compare that version string
to those available from our web site. Download the desired version onto your
computer’s hard drive. To update the Boot Loader Program:
Boot Loader Update Procedure
Step Displayed Message Operator Action
Comment(s)
As an example, this would be
entered as:
copy boottb~1.bs lpt1
(Where ‘lpt1’ is the host
computer’s output port;
however, your selection can
differ to include a serial or
other port, as the printer is
equipped.)
copy filename lpt1: The Ready Indicator will flash
as data is received.

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

No action required. The new program is being
stored and verified.

No action required. The printer has reset
automatically.

No action required. The new application is now
running.
þ Note: If ‘Uncalibrated’ is
displayed, the printer must
be calibrated (see Section
5.0).

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

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

If experiencing this problem…

Try this solution…

Cannot communicate through
the parallel port:

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

Cannot load media through
the optional cutter:

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

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

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

Erratic feeding:

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

Erratic printing (instead of the • The printer may be in Hex Dump Mode;
label format, strange characters
see Section 6.2.
are printed):
• If using the serial port for communicating,
check both the host and printer port
settings; the printer may be set to eight
data bits while the host is set to 7 (or vice
versa).

If experiencing this problem…

Try this solution…

Intellifont will not print:

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

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

• The Printhead Leveling Cam may be
incorrectly adjusted; see Section 5.1.1.

Missing information in the
printed label:

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

• The Platen Roller may be dirty or worn;
see Section 5.3.2.

• The available memory may have been
exceeded by the memory requirement of
the label format. Try reducing the memory
allocated to either the internal module or
scaleable font caches; see System Settings
/ Memory Settings, Section 4.1.5.
• If using serial communications, ensure that
the interface cable meets the requirements
found in Section 3.0.1.
Missing print on left or right
side of the label:

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

If experiencing this problem…

Try this solution…

No power (all indicator lights
are ‘Off”):

• Verify that the AC power cord connection
has been made at both the outlet and the
printer; also, ensure the power switch is
‘On’.
• Verify that the AC outlet is functioning, or
try moving the printer to another AC
circuit.
• The AC cord may be damaged; replace it.
• The line fuse may be blown; call for
service.

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

Examine the used ribbon for an image:
If there is an image on the used ribbon:
Ÿ Verify that the ribbon was properly loaded
per Section 3.3.
Ÿ If properly loaded, the wrong coating
configuration was used. (To verify the
inked side, press the adhesive backing of a
label against the ribbon surface. Ink will
only lift from the coated side of the
ribbon.) Clean the printhead (see Section
5.3.1); then replace the ribbon with the
correct type for the printer, Section 3.3.
If there is no image on the used ribbon:
• Run any Quick Test Label; see Section 4.3.
If an image printed, then check the
protocol and port settings for both the
printer and host. These must match.
• The heat setting may be too low. Make an
adjustment in the software program or
through the Front Panel. (The same
functional commands from the host
computer override the menu settings.)
• The media/ribbon combination may be
incorrect. Contact a Media Representative.
• The printhead or printhead cable(s) may be
loose; power ‘Off’ the printer then
reconnect; see Section 5.2 for locations.
85

If experiencing this problem…
Try this solution…
Nothing happens when trying • Ensure that the printer is at READY.
to print using a software
• Observe the Front Panel, if the READY
program:
light does not flash as you send the format
check the protocol and port settings
between the printer and host.
• Ensure the interface cable meets the
requirements found in Section 3.0.1.
Poor print quality:

• The printhead may need cleaning; see
Section 5.3.1.
• Adjust the Heat and Print Speed settings
through the Front Panel or by host
commands; see Section 4.1.3. (The same
functional commands from the host
computer override the menu settings.)
• The media/ribbon combination may not be
compatible; see Section 2.1.
• The Printhead Leveling Cam may be
incorrectly adjusted; see Section 5.1.1.
• The Platen Roller may be dirty or worn;
see Section 5.3.2.
• The Printhead Burn Line may need
adjusting; see Section 5.1.2.

Skips labels when printing:

• Quick Media Calibration may be needed;
see Section 3.4.
• The Media Sensor may be out of position;
readjust the position; see Section 3.2.
• The format may be within 1/8 inch of the
label’s edge. Try reducing or moving the
format slightly.

Unable to print rotated text:

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

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

Fault Messages:
Fault Messages receive the highest display priority. If more than one fault is
detected the display will cycle between messages.
þ Note: To return to normal operation after the printer enters a fault condition,
the fault must be corrected and then the FEED key must be pressed to
clear the condition.

Displayed Message

Printer Fault Messages
Description
Possible Solution(s)
The printer has
detected a drop in
the 24-volt power
supply.

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

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

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

The printer has
detected a cutter
mechanism fault.

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

Make sure the cutter option is
properly installed.
Carefully examine the cutter
for obstructions.

Printer Fault Messages (continued)
Displayed Message
Description
Possible Solution(s)
Try cycling the printer power
The printer has
‘Off’ and ‘On’. If the fault
detected a Direct
does not clear, call for
Memory Access
service.
failure.
Consistently low
sensor readings
were detected.

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

Consistently high
sensor readings
were detected.

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

The printer cannot
detect media.

Try the following:
1) Load media.
2) Ensure that the labels are
passing through the Media
Sensor.
3) Readjust the Media Sensor
over the TOF mark; see
Section 3.2.
4) If using media with large
gaps, adjust the Paper Out
Distance; see Section 4.1.2.
5) Calibrate the printer; see
Section 5.0.

Printer Fault Messages (continued)
Displayed Message
Description
Possible Solution(s)
Press the FEED key in an
The printer was
unable to complete attempt to clear the message.
If necessary, perform a media
the Media
Calibration; or, the calibration or correct the
related fault condition.
printer was
powered off or
reset during a
ribbon, out of stock
or TOF fault.
The printer has
detected a problem
within the print
logic.

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

The system has
detected a RAM
failure.

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

Consistently low
sensor readings
were detected.

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

Printer Fault Messages (continued)
Displayed Message
Description
Possible Solution(s)
Consistently high
sensor readings
were detected.

