Copyright This manual is copyrighted with all rights reserved. No portion of this manual may be copied or reproduced by any means without the prior consent of Brady Worldwide, Inc. While every precaution has been taken in preparation of this document, Brady assumes no liability to any party for any loss or damage caused by errors or omissions or by statements resulting from negligence, accident, or any other cause.
Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Corporate Headquarters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Contents Select a Data Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to the Computer or Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cord Specifications . . . . . . . . .
Contents Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 About This Document Who Should Use This Document Who Should Use This Document This User Guide is intended for use by any person who needs to operate or to troubleshoot problems with the printer. The guide is complete for the successful operation of the BBP81 Thermal Transfer 300 dpi, 4inch wide printer. However, it also lists specifics for the BBP81 Thermal Transfer 300 dpi, 6inch wide printer, as well as the 203 and 600 dpi printers. These other printers may not be available in your area at this time.
About This Document Contacts Contacts You can contact Brady Worldwide Inc. at the following: Corporate Headquarters Brady Worldwide, Inc. 6555 West Good Hope Road Milwaukee, WI 53223 U.S.A. T: 414-358-6600 USA Domestic F: 414-438-6958 Technical Service Brady Technical Service and the Brady Knowledge Center may be contacted at www.bradyid.com. Other Websites 5/13/08 USA www.bradyid.com Canada www.bradycanada.com Mexico www.bradylatinamerica.com Asia www.bradycorp.com Europe www.bradyeurope.
4 About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in Letter Gothic Std font.
About This Document Document Conventions Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example.
6 About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________
1 Introduction This section shows the operational controls and location of major components used when loading media. Contents External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Introduction External View External View Figure 2 and Figure 3 show the components and connections on the outside of the printer.
Introduction Printer Media Compartment Printer Media Compartment Figure 4 shows the components inside the media compartment of your printer. Depending on installed options, your printer may look slightly different. Note • For optimal printing quality and proper printer performance across our product line, Brady strongly recommends the use of genuine Brady supplies as part of the total solution.
10 Introduction Control Panel Control Panel The control panel contains the lights that indicate basic operation and the buttons that you may need to press during basic operation. The control panel buttons and lights are labeled in Figure 5. Descriptions for each are located in Table 1 and Table 2.
Introduction Control Panel Control Panel Buttons Table 1 • Control Panel Buttons Button Function FEED Forces the printer to feed one blank label each time the button is pressed. • Printer not printing: one blank label immediately feeds. • Printing: one blank label feeds after the current batch of labels is complete. PAUSE Starts and stops the printing process. • Printer not printing: no printing occurs. (Press PAUSE again to resume printing.
12 Introduction Control Panel Control Panel Lights Table 2 • Control Panel Lights Light Status Indication POWER Off The printer is off, or no power is applied. On The printer is on. Off Normal printer operation. On The printer has stopped all printing operations. Flashing The Pause light flashes when initializing FLASH memory and in Peel-Off Mode when the label is available. Off Normal printer operation (no errors). PAUSE ERROR On An error condition is preventing printing.
Introduction Printer Language Modes Printer Language Modes The BBP81 came from the factory with firmware that operates in, or allows you to use, certain commands for the ZPL printer programming language. Firmware Downloads You may download the latest firmware version at www.bradyid.com. Note • When the printer changes from one printer language to another, error messages may appear on the LCD, and some control panel lights may activate in error mode. You may ignore these error messages and lights.
14 Introduction Printer Language Modes Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___________________
2 Printer Setup This section provides the tasks that you must complete and the issues that you must consider before you load and configure your printer. Contents Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stress Free Setup Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 Printer Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your printer. Stress Free Setup Service To schedule a free phone setup assistance appointment, call 1-800-643-8766 and select menu option 4. Unpack and Inspect the Printer Have you unpacked the printer and inspected it for damage? If you have not, see Unpack and Inspect the Printer on page 17. Register Your Printer. Go to www.bradyid.com to register your BBP81.
