Brady 3481 manual

Brady Bradyprinter Models 2461, 3481, and 6441 Operator’s Manual (TEMP COVER) (DO NOT PRINT) (DO NOT print this page)[...]

(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 Trad[...]

Agency Compliance and Approvals: C US Listed UL1950 Information Technology Equipment C22.2 No. 950-M93 EN60950 For 230 Volt Operation (Europe): Use a cord set, marked “HAR,” consisting of a min H05VV-F cord which has a minimum 0.75 square mm diameter conductors, provided with an IEC 320 receptacle and a male plug for the country of installation[...]

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 equipmen[...]

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i 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[...]

ii 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 ..................................[...]

iii 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.[...]

iv 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 I[...]

1 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 die- cast construction with state-of-the-art electronics and user-friendly features to redefine the standard in industrial thermal printers. This manual provides all the in[...]

2 1.0.1 Standard Features This printer offers the following standard features: Bradyprinter Standard Features Listing Model Feature 2461 3481 6441 Printhead Density (Dots Per Inch) 203 300 600 Direct Thermal Printing X X X On-Demand and Batch Printing X X X Rotating Media Hub X X X Media Tear Bar X X X Fan-fold media capability X X X Flash memory 1[...]

3 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 Langua[...]

4 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 dev[...]

5 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 Sta[...]

6 1.2 Hardware Components The following drawing highlights the user-assessable components of the printer. Items denoted with an asterisk (*) are optional equipment.[...]

7 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. Com[...]

8 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[...]

9 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: [...]

10 • 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 woul[...]

11 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 [...]

12 3.0.1 Communicatio ns 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[...]

13 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[...]

14 3.1 Loadi ng Media Begin loading as follows: Œ Raise the Access Cover. • Rotate the Printhead Latch forward and raise the Printhead Assembly. Ž Slide the Media Guide out away from the frame and then lower it to the down position. • If using roll media, the Media Hub can accept 3.0-inch (76mm) and 1.5- inch (38mm) cores. To use 1.5-inch cor[...]

15 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[...]

16 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 M[...]

17 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 : ΠWith media loaded, as described in Section 3.1.1 or 3.1.2, grasp the Slide Tab and m[...]

18 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[...]

19 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[...]

20 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 continu[...]

21 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 th[...]

22 ‘ 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. ”[...]

23 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 [...]

24 • 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[...]

25 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 S[...]

26[...]

27 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[...]

28 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 f[...]

29 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 tes[...]

30 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 . ?[...]

31 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[...]

32 4.1 The Me nu 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 ‘*’ sym[...]

33 4.1.1 Entrance and Exit Prompts With ‘Ready’ displayed on the LCD, press the key to enter the Menu Mode . þ Note: Wh ile in the Menu Mode , the printer will stop processing new DPL (or bitmapped) data. MENU MODE Depending upon the configuration of the printer, the following Entrance and Exit Prompts may be displayed when accessing or leavin[...]

34 4.1.2 Media Settings MEDIA TYPE Selects the printing method. DIRECT THERMAL For use with heat sensitive media . ² THERMAL TRANSFER For use with media requiring a ribbon to create an image. SENSOR TYPE Selects the top-of-form (TOF ) sensing method for the media . ² GAP The printer recognizes the TOF by sensing gaps in the media . CONTINUOUS No [...]

35 4.1.3 Print Control + Refer to Section 2.1.1 for detailed information on print quality controls. HEAT ² 10 (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 [...]

36 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[...]

37 4.1.4 Printer Options MODULES Memory available for user storage of graphics, fonts and label formats. (The physical presence of the respective memory module must be detected to show the function selections for that module in the menu system.) See Appendix C for a listing of all possible modules. PRINT DIRECTORY Prints a label directory of select[...]

38 Printer Options (continued) CUTTER Used to cut media into separate labels. (The physical presence of a cutter must be detected to show the ENABLE/DISABLE selections.) ENABLED Enables label cutting. ² DISABLED Disables the cutter . NOT INSTALLED No cutter is detected. GPIO PORT Model dependant option used to interface the printer to an external [...]

39 4.1.5 System Settings CONFIGURATION FILE Options for storage and recall of printer configuration files. See Appendix F for details. RESTORE AS CURRENT 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. SAVE SETTING AS Saves[...]