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

Try the following:
1) Ensure that ribbon is
correctly loaded and that
the printhead assembly is
latched.
2) Check the ribbon supply
and ribbon take up hubs for
obstructions that may be
stopping movement.
3) Ensure that the ribbon core
fits snugly on the ribbon
supply hub.
4) Ensure that the media and
paper combination is not
slipping (usually caused by
an incorrect match).

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

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

Printer Fault Messages (continued)
Displayed Message
Description
Possible Solution(s)
The printer could
not find the TOF
mark within the
maximum label
length setting or it
found a TOF in an
unexpected place.
þ Note: When the
printer is set for
reflective media,
this indication is
given for an out of
stock condition.

If media is moving:
1) Press the FEED key. It may
be necessary to re-calibrate
the printer; see Section 5.0.
2) The Media Sensor may be
out of position. Readjust it;
see Section 3.2.
3) The media may not be
properly loaded. Reload
media, also ensure that the
Media Guide is positioned
properly; see Section 3.1.
4) The Leveling Cam may be
improperly adjusted; see
Section 5.1.1.
5) The label may be longer
than the default value for
maximum length. Check
the Media Settings /
Maximum Label Length;
see Section 4.1.2.
6) The Media Sensor may be
obstructed. Check and
carefully remove any
obstruction (labels, paper
dust, adhesive, etc).
If media is not moving:
The printhead assembly may
not be latched; close and
lock.

Warning Messages:
Warning Messages are displayed for a period of five seconds. If multiple
Warnings are detected, the display will reflect the highest priority message.

Displayed Message

Printer Warning Messages
Description
Action(s)
Replace the printhead if the
The printer has
print quality becomes
detected defective
unacceptable.
printhead elements.
The printer measured
only a small
difference between
the ‘empty’ and ‘gap’
sensor readings.

Transparent backing or
notched media typically
gives this indication. In this
case, there may be a slight
delay in the ‘Out of Stock’
indication, after the media
supply is emptied; no
action is required.

Power has been
removed and
shutdown is in
progress.

The printer power switch
was turned ‘Off’, the line
fuse has blown, or AC line
voltage has been lost.

The host has pending
configuration
changes that will not
take effect until a
‘host reset command’
is issued.

To save changes, send a host
reset command (in DPL), or
to discard changes perform a
soft reset; see Section
4.0.6.1.

The printer has
detected a low
operating voltage.

Possible low or fluctuating
line voltage level. Try
moving the printer to
another outlet. If the
condition persists, call for
service.

The printer was
Possible faulty Main PCB.
unable to save
If the condition persists, call
settings in permanent for service.
memory.
A high printhead
No action required.
temperature has been
detected.
92

6.2 Hex Dump Mode
The Hex Dump Mode is a useful tool for diagnosing problems, including
communication and DPL syntax errors, allowing a comparison of input strings
(sent by host) to output data (received by printer). To decode this information,
the Programmer’s Manual is an essential reference. This output can be used for
debugging the label format. In addition, by repeatedly sending a format, this
mode can uncover handshaking problems (if they exist). Handshaking problems
are identified by sections of missing data in the character string.
To begin, go to the Diagnostics menu and enable Hex Dump Mode; see Section
4.1.7. Exit the menu and save the changes. Now, ‘HEX DUMP MODE’ will be
indicated by the display and all data sent to the printer will now be output in
hexadecimal code, along with the printable ASCII equivalents.
The figure below is a sample Hex Dump Label. After sending a label format to
the printer, the hex code output will be immediate. As a final note, many
software programs use bit mapping to construct the label, making diagnosis
difficult. Contact Technical Support with any questions.

þ Note: To return to Ready Mode, re-enter the Diagnostics Menu and disable
the Hex Dump Mode, exit the menu, then save the changes.

7.0 General Specifications
Bar Codes
(See the Programmer’s Manual for details. See Appendix B for samples.)
Code 39, Interleaved 2 of 5, Code 128 (subsets A, B and C), Codabar,
LOGMARS, UPC-A, UPC-E, UPC 2 & 5 digit addendums, EAN-8, EAN-13,
EAN 2 & 5 digit addendums, UPC Random Weight, Code 93, Plessey,
Universal Shipping Container Symbology, Code 128 MOD 43, Postnet,
USS/EAN-128 Random Weight, Telepen, USD-8 (Code 11), UPS MaxiCode
(modes 2 & 3), PDF417, Data Matrix, QR Code, Aztec*, and MicroPDF417*.

Fonts
9 Bit-Mapped Fonts, rotatable 0, 90, 180, 270 degrees
CG Triumvirate Scalable Font
CG Triumvirate Condensed Bold Scalable Font

Communications
Interfaces:

EIA RS-232/DB-25 Serial, and
IEEE 1284 Compliant Parallel

Serial Data Rates:

1200, 2400, 4800, 9600, 19.2K, and 38.4K baud.

Handshaking:

Xon/Xoff; CTS/DTR

Parity:

Even, Odd, or None

Stop Bits:

1 or 2

Data Bits:

7 or 8

Electrical
Input Voltage:

90 – 132 or 180 – 264 VAC @ 47–63 Hz, autoranging.

Power Consumption:

Typical Operating: 90 Watts / Standby: 10 Watts

Grounding:

Unit must be connected to a properly grounded
receptacle.

Environmental Requirements
Operating Temperature:

32° F – 100° F (0° C to 38° C)

Storage Temperature:

0° F −140° F (-17° C to 60° C)

Humidity:

10% − 95% non-condensing

Dust:

Non-conducting, non-corrosive

Electromagnetic Radiation: Moderate RF fields can be tolerated

Mechanical
Height:

12.70” (322.6 mm)

Width:

12.62” (320.6 mm)

Depth:

18.60” (472.5 mm)

Weight:

45 lbs. (20.5 kg)

Printing Specifications
Printing Type:

Direct Thermal or optional Thermal Transfer

Print Speed:

2 – 8 IPS (51 – 203 mmps) 2461
2 – 8 IPS (51 – 203 mmps) 3481
2 – 4 IPS (51 – 102 mmps) 6441

Printhead Resolution:

203 DPI (8.0 dots/mm) 2461
300 DPI (11.8 dots/mm) 3481
600 DPI (23.6 dots/mm) 6441

Nominal Dot Size:

.0043” X .0052” (.11 mm x .13 mm) 2461
.0027” X .0043” (.07 mm X .11 mm) 3481
.0008” X .0015” (.03 mm X .06 mm) 6441

Printhead Protection Type: Thermistor Sensor. Temporary shutdown of
printing occurs upon over-temperature detection;
printing resumes automatically after cool-down.
Maximum Print Width:

(Continued next page)

4.10” (104.0 mm) 2461
4.16” (105.7 mm) 3481
4.16” (105.7 mm) 6441

Printing Specifications (continued)
Print Length Range:

.25” – 99” (6.4 mm – 2514.6 mm) 2461&3481
.25” – 55” (6.4 mm – 1397 mm) 6441
with an optional cutter: 1.25” – 99” (31.8 mm – 2514.6 mm) 2461&3481
1.25” – 55” (31.8 mm – 1397 mm) 6441
with an optional peel & 1.50” – 99” (38 mm – 2514.6 mm) 2461&3481
present mechanism: 1.50” – 55” (38 mm – 1397 mm) 6441

Print Justification:

Left

Flash Memory:

1 MB 2461
2 MB 3481&6441

SDRAM Memory:

8 MB 2461
16 MB 3481&6441

7.1 Media and Ribbon Requirements
Media Types:

Roll-Fed, Die-Cut, Continuous, and Fan-Fold. Flat
on the printable side with no more than .0007”
(.018 mm) protrusions on the opposite side.

Media Roll Capacity*:

8” (203 mm) outer diameter

Media Core:

1.5” or 3.0” (38 mm or 76.2 mm) inner diameter

Ribbon Core:

1.010” ± .006” (25.6 mm ± .2 mm) inner diameter.
Core not to protrude beyond ribbon edge.

Ribbon Width Range**:
**

Ribbon Length :
*

1.0” – 4.5” (25.4 mm – 114.3 mm)
1968’ (600 meters) maximum

Wound out labels only.
Coated side ‘in’ or ‘out’ not interchangeable, dependent upon the Ribbon Supply Hub
type; the ribbon width to slightly exceed label width (including backing material).

Media and Ribbon Requirements (continued)
G

I
H
J

A
B

Designator
A
B
C
D
E
F
G
H
I
J

Media Dimensions
Description

Maximum [1] Minimum[1]
label width
4.65
1.00
liner width
4.65
1.00
gap (or notch) between labels[4]
–
.100
label length [4]
–
.250
media thickness[2]
.0100
.0025
notch opening width
.500
.200
distance from the media’s edge to the
2.250
.200
media sensor aperture (left justified)
reflective (black) mark width [3]
4.65
.500
distance between reflective marks[4]
–
.500
reflective mark length [4]
–
.100

[1]

Units of measure given in inches.
If the optional Light-Duty Cutter is attached, it must be aligned to only cut liner, where
the thickness can be no greater than .005” (.127mm).
[3]
The reflective (black) mark must be carbon based, placed on the backside of the stock,
and the reflectance shall be less than 10% at wavelengths of 950 and 640 nm.
[4]
The maximum allowable length of the combined label and gap (or mark) measurement
cannot exceed 99.99 inches.
[2]

Approved Media
To achieve optimum print quality and maximum printhead life, we recommend
the use of our media and ribbons. These supplies are specially formulated for
use in our printers; use of other supplies may affect the print quality,
performance, and life of the printer or its components. For a current list of
approved media and ribbons for use in direct thermal and thermal transfer
applications consult Section 2.1.1 or contact a Media Representative.
98

Appendix A
ASCII Control Code Chart
Ctrl @
Ctrl A
Ctrl B
Ctrl C
Ctrl D
Ctrl E
Ctrl F
Ctrl G
Ctrl H
Ctrl I
Ctrl J
Ctrl K
Ctrl L
Ctrl M
Ctrl N
Ctrl O
Ctrl P
Ctrl Q
Ctrl R
Ctrl S
Ctrl T
Ctrl U
Ctrl V
Ctrl W
Ctrl X
Ctrl Y
Ctrl Z
Ctrl [
Ctrl \
Ctrl ]
Ctrl ^
Ctrl _

Char
NUL
SOH
STX
EXT
EOT
ENQ
ACK
BEL
BS
HT
LF
VT
FF
CR
SO
SI
DLE
DC1
DC2
DC3
DC4
NAK
SYN
ETB
CAN
EM
SUB
Esc
FS
GS
RS
US

Dec
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Hex
00
01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
0E
0F
10
11
12
13
14
15
16
17
18
19
1A
1B
1C
1D
1E
1F

Char
!
“
#
$
%
&
‘
(
)
*
+
,
.
/
0
1
2
3
4
5
6
7
8
9
:
;
<
=
>
?

Dec
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63

Hex
20
21
22
23
24
25
26
27
28
29
2A
2B
2C
2D
2E
2F
30
31
32
33
34
35
36
37
38
39
3A
3B
3C
3D
3E
3F

Char
@
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
^
_

Dec
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95

Hex
40
41
42
43
44
45
46
47
48
49
4A
4B
4C
4D
4E
4F
50
51
52
53
54
55
56
57
58
59
5A
5B
5C
5D
5E
5F

Char
`
a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q
r
s
t
u
v
w
x
y
z
{
|
}
~

Dec
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127

Hex
60
61
62
63
64
65
66
67
68
69
6A
6B
6C
6D
6E
6F
70
71
72
73
74
75
76
77
78
79
7A
7B
7C
7D
7E
7F

ASCII Control Code Chart (continued)
Char
Ç
ü
é
â
ä
à
å
ç
ê
è
è
ï
î
ì
Ä
Å
É
Æ
Æ
ô
ö
ò
û
ù
ÿ
Ö
Ü
Ø
£
Ø
x
ƒ

100

Dec
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159

Hex
80
81
82
83
84
85
86
87
88
89
8A
8B
8C
8D
8E
8F
90
91
92
93
94
95
96
97
98
99
9A
9B
9C
9D
9E
9F

Char
á
í
ó
ú
ñ
Ñ
a
°
¿
®
1/2
1/4
¡
–

Dec
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191

Hex
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
AA
AB
AC
AD
AE
AF
B0
B1
B2
B3
B4
B5
B6
B7
B8
B9
BA
BB
BC
BD
BE
BF