Printer Setup Handling the Printer Handling the Printer This section describes how to handle your printer. Stress Free Setup Service Brady’s Stress Free Service helps you set up your new printer and software. To schedule a free phone setup assistance appointment, call 1-800-643-8766 and select menu option 4. Unpack and Inspect the Printer When you receive the printer, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage.
18 Printer Setup Handling the Printer Ship the Printer If you must ship the printer: • Turn off (O) the printer, and disconnect all cables. • Remove any media, ribbon, or loose objects from the printer interior. • Close the printhead. • Carefully pack the printer into the original container or a suitable alternate container to avoid damage during transit. A shipping container can be purchased from Brady if the original packaging has been lost or destroyed.
Printer Setup Select a Site for the Printer Select a Site for the Printer Consider the following when selecting an appropriate location for your printer. Select a Surface Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart. For the printer’s weight and dimensions, see General Specifications on page 110.
20 Printer Setup Select a Data Communication Interface Select a Data Communication Interface Table 5 provides basic information about data communication interfaces that you can use to connect your printer to a computer. You may send label formats to the printer through any data communication interface that is available. Select an interface that is supported by both your printer and your computer or your Local Area Network (LAN).
Printer Setup Select a Data Communication Interface Data Cables You must supply all data cables or wireless cards for your application. Data Cables Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with metal or metallized connector shells. Unshielded data cables may increase radiated emissions above the regulated limits. To minimize electrical noise pickup in the cable: • Keep data cables as short as possible.
22 Printer Setup Select a Data Communication Interface Table 6 • Connecting the Printer to a Computer or Network (Continued) Interface Connection and Configuration IEEE 1284 Bidirectional Parallel No additional configuration is necessary. USB No additional configuration is necessary. Caution • Be careful not to plug the USB cable into the wired Ethernet print server connector on the printer because doing so will damage the connector.
Printer Setup Select a Data Communication Interface Table 6 • Connecting the Printer to a Computer or Network (Continued) 5/13/08 Interface Connection and Configuration Internal wired Ethernet print server Refer to the BradyConnect 10/100 Print Server User and Reference Guide for configuration instructions. A copy of this manual is available at www.bradyid.com/bbp81.
24 Printer Setup Connect the Printer to a Power Source Connect the Printer to a Power Source The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 25. Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation.
Printer Setup Connect the Printer to a Power Source Power Cord Specifications Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration. Depending on how your printer was ordered, a power cord may or may not be included.
26 Printer Setup Types of Media Types of Media Brady strongly recommends the use of Brady-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to prevent premature printhead wear. To view supplies, go to www.bradyid.com/bbp81.
Printer Setup Types of Media Table 7 • Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description Roll media is wound on a 3-in. (76-mm) core. Individual labels are separated by one or more of the following methods: • Web media separates labels by gaps or notches. • Black mark media uses pre-printed black marks on the back side of the media to indicate label separations. • Perforated media has perforations that allow the labels or tags to be separated from each other easily.
28 Printer Setup Ribbon Overview Ribbon Overview Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
Printer Setup Ribbon Overview 4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label? If ink from the ribbon... Then... Adhered to the label The ribbon is coated on the outside and can be used with the standard Thermal Transfer option (black ribbon spindle). In the ribbon loading procedure, instructions are marked with this symbol. Ribbon Scratch Test Perform the ribbon scratch test when labels are unavailable.
30 Printer Setup Ribbon Overview Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _________________________
3 Operations This section provides the procedures for loading and calibrating the printer. Note • Complete the tasks and resolve the issues in Printer Setup on page 15 before operating the printer. Contents Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Descriptions and Printer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 Operations Print Modes Print Modes The printer can use different print modes and options for label removal (Table 8). Use a print mode that matches the media being used. For more information on the types of media, see Types of Media on page 26. To select a print mode, see Select Print Mode on page 61. Print Mode Descriptions and Printer Requirements Table 8 • Print Modes Print Mode When to Use/Printer Options Required Printer Actions Tear-Off (default setting) Use for most applications.