40 System Settings (continued) DOUBLE BYTE SYMBOLS When equipped with the ILPC option, this selects the code page used to print double byte fonts unless otherwise specified in DPL; see the Programmer’s Manual for details. JIS Japanese Industry Standard SHIFT JIS Shift Japanese Industry Standard EUC Extended UNIX Code ² UNICODE Unicode (including[...]

41 System Settings (continued) CONFIGURATION LEVEL To upgrade the application program (resident software) version of the printer, the hardware and software compatibility levels must match for the update to be accepted. This information is displayed here; it is also printed on a configuration label . Each printer has a unique KEY number in the follo[...]

42 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 [...]

43 System Settings (continued) PAUSE MODE When enabled, Pause Mode suspends printing between each label until the PAUSE key is pressed. ENABLED Printer requires operator to press the PAUSE key after each label . ² DISABLED Printer completes label batch without pausing between labels. SECURITY ♦ Provides the user with the ability to password prot[...]

44 System Settings (continued) þ Note: As indicated, the following menu selections will only appear according to the model of your printer. PLUS EMULATION This instructs the firmware to process specific DPL data as would the Prodigy Plus ® printer without all of the variations. ENABLED This list of exceptions will be updated with new firmware rel[...]

45 System Settings (continued) þ Note: As indicted, the following menu selections will only appear according to the model of your printer. DPI EMULATION For users who want to print DPL files intended for a 203 or 300 DPI printer. ² DISABLED Label formats interpreted as intended for 600 DPI. 300 DOTS PER INCH Label formats interpreted as intended [...]

46 System Settings (continued) SOP EMULATION Enables the <STX>O and <STX>f print positioning commands to allow backward compatibility with label formats designed for other printers. (When changing these values, the printer will automatically feed two labels to setup the new print position.) 110 (PRODPLUS) Emulates the Prodigy Plus ® pr[...]

47 4.1.6 Communications SERIAL PORT A ♦ Controls the communications settings for Serial Port A. BAUD RATE Determines the serial communication rate. 38400 38400 bits per second 28800 28800 bits per second 19200 19200 bits per second ² 9600 9600 bits per second 4800 4800 bits per second 2400 2400 b its per second 1200 1200 bits per second PROTOCOL[...]

48 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 ac[...]

49 Communications (continued) PROTOCOL The network protocols recognized by the NIC Adapter . IP This protocol is always supported. LAT Local Area Transport is a DEC VMS network protocol that requires a LAT license number. ² ENABLED Protocol is enabled by default. DISABLED Ignore LAT protocol. Select this option if LAT is not needed. MOP ² ENABLED[...]

50 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 Dynamic Host Control Prot[...]

51 Communications (continued) HOST SETTINGS Settings which affect all communications with a host. HOST TIMEOUT ² 10 SEC (1-60) The number of seconds a communications port must be idle before the printer may process data from a different port. This value is also used to “timeout” an image / label format download. CONTROL CODES ♦ Allows the op[...]

52 Communications (continued) HEAT COMMAND Allows the user to disable the DPL Heat Command, providing compatibility with other printers. ² ENABLED Normal printer operating mode. 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 [...]

53 4.1.7 Diagnostics HEX DUMP MODE Most commonly used for troubleshooting. Prints data and instructions received from the host rather than interpreting them as label formats; see Section 6.2. ENABLE Prints raw ASCII data received from the host rather than executing the commands. ² DISABLE Executes and prints label formats (normal operating mode). [...]

54 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 Sec[...]

55 User Prompts and Condition Messages (continued) Displayed Message Description Condition(s) Normal power-up and soft reset condition. Follows the ‘SYSTEM RESET IN PROGRESS’ message after a reset or power-up. Normal power-up and soft reset condition. Occurs when the user resets the printer via the host or Front Panel. The media calibration is [...]

56 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[...]

57 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 wid[...]

58 4.3.3 Qui ck 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. • Pr[...]

59 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[...]

60 4.3.5 Validation Label The Validation Label is another useful tool for evaluating overall print quality. To generate a Validation Label: Œ Press the key. • Use the key to scroll to ‘Validation Label ’. Ž Use the key to select a quantity; see Section 4.0.3. • Press the key to start printing. 4.3.6 User Defined Label The User Defined Lab[...]

61 5.0 Media Sensor Ca libration 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 St[...]

62 Standard Calibration (continued) Step Operator Action Displayed Message Comment 3 Press the key to enter the Media Settings menu. See Section 4.1.2 for menu layout. 4 Press the key and scroll to ‘Sensor Calibration’. Press the key to abort this procedure. 5 Press the key. You are beginning the standard calibration procedure. 6 Press the key.[...]