Char

ã
Ã

Ò
D
Ê
Ë
È
Í
Î
Ï

Dec
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223

Hex
C0
C1
C2
C3
C4
C5
C6
C7
C8
C9
CA
CB
CC
CD
CE
CF
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
DA
DB
DC
DD
DE
DF

Char
Ó
ß
Ô
Ò
õ
Õ
µ
p
p
Ú
Û
Ù
´y
´Y

±
3/4

÷
¸
°
¨
·

Dec
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255

Hex
E0
E1
E2
E3
E4
E5
E6
E7
E8
E9
EA
EB
EC
ED
EE
EF
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
FA
FB
FC
FD
FE
FF

Appendix B
Available Fonts and Bar Codes
All character fonts and bar codes available with the printer are described in this
section. Each font and bar code has a name associated with it for use in
programming. Human-readable fonts have numeric names, while bar code fonts
have alpha names. Consult the Programmer's Manual for detailed information.

Fonts
Fonts 0 through 8 use the slash zero (Ø) convention for distinguishing between
the number zero and the letter O. The slash can be removed with the ‘Z’ labelformatting command. These fonts are non-proportional (monospaced): each
character takes the same amount of space for printing.
The Triumvirate font number 9 is a proportional font: each character will take
up a different amount of space when printed.
Font

Valid ASCII Characters

0
1
2
3

32-127
32-168, 171, 172, 225
32-168, 171, 172, 225
32, 35-38, 40-58, 65-90, 128, 142-144, 146, 153, 154,
156, 157, 165, 168, 225
32, 35-38, 40-58, 65-90, 128, 142-144, 146, 153, 154,
156, 157, 165, 168, 225
32, 35-38, 40-58, 65-90, 128, 142-144, 146, 153, 154,
156, 157, 165, 168, 225
32, 35-38, 40-58, 65-90, 128, 142-144, 146, 153, 154,
156, 157, 165, 168, 225
32-126
32, 48-57, 60, 62, 67, 69, 78, 83, 84, 88, 90
32-126, 128-169, 171-173, 181-184, 189, 190, 198, 199, 208-216, 222, 224 237, 241, 243, 246-250

4
5
6
7
8
9

101

The table below lists the font sizes; the numbers indicate the number of dots.
Font
0
1
2
3
4
5
6
7
8

Height
7
13
18
27
36
52
64
32
28

Width
5
7
10
14
18
18
32
15
15

Spacing
1
2
2
2
3
3
4
5
5

Font 0: 96-character alphanumeric,
upper and lower case.

Font 1: 145-character upper and
lower case alphanumeric
with descenders and
ascenders.

Font 2: 138-character alphanumeric,
upper and lower case.

Font 3: 62-character alphanumeric,
uppercase.

102

Font 4: 62-character alphanumeric,
uppercase.

Font 5: 62-character alphanumeric,
uppercase.

Font 6: 62-character alphanumeric, uppercase.

103

Font 7: OCR-A, size I.

Font 8: OCR-B, size III.

Font 9: Internal Triumvirate font. The number in the bar code height field
sets the point sizes. Larger point sizes can be obtained by increasing
the height and width multipliers.

104

Bar Code Summary Data
Bar Code fonts have alpha names (left column in the table below). Uppercase
alpha names will print barcodes with human-readable interpretations. Lowercase
alpha names will print barcodes only. The table is followed by visual samples.
Bar
Code
ID
A

Type
Code 3 of 9

Length Checksum
Varies

Yes

Valid ASCII Characters,
decimal value
representation
32, 36, 37, 42, 43, 45-57, 6590
48-57 Numeric only.
Option V used in the 6th &
7th position
48-57 Numeric only
48-57 Numeric only
32-127
48-57 Numeric only. Option
V used in the 7th & 8th
position
48-57 Numeric only
32, 36-39, 42, 43, 45-57, 6590
36, 43, 45-58, 65-68
48-57 Numeric only

UPC-A

C
D
E
F

UPC-E
Interleaved 2 of 5 (I 2 of 5)
Code 128
EAN-13

6
Varies
Varies
12

Yes
No
M-103
Yes

G
H

EAN-8
HBIC

7
Varies

Yes
M-43

I
J

Codabar
Interleaved 2 of 5 with a
modulo 10 checksum
Plessey

Varies
Varies

No
M-10

Up to
14

M-10

48-57 Numeric only. Option
+ is Last Character for
Second M-11 Checksum
48-57 Numeric only

2
5
Varies
Varies
19
18

Yes
Yes
No
Yes
Yes
Yes

48-57 Numeric only
48-57 Numeric only
35-38, 42-58, 65-90, 97-122
48-57 Numeric only
48-57 Numeric only
48-57 Numeric only

34 +

Yes

48-57 Numeric only

Varies
84
1
Varies
Varies
Varies
Varies
Varies

Yes
Yes
No
Yes
Yes
Yes
Yes
Yes

Varies
Varies

Yes
Yes

Alphanumeric
Alphanumeric
A, B, C, D
All
45, 48-57
All 8-bit values
Alphanumeric
Single byte or Kanji double
byte
All
All

T
U
v
z
WG
W1c
W1d
W1D

Interleaved 2 of 5 with a
modulo 10 checksum &
shipping bearer bars
2 digit UPC addendum
5 digit UPC addendum
Code 93
Postnet
UCC/EAN Code 128
UCC/EAN Code 128
K-Mart NON EDI barcode
UCC/EAN Code 128
Random Weight
Telepen
UPS MaxiCode
FIM
PDF-417
USD-8 (Code 11)
DataMatrix
QR Code – Auto format
QR Code – Manual format

W1f
W1z

Aztec
MicroPDF417

M
N
O
p
Q
R
S

105

Bar Code A: Code 3 of 9
Bar Code B: UPC-A

Bar Code C: UPC-E

Bar Code D: Interleaved 2 of 5

Bar Code E: Code 128
Bar Code F: EAN-13

Bar Code G: EAN-8

Bar Code I: Codabar

106

Bar Code H: Health Industry Bar
Code (HBIC)