Operations Print Modes Media Paths Table 9 shows the media paths for print mode and printer option combinations using roll media. Fanfold media uses the same print modes and printer options as roll media.
34 Operations Load Media Load Media The beginning steps for loading media are shown below. For more information about print modes and printer options, see Print Modes on page 32. Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Brady recommends it as a precaution.
Operations Load Media 3. Insert media into the printer. Follow the instructions for roll or fanfold media, as appropriate. Fanfold Media Roll Media a. Remove and discard any tags or labels that are dirty or that are held by adhesives or tape. a. Feed the media through the rear or bottom access slot.
36 Operations Load Media Fanfold Media (Continued) Roll Media (Continued) b. Place the roll of media on the media supply spindle. Push the roll as far back as it will go. b. Drape the media over the media supply spindle. OR PermaSleeve Material Only 4. Feed the media under the dancer assembly (1), the upper media sensor (2), the ribbon sensor (3), and the adjustable sensor (4). (See Step 5 for sensor location of media type.
Operations Load Media 5. Adjust sensor to proper location, depending on media type. 6. Slide in the media guide until it touches the outer edge of the media. 7. Set the printer to Tear-Off mode. See Select Print Mode on page 61 for instructions. 8. Close the printhead assembly. 9. If the printer is paused (the Pause light is on), press PAUSE to enable printing.
38 Operations Load Ribbon Load Ribbon Always use ribbon that is wider than the media to protect the printhead from wear. For direct thermal printing, do not load ribbon in the printer. The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the outside. To avoid damaging your printer, follow the directions for the Thermal Transfer option installed in your printer. Figure 8 shows the ribbon paths for ribbon coated on the outside.
Operations Load Ribbon Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead. You are not required to turn off the printer power when working near an open printhead, but Brady recommends it as a precaution. If you turn off the power, you will lose all temporary settings, such as label formats, and you must reload them before you resume printing.
40 Operations Load Ribbon 3. Insert the ribbon into the printer. Follow these instructions for the Thermal Transfer option installed in your printer. Ribbon Coated Outside (black ribbon spindle) a. Hold the ribbon with the loose end unrolling clockwise. b. Place the roll of ribbon on the ribbon supply spindle (1) and push it all the way back. 1 c. Pull the end of the ribbon under the printhead assembly (1) and out the front of the printer. Extend the ribbon approximately 24 in.
Operations Load Ribbon 4. Close the printhead assembly. 5. Wind the ribbon clockwise onto the ribbon take-up spindle (1).
42 Operations Load Ribbon Remove Used Ribbon To remove used ribbon, complete these steps: 1. Caution • Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may damage the spindle. If the ribbon has not run out, cut or break it before the ribbon take-up spindle (1). 1 2. To loosen the ribbon, squeeze it against the ribbon take-up spindle tension blades (1). At the same time, turn the ribbon take-up spindle release knob counterclockwise (2).
Operations Calibrate the Printer Calibrate the Printer Auto Calibration By default, the printer automatically calibrates on power up, when the printhead is closed. During auto calibration, the printer determines the label length and sensor settings. The results of the auto calibration are stored in the printer’s memory and are retained even if printer power is removed. These parameters remain in effect until the next calibration is performed.
44 Operations Adjust Printhead Pressure Adjust Printhead Pressure You may need to adjust printhead pressure if printing is too light on one side, if you use thick media, or if the media drifts from side to side during printing. See Figure 10. The BBP81 (4”) pressure adjustment dials have four possible settings designated by blocks of increasing size embossed on the print mechanism.
Operations Adjust Printhead Pressure Table 11 • BBP81 (6”) Printhead Pressure Media Width Inside Dial Outside Dial 2 in. (50 mm) 6 1 3 in. (75 mm) 6 2 4 in. (100 mm) 7 3 5 in. (125 mm) 7 4 5.5 in. and up (140 mm and up) 6 6 2. If necessary, adjust the pressure adjustment dials as follows: 5/13/08 If the media... Then... Requires higher pressure to print well Increase both dials one position.