63 Standard Calibration (continued) Step Operator Action Displayed Message Comment 7 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[...]

64 Standard Calibration (continued) Step Operator Action Displayed Message Comment 9 Observe the display. Or, for reflective media: Or, for continuous media: The calibration was successful. See note below if another message was displayed. 10 Exit upon successful calibration: B ack out of the menu tree by repeatedly pressing the key . If using gap o[...]

65 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 fo[...]

66 Advanced Entry Calibration (continued) Step Operator Action Displayed Message Comment 6 Press the key to scroll to ‘Advanced Entry’. You are entering Advanced Entry Calibration. 7 Press the key. Press the key to abort this procedure. 8 Press the key. You are beginning the Advanced Entry Calibration. 9 Press the key. Place the label under the[...]

67 Advanced Entry Calibration (continued) Step Operator Action Displayed Message Comment 11 Proceed according to your media type: Die-cut stock: strip the media from the backing and then reinsert it into the sensor; adjust the Sensor Eye Mark over the center of the backing. Notched stock: adjust the Sensor Eye Mark over the center of the notch. Ref[...]

68 Advanced Entry Calibration (continued) Step Operator Action Displayed Message Comment 12 From the data collected in Steps 10 and 11, where both the sensor readings are above 20, subtract each Label Value from the corresponding TOF Value. These are the Difference Values . From the resulting list, find the largest Difference Value (s ee example be[...]

69 Advanced Entry Calibration (continued) Step Operator Action Displayed Message Comment 13 Using the key, select the Gain Number determined in Step 12. Press the key to select the setting. Or, for reflective media: Selection is denoted with an ‘*’. 14 Œ Place the media in the Media Sensor. Record the sensor reading and label it ‘P’ (paper[...]

70 Advanced Entry Calibration (continued) Step Operator Action Displayed Message Comment 16 Press the key. Using the or the key, set the ‘Paper’ level to the value determined in the previous step. Press the key to set the entry (indicated by the ‘*’) and advance the menu. Repeat for the ‘Gap’ (or ‘Mark’) and ‘Empty’ levels. â ?[...]

71 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 ev[...]

72 5.1.2 Burn Line Adjustment The Burn Line has been adjusted at the factory for strict compliance using 6.5- mil (.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[...]

73 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 pri[...]

74 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 For your safety and to avoid damagi[...]

75 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: Π[...]

76 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 Pri[...]

77 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 [...]

78 5.4.1 Updating from Ready Mode Update Procedure for Application Version 2.091 or greater Step Displayed Message Operator Action Comment(s) 1 Using the DOS copy command (where ‘filename’ is the program to be loaded and ‘lpt1’ is the selected interface port), enter the following: copy filename lpt1: As an example, this would be entered as:[...]

79 5.4.2 Updating from Download Mode Required Update Procedure for Application Version 2.08 or earlier * Step Displayed Message Operator Action Comment(s) 1 Press and hold the PAUSE and TEST keys while turning ‘On’ the printer to enter the Download Mode . The Boot Loader version is displayed. þ Note: This information will vary with the printer[...]

80 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) Us[...]

81 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 ret[...]

82[...]

83 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 e[...]

84 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 Sect[...]

85 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 cor[...]

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

87 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 poss[...]

88 Printer Fault Messages (continued) Displayed Message Description Possible Solution(s) The printer has detected a Direct Memory Access 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 media was insert[...]

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

90 Printer Fault Messages (continued) Displayed Message Description Possible Solution(s) 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 pr[...]

91 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[...]

92 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. Printer Warning Messages Displayed Message Description Action(s) The printer has detected defective printhead elements. Replace the printhead if the print quality becomes unacce[...]

93 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 lab[...]

94[...]

95 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 Sy[...]

96 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[...]

97 Printing Specifications (continued) Print Length Range: with an optional cutter: with an optional peel & present mechanism: .25” – 99” (6.4 mm – 2514.6 mm) 2461&3481 .25” – 55” (6.4 mm – 1397 mm) 6441 1.25” – 99” (31.8 mm – 2514.6 mm) 2461&3481 1.25” – 55” (31.8 mm – 1397 mm) 6441 1.50” – 99” (38[...]