Bar Code J: Interleaved 2 of 5
w/modulo 10 checksum

Bar Code K: Plessey

Bar Code L: Interleaved 2 of 5
w/modulo 10 checksum and
shipping bearer bars

Bar Code M: 2 Digit UPC addendum

Bar Code N: 5 Digit UPC addendum

Bar Code p: Postnet
Bar Code O: Code 93

Bar Code Q: UCC/EAN Code 128

Bar Code R: UCC/EAN Code 128
KMART NON EDI

107

Bar Code S: UCC/EAN Code 128
Random Weight

Bar Code T: Telepen

Bar Code v: FIM
Bar Code u: UPS MaxiCode

108

Bar Code z: PDF-417

Bar Code WG: USD-8

Bar Code W1c: DataMatrix

Bar Code W1d: QR Code

Bar Code W1f: Aztec

Bar Code W1z: MicroPDF417

Appendix C
Module Assignments
Memory Module
Designator Module Size Volatile*
A
B

N/A
N/A
Yes

Future Option
Future Option
1024 KB
(default size)
4 MB

256 KB

Y
Z

64 KB
4 MB

No
No

Location / Use
N/A
N/A
Main PCB SDRAM – user addressable
for graphics, fonts, and label formats
Optional Flash Card – user addressable
for graphics, fonts, and label formats
Main PCB Flash – user addressable for
graphics, fonts, and label formats
(unavailable on the 2461 model).
Main PCB Flash – reserved for EFIGS
Optional Flash Card – reserved for
ILPC

*When power is removed from the printer, stored data will be lost.

Print Resolutions and Maximum Label Widths
Model
2461
3481
6441

Resolutions and Widths
Maximum Print
Printhead
Width
Resolution
Inches Millimeters
203 dots/inch
4.10
104
(8 dots/mm)
300 dots/inch
4.16
105.7
(11.8 dots/mm)
600 dots/inch
4.16
108.2
(23.6 dots/mm)

Factory Default
Setting
4.10
4.16
4.16

109

Available Speeds and Default Settings
Printer Speed Ranges and Defaults*
Model
2461
Print
Feed
Reverse
3481
Print
Feed
Reverse
6441
Print
Feed
Reverse

Speed Range
IPS
MMPS
2-8
51 – 203
2-8
51 – 203
2-4
51 – 102
2-8
51 – 203
2-10
51 – 254
2-4
51 – 102
2-4
51 – 102
2-4
51 – 102
2-4
51 – 102

*Consult the Programmer's Manual for detailed information.

110

Default Setting
IPS
MMPS
8.0
203
8.0
203
4.0
102
6.0
152
6.0
152
4.0
102
3.0
76
4.0
102
4.0
102

Appendix D
GPIO Port Description
With the optional GPIO PCB, the printer can easily be programmed to interface
with most applicator devices. The GPIO functions are enabled and configured
using the menu system of the printer (see Section 4.1.4). These parameters are
stored in non-volatile memory and saved for subsequent power-ups.
When the GPIO is enabled, the printer will not print a label unless the Start of
Print signal is active. When a label is ready to print and the printer is waiting for
the Start of Print signal the printer will display “WAITING FOR SIGNAL”.

GPIO Port Connections
The external connection (see next page) is a 9-pin Mini-DIN Female connector
(for example, KYCON KMDG-9S-BS). Each pin function is detailed in the
table below:

Pin
#
1
2
3
4
5
6
7
8

GPIO Pin Functions
Signal
Signal
Signal
Description
Direction*
Name
State
Vcc
+5 VDC
Output
Printer +5 VDC
Ribbon
Low
Output Goes low when the printer
Fault
detects a ribbon fault.
Paper
Low
Output Goes low when the printer
Fault
detects a label movement fault.
Printer
Low
Output Goes low when any printer fault
is detected.
Fault
Spare
Reserved
Output
N/A
End of Print Programmable Output
Programmable
Spare
Reserved
Input
N/A
Start of
Low
Input
When ready to print a label, the
Print Signal
Applicator should set this signal
low for at least 50ms or until the
End of Print signal goes not
active.
Signal
Ground
N/A
N/A
Ground

*Signal direction is given relative to the printer.

111

GPIO Pin Configuration
(as viewed from the rear of the printer)

External Start of Print Control
Connections for an external Start
of Print control can be made (1)
directly to Pin 8 using a TTLlevel input or (2) with an
interface circuit similar to the
one shown right. For additional
interfacing requirements, see the
table below.

Vin max
VIH
VIL
IOH
IOL
VOH
VOL

GPIO Port Specifications*
5.5 VDC maximum input into any pin
3.8 VDC minimum (high level input voltage)
1.65 VDC maximum (low level input voltage)
-8 mA typical, - 25 mA maximum (high level output current)
8 mA typical 25 mA maximum (low level output current)
IOH = -8 mA, minimum 3.8 VDC
IOL = 8 mA, maximum .44 VDC

*See the SN74AHC244 data sheet for more information.

112

Appendix E
Menu System Multi-Language Support
This printer provides the user with the ability to download new menu system
languages and/or replace the provided translations. A Microsoft Excel
Spreadsheet defines the menu dictionary – the user adds a new language column
or modifies an existing column in the spreadsheet, clicks on the ‘Generate DPL
file(s)’ radio button and sends the generated DPL file(s) to the printer.
Here are the highlights and restrictions of the feature:
•

The printer can register up to 10 different display languages, including
EFIGS.

•

The EFIGS languages and any additional languages are stored on Module
Y: a 64KB Flash Module located on the Main PCB.

•

It is okay to download menu files generated for a lesser firmware revision to
new firmware – any messages that are not defined are displayed in English.

•

For the procedures below, the printer will accept the menu downloads from
any available port.

•

The language creation programs support Windows 95, Windows 98,
Windows NT, and Windows 2000.

Required Software
Application Version 3.0 or
greater*
Microsoft Excel 97
Img2dl.exe**

Comment
Must reside in the target printer. (See
Section 5.4 for details.)
Must be purchased by user.
Program used during the process to
create DPL file.
Menu Dictionary

Gemmsgxls.xls**
* Available from our web site
**Recommended that the Img2dl.exe and Gemmsgxls.xls files reside in the same
directory.

113

Creating a Menu Language:
Œ Invoke Excel and open the gemmsglst.xls file. Excel opens the file and the
following screen appears.