46 Operations Adjust Printhead Pressure Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________
4 Configuration This section describes the control panel parameters that are used to configure the printer for operation. Contents Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 Configuration Setup Mode Setup Mode After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays BBP81 READY. You may now set printer parameters for your application using the control panel display and the buttons directly below it. If it becomes necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 105.
Configuration Setup Mode LCD Description LOAD DEFAULTS Restores all parameters other than the network settings back to the factory defaults. Use care when loading defaults because you will need to reload all settings that you changed manually. Note • Loading factory defaults causes the printer to auto-calibrate. LOAD LAST SAVE Loads values from the last permanent save. DEFAULT NET Restores the wired and wireless network settings back to factory defaults. 3.
50 Configuration Change Password-Protected Parameters Change Password-Protected Parameters Certain parameters, including the communication parameters, are password-protected by factory default. Caution • Do not change password-protected parameters unless you have a complete understanding of the parameters’ functions. If the parameters are set incorrectly, the printer may function unpredictably. The first time that you attempt to change a password-protected parameter, the printer displays ENTER PASSWORD.
Configuration Print a Configuration Label Print a Configuration Label A configuration label lists the printer settings that are stored in configuration memory. After you load the media, print a configuration label as a record of your printer’s current settings. Keep the label to use when troubleshooting printing problems. To print a configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2. Press or to scroll through the parameters until you reach LIST SETUP. 3.
52 Configuration Print a Network Configuration Label Print a Network Configuration Label If you are using a print server, you can print a network configuration label after the printer is connected to the network. To print a network configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2. Press PLUS (+) or MINUS (-) to scroll through the parameters until you reach LIST NETWORK. 3. Press SELECT to select the parameter. 4. Press PLUS (+) to confirm printing.
Configuration Control Panel Parameters Control Panel Parameters Use the LCD on the control panel to view and adjust printer settings. How to View or Modify Parameters While viewing parameters, press PLUS (+) to continue to the next parameter, or press MINUS (-) to return to the previous parameter in the cycle. Press SELECT when you want to modify a parameter or view its options.
54 Configuration Control Panel Parameters Standard Printer Parameters Table 12 shows parameters in the order in which they are displayed when you press PLUS (+) after entering Setup mode. Table 12 • Printer Parameters (Page 1 of 22) Parameter ZPL and XML EPL Action/Explanation Adjust Print Darkness Darkness (burn duration) settings depend on a variety of factors, including ribbon type, media type, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 2 of 22) Parameter Action/Explanation Calibrate Media and Ribbon Sensor Sensitivity Use this procedure to adjust sensitivity of media and ribbon sensors. Important • Follow this procedure exactly as presented. All of the steps must be performed even if only one of the sensors requires adjustment. You may press MINUS (-) at any step in this procedure to cancel the process. To perform a media and ribbon sensor calibration: 1.
56 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 3 of 22) Parameter Action/Explanation Select Media Power-Up Option This parameter sets the action of the media when you turn on the printer. Default Value: CALIBRATION Selections: CALIBRATION, SHORT CAL, LENGTH, NO MOTION, FEED • Calibration adjusts sensor levels and thresholds, determines length, and feeds the media to the next web.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 4 of 22) Parameter Action/Explanation Adjust the Tear-Off Position This parameter establishes the position of the media over the tear-off/peel-off bar after printing. See Figure 13. Higher numbers move the media out (the tear line moves closer to the leading edge of the next label), and lower numbers move the media in (the tear line moves closer to the edge of the label just printed).