98 Media and Ribbon Requirements (continued) E A B C D G H I J F Media Dimensions Designator Description Maximum [1] Minimum [1] A label width 4.65 1.00 B liner width 4.65 1.00 C gap (or notch) between labels [4] – .100 D label length [4] – .250 E media thickness [2] .0100 .0025 F notch opening width .500 .200 G distance from the media’s edge[...]

99 Appendix A ASCII Control Code Chart Char Dec Hex Char Dec Hex Char Dec Hex Char Dec Hex Ctrl @ NUL 0 00 32 20 @ 64 40 ` 96 60 Ctrl A SOH 1 01 ! 33 21 A 65 41 a 97 61 Ctrl B STX 2 02 “ 34 22 B 66 42 b 98 62 Ctrl C EXT 3 03 # 35 23 C 67 43 c 99 63 Ctrl D EOT 4 04 $ 36 24 D 68 44 d 100 64 Ctrl E ENQ 5 05 % 37 25 E 69 45 e 101 65 Ctrl F ACK 6 06 &[...]

100 ASCII Control Code Chart (continued) Char Dec Hex Char Dec Hex Char Dec Hex Char Dec Hex Ç 128 80 á 160 A0 192 C0 Ó 224 E0 ü 129 81 í 161 A1 193 C1 ß 225 E1 é 130 82 ó 162 A2 194 C2 Ô 226 E2 â 131 83 ú 163 A3 195 C3 Ò 227 E3 ä 132 84 ñ 164 A4 196 C4 õ 228 E4 à 133 85 Ñ 165 A5 197 C5 Õ 229 E5 å 134 86 a 166 A6 ã 198 C6 µ 230[...]

101 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 inform[...]

102 The table below lists the font sizes; the numbers indicate the number of dots. Font Height Width Spacing 0 7 5 1 1 13 7 2 2 18 10 2 3 27 14 2 4 36 18 3 5 52 18 3 6 64 32 4 7 32 15 5 8 28 15 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: 1[...]

103 Font 4: 62-character alphanumeric , uppercase. Font 5: 62-character alphanumeric , uppercase. Font 6: 62-character alphanumeric , uppercase.[...]

104 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.[...]

105 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 Type Length Checksum Valid ASCII Characters, decimal value representation A Co[...]

106 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 H: Health Industry Bar Code (HBIC) Bar Code I: Codabar Bar Code J: Interleaved 2 of 5 w/modulo 10 checksum[...]

107 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 O: Code 93 Bar Code p: Postnet Bar Code Q: UCC/EAN Code 128 Bar Code R: UCC/EAN Code 128 KMART NON EDI[...]

108 Bar Code S: UCC/EAN Code 128 Random Weight Bar Code T: Telepen Bar Code u: UPS MaxiCode Bar Code v: FIM 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[...]

109 Appendix C Module Assignments Memory Module Designator Module Size Volatile* Location / Use A Future Option N/A N/A B Future Option N/A N/A D 1024 KB (default size) Yes Main PCB SDRAM – user addressable for graphics, fonts, and label formats F 4 MB No Optional Flash Card – user addressable for graphics, fonts, and label formats G 256 KB No [...]

110 Available Speeds and Default Settings Printer Speed Ranges and Defaults * Speed Range Default Setting Model IPS MMPS IPS MMPS 2461 Print 2-8 51 – 203 8.0 203 Feed 2-8 51 – 203 8.0 203 Reverse 2-4 51 – 102 4.0 102 3481 Print 2-8 51 – 203 6.0 152 Feed 2-10 51 – 254 6.0 152 Reverse 2-4 51 – 102 4.0 102 6441 Print 2-4 51 – 102 3.0 76 [...]

111 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 [...]

112 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 TTL- level input or (2) with an interface circuit similar to the one shown right. For additional interfacing requirements, see the table below. GPIO Port Spe[...]

113 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 ‘Ge[...]

114 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:[...]

115 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 ?[...]

116 ‘ 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 SYST[...]

117 Ÿ 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. Ÿ Downloading the same language twice will automatically delete the first occurrence, but will not free the memory space. Use the Pack Modu[...]

118[...]

119 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 pr[...]

120 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 Comment(s) 1 Press the key. You are entering ‘Menu Mode’ . 2 Use the key to scroll to ‘System Settings’. The key can also be use[...]

121 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) d[...]

122 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 us[...]

123 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, express[...]

124[...]

125 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 [...]

126 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 . di[...]

127 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 [...]

128 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”. r[...]

129 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 - [...]

130 M 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, [...]