• Click the “Enable Macro” box and the following appears:

114

Ž Click On Column J and enter your new language, or modify an existing one.
Tips:
A) Message Size – When entering new messages, reference the ‘MAX’
column: this is the maximum number of characters allowed for this
field. Warnings are displayed when the number of characters is
exceeded or when trying to modify the MAX value. Beware that
“cutting” and “pasting” fields could defeat this warning system.
B) Two Line Messages – Some of the message are displayed as two lines.
These are indicated in the comment fields.
C) Comments – This field can be modified with no effect.

• When editing has been completed, highlight all of the columns you desire to
create (more than one language may be selected) by pressing the letter
above the column.
• Press the Generate DPL File(s) radio button. A
file will be generated for each of the selected
columns and Excel will provide confirmation.
(Example: small.ls)

115

‘ Download the generated files to the printer – one method is the DOS copy
command:
copy small.ls lpt1: /b
’ Reset the printer by pressing and holding the CANCEL key for
approximately four seconds.
“ Verify the operation by printing a Configuration Label (see Section 4.3.2).
The new font selection will be printed on the label under SYSTEM
INFORMATION / OPTIONAL LANGUAGES or select the new language
in the SYSTEM SETTINGS / MENU LANGUAGE in the printer’s menu.
This is the only method to determine whether the download was successful.
If the menu system displays the new language selection, but all displayed
messages remain in English an error has occurred. Re-check the process.
Contact Technical Support if problems continue (be prepared to provide the
Gemmsglst.xls and the DPL download file that you have created). Other
possible error messages are as follows:
Menu Language Error Message
Please select the entire column(s)
or the desired language(s), by
clicking on the column letter(s)
Message text may not exceed
MAX = xx designated characters
for this MID

Description
After pressing the Generate DPL
File(s) radio button, the languages
to convert were not correctly
selected.
The entered message exceeds the
number of characters specified in
column C. You may not modify
this number.

Advance File Handling Information
Ÿ

The Standard Printer leaves the factory with EFIGS loaded into module Y.
At this point, Module Y is LOCKED and will only accept additional
Language Downloads.

After downloading a language update, Module Y is left UNLOCKED until
the printer is reset or power is cycled. In this state, Module Y will accept
font, image and label format downloads. The module will also honor the
Clear Module request. Therefore, following an update it is recommended
that a reset be performed to lock the module; otherwise, a software package
may ‘Clear All Modules’ thus destroying the new menu language(s).

Module Y can be UNLOCKED by sending this DPL string: KpY0.

116

To restore the factory generated EFIGS image, download the file
*832296.01A to the printer. This file is located on our web site. The letter at
the end of the file name (e.g., A) specifies the revision.

Downloading the same language twice will automatically delete the first
occurrence, but will not free the memory space. Use the Pack Module
feature (see Section 4.1.4) or reload the FIGS file to free the space.

Deletion of the selected language will set the printer to English.

The total number of languages that the printer can now accept is limited to
10, but this number is dependent upon the size of each language translation.
The translation size will vary with the number of messages that are
translated for that particular language. Current complete language files are
about 7,000 bytes each but with product growth, the total number of
languages is expected to drop to seven.

117

118

Appendix F
Saving a Configuration File
With application version 5.01, the printer can save and restore complete printer
settings, including media calibration parameters, as internal Configuration Files.
Here are the highlights and restrictions of this feature:
•

Configuration files eliminate the need to repeat the manual steps of a
special printer setup, making future changeovers faster and easier.

•

Configuration files can be setup, saved, and restored either from the host or
via the front panel as ‘C-type’ files on Module Y under unique filenames
that can be up to nineteen characters in length.

•

Configuration files enable the host, via special DPL commands, to control
parameters previously accessible only from the front panel (consult the
Programmers Manual for details).

•

Regular host settings can not be saved using the front panel menu.

þ Note: Configuration files will typically correspond to a particular printer and
media application. If a file will be shared among printers, do not
include unique parameters (such as calibrations and adjustments)
because those settings will vary from one unit to another.

When using the front panel to save a configuration file (see Section 4.1.5), the
keypad functions within the ‘Save Setting As’ submenu are as follows:
Œ
The DOWN ARROW key scrolls down through the
alphanumeric, underscore, and delete character.
•
The UP ARROW key scrolls up through the alphanumeric
and underscore characters, and the delete function.
Ž
The ENTER key accepts the displayed character and
advances the cursor.
•
Saves the displayed file.

119

To save a manually entered setup (for example, an application that required an
Advanced Entry Calibration before beginning) as a configuration file using the
front panel:
Step

Displayed Message

Operator Action

1
Press the

key.

Comment(s)
You are entering
‘Menu Mode’.

Use the
key
to scroll to ‘System
Settings’.

The
key can
also be used.

Press the
key to select ‘System
Settings’.

You are entering the
‘System Settings’
menu.

Press the
key to select
‘Configuration File’.

You are entering the
‘Configuration File’
submenu.

Press the
key to scroll to ‘Save
Setting As’.

The
key can
also be used.

Press the
key.

Press the
key
to exit this selection.

Enter a file name using The
key can
the
key to
also be used.
scroll through the
characters.
þ Note: To change an accepted character,
select the delete function (solid flashing block)
and press the ENTER key.

Use the
key Continue entering the
to accept the character. file name in this
manner (“SPECIAL
STOCK” has been
used as an example).
þ Note: To abort the “save setting” function,
delete all entered characters in the file name
and press the ESCAPE key.

120

Press the
key
repeatedly to save the
file name and return to
‘Ready’.

Save complete. (To
restore a saved file
using the front panel
see Section 4.1.5.)

Warranty Information
Brady Products
Limited Warranty Statement
Bradyprinter Models 2461 and 3481

Printer
Brady warrants to Purchaser that under normal use and service, the 2461, 3481
and 6441 Printers, (with the exception of the thermal printhead) purchased
hereunder shall be free from defects in material and workmanship for a period of
(365) days from the date of shipment by Brady.
Expendable and/or consumable items or parts such as lamps, fuses, labels and
ribbons are not covered under this warranty. This warranty does not cover
equipment or parts which have been misused, altered, neglected, handled
carelessly, or used for purposes other than those for which they were
manufactured. This warranty also does not cover loss, damages resulting from
accident, or damages resulting from unauthorized service.