58 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 5 of 22) Parameter Action/Explanation Adjust Print Speed Adjusts the speed for printing a label (given in inches per second). Slower print speeds typically yield better print quality. Print speed changes take effect upon exiting Setup mode. Default Value: 2 IPS Range: • 200 dpi: 2 to 10 IPS • 300 dpi: 2 to 8 IPS • 600 dpi: 1 to 4 IPS To change the value shown: 1. 2. 3. 4. Press SELECT to select the parameter.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 6 of 22) Parameter Action/Explanation Set Print Width This parameter specifies the printable area across the width of the label. Table 13 shows the ranges and default values for print width, which are based on the printer model and the printhead resolution.
60 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 7 of 22) Parameter Action/Explanation Set Maximum Label Length This parameter is used during the media portion of the calibration process. Always set maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length (Figure 14). If the value is set to a smaller value than the label length, the printer assumes that continuous media is loaded, and the printer cannot calibrate.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 8 of 22) Parameter Action/Explanation Select Print Mode This parameter tells the printer how printed labels will be removed. Make sure that you select a print mode that is compatible with your printer and printer options. For information about how the print modes work with different printer options, see Print Modes on page 32.
62 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 9 of 22) Parameter Action/Explanation Set Printhead Cleaning Interval for Early Warning This parameter appears only when Early Warning for Maintenance is enabled. This value should correspond to the length of the media or ribbon roll that you are using. Default Value: 450 M/1476 FT Selections: 100 M/328 FT to 450 M/1476 FT in 50 M increments To change the value shown: 1. Press SELECT to select the parameter. 2.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 10 of 22) Parameter Action/Explanation Reset Printhead Life Counter for Early Warning This parameter appears only when Early Warning for Maintenance is enabled. To reset the printhead life counter: 1. Press SELECT to select the parameter. 2. Did you replace the printhead? • If you replaced the printhead, press PLUS (+) to select YES. • If you did not replace the printhead, press MINUS (-) to select NO. 3.
64 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 11 of 22) Parameter Action/Explanation List Fonts This option prints a label that lists the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory. To print a list of the available fonts: 1. Press SELECT to select the parameter. 2. Press PLUS (+) to select PRINT. 3. Press SELECT to deselect the parameter.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 12 of 22) Parameter Action/Explanation List Network Settings This option prints a network configuration label (see Figure 12 on page 52), which lists the settings for any print server that is installed. To print a network configuration label: 1. Press SELECT to select the parameter. 2. Press PLUS (+) to select PRINT. 3. Press SELECT to deselect the parameter.
66 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 13 of 22) Parameter Action/Explanation Initialize Flash Memory This option erases all previously stored information from Flash memory. Caution • This option completely erases the Flash memory. To initialize Flash memory: 1. Press SELECT to select the parameter. 2. If prompted for a password, enter the printer password. For instructions, see Change Password-Protected Parameters on page 50.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 14 of 22) Parameter Action/Explanation Set Parallel Communications Select the communications port that matches the one being used by the host computer. Default Value: BIDIRECTIONAL Selections: BIDIRECTIONAL, UNIDIRECTIONAL To change the value shown: 1. Press SELECT to select the parameter. 2. Press PLUS (+) or MINUS (-) to scroll through the options. 3. Press SELECT to accept any changes and deselect the parameter.
68 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 15 of 22) Parameter Action/Explanation Set Data Bits This setting applies only when the serial port is used. The data bits of the printer must match the data bits of the host computer for accurate communications to take place. Set the data bits to match the setting being used by the host computer. Default Value: 8 BITS Selections: 7 BITS, 8 BITS To change the value shown: 1. Press SELECT to select the parameter. 2.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 16 of 22) Parameter ZPL and XML only Action/Explanation Set Protocol Protocol is a type of error checking system. Depending on the selection, an indicator may be sent from the printer to the host computer signifying that data has been received. Select the protocol that is requested by the host computer. Further details on protocol can be found in the ZPL Programming Guide.
70 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 17 of 22) Parameter ZPL and XML only Action/Explanation Set Control Prefix Character The printer looks for this two-digit hex character to indicate the start of a ZPL/ZPL II control instruction. Note • Do not use the same hex value for the control, format, and delimiter character. The printer must see different characters to work properly. Default Value: 7E ~ Range: 00 to FF To change the value shown: 1. 2. 3. 4.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 18 of 22) Parameter ZPL and XML only Action/Explanation Set Delimiter Character The delimiter character is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. See the ZPL Programming Guide for more information. Note • Do not use the same hex value for the control, format, and delimiter character. The printer must see different characters to work properly.
72 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 19 of 22) Parameter Action/Explanation Adjust Label Top Position This parameter adjusts the print position vertically on the label. Positive numbers adjust the label top position farther down the label (away from the printhead) by the specified number of dots. Negative numbers adjust the position up the label (toward the printhead). Default Value: +000 Range: –120 to +120 dots To change the value shown: 1. 2. 3. 4.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 20 of 22) Parameter See next column Action/Explanation View Sensor Settings These parameters are automatically set during the calibration procedure and should be changed only by a qualified service technician. Refer to the ZPL II Programming Guide for information on these parameters. To skip these parameters: 1.
74 Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 21 of 22) Parameter Action/Explanation Select Idle Display This parameter selects the LCD options for the real-time clock. Note • If the default value is not selected, pressing PLUS (+) or MINUS (-) briefly displays the firmware version of the printer. Default Value: FIRMWARE (FW) VERSION Selections: MM/DD/YY (24HR), MM/DD/YY (12HR), DD/MM/YY (24HR), DD/MM/YY (12HR), FW VERSION To change the value shown: 1.
Configuration Control Panel Parameters Table 12 • Printer Parameters (Page 22 of 22) Parameter Action/Explanation Select the Display Language This parameter changes the language displayed on the LCD. Each language selection is displayed in the language itself. Default Value: ENGLISH Selections: ENGLISH, SPANISH, FRENCH, GERMAN, ITALIAN, NORWEGIAN, PORTUGUESE, SWEDISH, DANISH, SPANISH 2, DUTCH, FINNISH, JAPANESE, KOREAN, SIMPLIFIED CHINESE, TRADITIONAL CHINESE To change the value shown: 1.
76 Configuration Control Panel Parameters Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________
5 Routine Maintenance This section provides routine cleaning and maintenance procedures. Contents Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78 Routine Maintenance Replacing Printer Components Replacing Printer Components Some printer components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Cleaning Schedule and Procedures on page 79 for the recommended cleaning intervals.
Routine Maintenance Cleaning Schedule and Procedures Cleaning Schedule and Procedures Important • Brady is not responsible for damage caused by the use of cleaning fluids on this printer. Specific cleaning procedures are provided on the following pages. Table 14 shows the recommended cleaning schedule. These intervals are intended as guidelines only. You may have to clean more often, depending upon your application and media. .
80 Routine Maintenance Cleaning Procedures Clean the Printhead and Platen Roller You can minimize printhead wear and maintain print quality with regular preventive measures. Over time, the movement of media or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion: • Minimize printhead pressure and burn temperature settings by optimizing the balance between the two.
Routine Maintenance Cleaning Procedures Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Caution • Before touching the printhead assembly, discharge any built-up static electricity by touching the metal printer frame or by using an antistatic wriststrap and mat. To clean the printhead and platen roller, complete these steps: 1. Open the printhead assembly. 2. Remove the media and ribbon. 3.
82 Routine Maintenance Cleaning Procedures 4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the solvent to evaporate. 5. Reload media and ribbon, and close the printhead assembly. Note • If performing this procedure does not improve print quality, try cleaning the printhead with Cleaning Film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Brady reseller for more information.
Routine Maintenance Cleaning Procedures Clean the Media Compartment and Sensors To clean the media compartment and sensors, complete these steps: 1. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon paths. 2. Brush or vacuum any paper lint and dust away from the sensors (see Figure 16).