*When returned to the factory for service.

121

Thermal Printhead, Platen Roller, and Belts
This warranty* is limited to a period of one year, (365 days), or one million
(1,000,000) linear inches of use, whichever comes first, for the 2461, 3481 or
6441 thermal printhead, platen roller, and belts. This one year (365 days)
warranty is valid only if a Brady - approved thermal label media is used, as
defined in the then current list of approved thermal/thermal transfer media, a
copy of which is available from Brady. Failure to use Brady -approved media is
justification for invalidation of this warranty. This warranty does not cover
printheads or platen rollers which have been misused, altered, neglected,
handled carelessly, or damaged due to improper cleaning or unauthorized
repairs.
*When returned to the factory for service

Warranty Service Procedures
If a defect should occur during the warranty period, the defective unit shall be
returned, freight and insurance prepaid, in the original shipping containers, to
Brady at: 6555 W. Good Hope Road, Milwaukee, Wisconsin, 53223. A Return
Material Authorization (RMA) number must be issued before the product can be
returned. To open an RMA please call the Brady Customer Service Department
at 1-800-537-8791. Please include your RMA number on the outside of the box
and on the shipping document. Include a contact name, action desired, a detailed
description of the problem(s), and examples when possible with the defective
unit. Brady shall not be responsible for any loss or damages incurred in
shipping. Any warranty work to be performed by Brady shall be subject to
Brady’s confirmation that such product meets Brady warranty. In the event of a
defect covered by its warranty, Brady will return the repaired or replaced
product to the Purchaser at Brady’s cost.
With respect to a defect in hardware covered by the warranty, the warranty shall
continue in effect until the end of the original warranty period, or for sixty (60)
days after the repair or replacement, whichever is later.

122

General Warranty Provisions
Brady makes no warranty as to the design, capability, capacity or suitability of
any of its hardware, supplies, or software.
Software is licensed on an “as is” basis without warranty. Except and to the
extent expressly provided in this warranty and in lieu of all other warranties,
there are no warranties, expressed or implied, including, but not limited to, any
warranties of merchantability or fitness for a particular purpose.
Purchaser shall be solely responsible for the selection, use, efficiency and
suitability of Brady’s products.

Limitation of Liability
In no event shall Brady be liable to the purchaser for any indirect, special or
consequential damages or lost profits arising out of or relating to Brady’s
products, or the performance or a breach thereof, even if Brady has been advised
of the possibility thereof. Brady’s liability, if any, to the purchaser or to the
customer of the purchaser hereunder shall in no event exceed the total amounts
paid to Brady hereunder by the purchaser for a defective product.
In no event shall Brady be liable to the purchaser for any damages resulting
from or related to any failure or delay of Brady in the delivery or installation of
the computer hardware, supplies or software or in the performance of any
services.
Some states do not permit the exclusion of incidental or consequential damages,
and in those states the foregoing limitations may not apply. The warranties here
give you specific legal rights, and you may have other legal rights which vary
from state to state.

123

124

Glossary
alphanumeric Consisting of alphabetic, numeric, punctuation and
other symbols.
backing material The silicon-coated paper carrier material to which
labels with adhesive backing are affixed. Also referred to as
“liner”.
bar code A representation of alphanumeric information in a pattern of
machine-readable marks. The basic categories are divided into
one-dimensional (UPC, Code 39, Postnet, etc.) and twodimensional barcodes (Data Matrix, MaxiCode, PDF417, etc.).
boot loader The resident program that loads the application from
Flash memory, decompresses it into the SRAM, and starts
operations.
burn line The row of thermal elements in the printhead that create the
images on the media.
calibration The process through which sensor readings are entered into
the printer for correct sensor function (for example, detection of
a given media type) and TOF positioning.
character set The entire complement of alphanumeric symbols
contained in a given font.
checksum An alphanumeric error detection method used in many bar
code symbologies for informational security.
continuous media An uninterrupted roll or box of label or tag stock
media that contains no gap, notch, or mark to separate individual
labels or tags.
core diameter The inside diameter measurement of the cardboard core
at the center of a ribbon or media roll.
cutter A mechanical device with a rotary or guillotine type blade used
to cut labels or tags following printing.

125

defaults The functional setting values returned following a factory
reset of the printer.
diagnostics Programs used to locate and diagnose hardware problems.
die-cut media Media that has been cut into a pattern using a press,
where the excess paper is removed leaving individual labels,
with gaps between them, attached to a backing material.
direct thermal The printing method that uses a heat sensitive media
and only the heat of the thermal printhead to create an image on
the label.
direct thermal media Media coated with special chemicals that react
and darken with the application of heat.
DPI (dots per inch) A measurement of print resolution, rated in the
number of thermal elements contained in one inch of the
printhead. Also referred to as “resolution”.
DPL programming commands used specifically for control of and label
production. A complete listing of commands can be found in the
Programmer’s Manual.
EFIGS English, French, Italian, German, Spanish, and other multilanguage support as programmed for the printer’s menu system
and configuration label.
fan-fold Media that is folded and stacked.
feed speed The speed at which the media moves under the printhead in
non-printed areas and between labels.
Flash memory Non-volatile memory (does not require printer power to
maintain data) that can be erased and reprogrammed, used to
hold the printer’s operating program.
font A set of alphanumeric characters that share a particular typeface.
gap A space between die-cut or notched labels used to sense the top-ofform.
IPS (inches per second) Imperial measurement of printer speeds.

126

label A paper or synthetic printing material, typically with a pressure
sensitive adhesive backing.
label length The distance from the top of the label to the bottom of the
label as it exits the printer.
label repeat The distance from the top of one label to the top of the
next label.
label tracking Excessive lateral (side to side) movement of the media
as it travels under the printhead.
label width The left to right measurement of the label as it exits the
printer.
media Generalized term for all types of printing stocks, including: roll
fed, continuous, die-cut, reflective, and fanfold.
media hub Device in the printer used to support roll media.
media sensor An electronic device equipped with photosensors to
detect media and the top-of-form on die-cut, notched or
reflective media.
MMPS (millimeters per second) Metric measurement of printer
speeds.
notched stock Media, typically tag stock, with holes or notches in the
material that is used to signal the top-of-form. The printer must
be set to ‘gap’ to use this media type.
preprinted media Label stock that contains borders, text, or graphics,
floodcoating, etc.
perforation Small cuts extending through the backing and/or label
material to facilitate their separation. Also referred to as “perf”.
print speed The speed at which the media moves under the printhead
during the printing process.
reflective media Media imprinted with carbon-based black marks on
the underside of the material, which is used to signal the top-ofform when the ‘reflective’ sensor is enabled.
registration Repeatable top to bottom alignment of printed labels.

127

reverse speed The backward rate of media motion into the printer
during tear-off, peel and present and cutting operations for
positioning the label at the start of print position.
ribbon An extruded polyester tape with several layers of material, one
of which is ink-like, used to produce an image on the label. Also
referred to as “foil”.
ribbon wrinkle An undesirable overlapping of the ribbon during the
printing process that leads to voids on the printed label, typically
caused by an improper printhead leveling cam adjustment.
roll media A form of media that is wound upon a cardboard core.
start of print The position on the label where the printing actually
begins.
tag stock A heavy paper or synthetic printing material, typically
featuring a notch or black mark for TOF and no adhesive
backing.
thermal transfer The printing method that creates an image by
transferring ink from a ribbon onto the media using the heat
from the thermal printhead.
TOF (top-of-form) The start of a new label as indicated by a label gap,
notch, mark or programming.
void An undesirable blank space in a printed image.

128

Index
A
alphanumeric, 125
application program, 77
ASCII, 93, 99 - 101, 105

B
bar code, 84, 86, 95, 105 - 108, 125
boot loader, 79 - 81, 125
burn line, 72, 75, 86, 125

C
cable listings, 12, 13
calibration
advanced entry, 34, 65 - 70
defined, 125
problems, 55, 83, 86, 88 - 90
quick media, 20, 27, 54
standard, 31, 34, 61 - 64
checksum, 105 - 107, 125
cleaning, 59, 74 - 77, 86
communications
menu settings, 47 - 52
methods, 12, 13, 95
problems, 80, 83, 84, 86
condition messages, 54, 55
configuration file, 39, 119, 120
configuration label, 29, 43, 46, 48, 57,
126
configuration level, 41, 80
core diameter, 14, 90, 97, 125
custom adjustments, 10, 36, 42, 73, 84
cutter, 2, 5, 25, 38, 46, 53, 74, 83, 87,
97, 98, 125

D
diagnostics, 53, 126
direct thermal printing, 9, 34, 96, 126
display, 30, 83, 87, 92
dot test pattern label, 59
double byte symbols, 40 , 105

download mode, 77, 79, 80
DPI, 44, 45, 96, 109, 126
DPL, 33, 41, 44, 45, 52, 93, 126

E
EFIGS, 2, 46, 77, 109, 113 - 117, 126
emulation, 44 - 46

F
factory default settings, 31, 32, 34 - 53,
91, 109, 110, 126
fault messages, 87 - 91
feed speed, 35, 110, 126
flash memory, 97, 109, 126
font, 2, 3, 37, 39 - 41, 51, 95, 101 109, 126

G
gap, 17, 20, 34, 53, 63 - 65, 88, 92, 98,
125 - 128
GPIO port, 38, 46, 53, 111, 112

H
hex dump mode, 53, 83, 93

I
indicators, 12, 30, 85, 87
IPS, 10, 96, 110, 126

L
liner. See Media Backing Material
label, 1, 8, 9, 21, 42 - 46, 51, 53 - 61,
84, 86, 91, 93, 97, 98, 109, 125 - 128
language. See EFIGS
LCD. See Display
leveling cam, 15, 16, 71, 84, 86, 91,
128

129

media
continuous, 17, 20, 34, 97, 125
backing material, 18, 20, 21, 23 - 25,
61, 64, 97, 98, 125, 126
black mark, 17, 61, 63, 67, 89, 98,
127, 128
die-cut, 17, 97, 126
direct thermal, 9, 10, 34, 126
fan-fold, 16, 97, 126
preprinted, 63, 66, 127
notched, 17, 20, 64, 127, 128
roll, 14, 15, 97, 128
tag, 10, 72, 125, 127, 128
thermal transfer, 9, 10, 18, 34, 58,
96, 128
media sensor, 17, 20, 34, 74, 86, 88 91, 98, 127
media settings, 34
menu mode, 27, 28, 30, 33
menu system, 32, 33
MMPS, 96, 110, 127
module, 37, 39, 60, 84, 109

ready mode, 27, 28, 30, 77, 78, 93
reflective mark. See Media Black Mark
registration, 127
resetting, 12, 27, 31, 32, 39, 40, 55, 89,
92
reverse speed, 35, 52, 110, 128
ribbon, 9, 10, 18, 19, 34, 85, 86, 89, 97,
98, 128
ribbon sensor, 42, 53, 90
ribbon test label, 58
ribbon wrinkling, 71, 128
rotation, 86, 95

S
serial port, 13, 47, 83
single byte symbols, 39
skipping labels, 86
specifications, 95 - 97, 112
speed settings, 110
start of print, 17, 35, 36, 46, 111, 112,
128
system settings, 31, 39, 40 - 46, 84

N
NIC Adapter, 12, 48 - 50

P
parallel port, 12, 47, 48, 79, 83, 95
peel and present, 3, 4, 23, 97
perforation, 63, 66, 67, 127
present sensor, 4, 24, 35, 37, 46, 53, 54
print control, 9, 10, 35, 36, 73, 84, 112
print quality, 56, 58, 60, 72, 75, 76, 86,
92, 98
print resolutions. See DPI
print speed, 9, 10, 35, 86, 96, 110, 127
printer key, 41, 80
printer options, 37, 38
printhead, 2, 9, 10, 18, 35, 36, 53, 59,
71 - 75, 84, 86, 90, 92, 96, 98, 109

Q
quick test mode, 29, 53, 54, 56 - 60, 87

130

T
top of form, 20, 34, 61, 65, 70, 88, 89,
91, 125, 128
troubleshooting, 83 - 93

U
user defined label, 60
user prompts, 54, 55

V
validation label, 60
voids, 77, 128

W
warning messages, 87, 92

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