84 Routine Maintenance Cleaning Procedures Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________
6 Troubleshooting This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 Troubleshooting Troubleshooting Checklists Troubleshooting Checklists If an error condition exists with the printer, review this checklist: Is there an error message on the LCD? If yes, see LCD Error Messages on page 87. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 55. Is the printer reporting a ribbon error when ribbon is loaded properly? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 55.
Troubleshooting LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 15 for LCD errors, the possible causes, and the recommended solutions. Table 15 • LCD Error Messages LCD Display/ Printer Condition ERROR CONDITION INVALID HEAD Possible Cause Recommended Solution The printhead was replaced with one that is not a genuine Brady printhead. Install a genuine Brady printhead. In thermal transfer mode, ribbon is not loaded or incorrectly loaded.
88 Troubleshooting LCD Error Messages Table 15 • LCD Error Messages (Continued) LCD Display/ Printer Condition WARNING RIBBON IN Possible Cause Recommended Solution Ribbon is loaded, but the printer is set for direct thermal mode. Ribbon is not required with direct thermal media. If you are using direct thermal media, remove the ribbon. This error message will not affect printing. The ERROR light flashes. ERROR CONDITION PAPER OUT The printer stops; the ERROR light flashes.
Troubleshooting LCD Error Messages Table 15 • LCD Error Messages (Continued) LCD Display/ Printer Condition WARNING HEAD COLD The printer prints while the ERROR light flashes. Possible Cause Recommended Solution Caution • An improperly connected printhead data or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printhead temperature is approaching its lower operating limit.
90 Troubleshooting LCD Error Messages Table 15 • LCD Error Messages (Continued) LCD Display/ Printer Condition DEFRAGMENTING Possible Cause The printer is defragmenting memory. The printer stops. OUT OF MEMORY (function) Recommended Solution Caution • Do NOT turn off the printer power during defragmenting. Doing so can damage the printer. Allow the printer to finish defragmenting. If you get this error message frequently, check your label formats.
Troubleshooting Print Quality Problems Print Quality Problems Table 16 identifies problems with print quality, the possible causes, and the recommended solutions. Table 16 • Print Quality Problems Problem Possible Cause Recommended Solution General print quality issues The printer is set at the incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software. See Adjust Print Speed on page 58.
92 Troubleshooting Print Quality Problems Table 16 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Wrinkled ribbon Ribbon fed through the machine incorrectly. See Load Ribbon on page 38. Incorrect burn temperature. Set the darkness to the lowest possible setting for good print quality. See Adjust Print Darkness on page 54. Incorrect or uneven printhead pressure. Set the printhead pressure to the minimum needed for good print quality.
Troubleshooting Print Quality Problems Table 16 • Print Quality Problems (Continued) Problem Possible Cause Vertical drift in top-of-form position The printer is out of calibration. Recalibrate the printer. Vertical image or label drift The bar code printed on a label does not scan. 5/13/08 Recommended Solution Vertical drift occurs during normal printer operation. Note • A vertical drift of ± 4 to 6 dot rows (approximately 0.5 mm) is within normal tolerances. Calibrate the printer.
94 Troubleshooting Calibration Problems Calibration Problems Table 17 identifies problems with calibration, the possible causes, and the recommended solutions. Table 17 • Calibration Problems Problem Possible Cause Recommended Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. The platen roller is dirty. Clean the platen roller according to the instructions in Clean the Printhead and Platen Roller on page 80.
Troubleshooting Communications Problems Communications Problems Table 18 identifies problems with communications, the possible causes, and the recommended solutions. Table 18 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable).
96 Troubleshooting Ribbon Problems Ribbon Problems Table 19 identifies problems that may occur with ribbon, the possible causes, and the recommended solutions. Table 19 • Ribbon Problems Problem Possible Cause Recommended Solution Broken or melted ribbon Darkness setting too high. 1. Reduce the darkness setting. 2. Clean the printhead thoroughly. The printer does not detect when the ribbon runs out. The printer was calibrated without ribbon.
Troubleshooting Miscellaneous Printer Problems Miscellaneous Printer Problems Table 20 identifies miscellaneous problems with the printer, the possible causes, and the recommended solutions. Table 20 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The LCD displays a language that I cannot read The language parameter was changed through the control panel or a firmware command. 1. Press SETUP/EXIT to enter configuration mode. 2. Press MINUS (-).
98 Troubleshooting Miscellaneous Printer Problems Table 20 • Miscellaneous Printer Problems (Continued) Problem Possible Cause Recommended Solution The printer fails to calibrate or detect the top of the label. The printer was not calibrated for the label being used. Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 55. The printer is configured for continuous media. Set the media type to noncontinuous media. See Set Media Type on page 58.
Troubleshooting Printer Diagnostics Printer Diagnostics Self tests and other diagnostics provide specific information about the condition of the printer. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. The most commonly used are the Power-On and the CANCEL self tests. Important • Use full-width media when performing self tests. If your media is not wide enough, the test labels may print on the platen roller.
100 Troubleshooting Printer Diagnostics CANCEL Self Test The CANCEL self test prints a configuration label (Figure 17). To perform the CANCEL Self Test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold CANCEL while turning on (I) the printer. Hold CANCEL until the first control panel light turns off. A printer configuration label prints (Figure 17).
Troubleshooting Printer Diagnostics PAUSE Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies or to determine if any printhead elements are not working. Figure 18 shows a sample printout. To perform a PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control panel light turns off.
102 Troubleshooting Printer Diagnostics FEED Self Test Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the FEED self test, labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label.
Troubleshooting Printer Diagnostics 4. See Figure 20 and Table 21. Inspect the test labels and determine which one has the best print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
104 Troubleshooting Printer Diagnostics Table 21 • Judging Bar Code Quality Print Quality Description Too dark Labels that are too dark are fairly obvious. They may be readable but not “in-spec.” • The normal bar code bars increase in size. • The openings in small alphanumeric characters may fill in with ink. • Rotated bar code bars and spaces run together. Slightly dark Slightly dark labels are not as obvious. • The normal bar code will be “in-spec.
Troubleshooting Printer Diagnostics FEED and PAUSE Self Test Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. If the factory default values are permanently saved, a media calibration procedure must be performed. To perform a FEED and PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2.
106 Troubleshooting Printer Diagnostics Communications Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text. The printer prints all characters received, including control codes such as CR (carriage return).
Troubleshooting Printer Diagnostics Sensor Profile Use the sensor profile label to troubleshoot the following types of problems: • If the media sensor experiences difficulty in determining gaps (web) between labels. • If the media sensor incorrectly identifies preprinted areas on a label as gaps (web). • If the ribbon sensor cannot detect ribbon. For instructions on printing a sensor profile, see Print Sensor Profile on page 66.
108 Troubleshooting Printer Diagnostics Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________
7 Specifications This section provides the features of and specifications for the printer. Contents General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Ribbon Specifications. . .
110 Specifications General Specifications General Specifications General Specifications BBP81 (4”) Height 13.3 in. 338 mm 13.3 in. 338 mm Width 10.9 in. 278 mm 13.4 in. 341 mm Depth 18.7 in. 475 mm 18.7 in. 475 mm Weight (without options) 32.4 lbs. 15 kg 34.7 lbs.
Specifications Printing Specifications Printing Specifications Printing Specifications BBP81 (4”) Print resolution 203 dots/in. 8 dots/mm 203 dots/in. 8 dots/mm 300 dots/in. 12 dots/mm 300 dots/in. 12 dots/mm 600 dots/in. 24 dots/mm N/A N/A 203 dots/in. 0.0049 in. x 0.0049 in. 0.125 mm x 0.125 mm 0.0049 in. x 0.0049 in. 0.125 mm x 0.125 mm 300 dots/in. 0.0033 in. x 0.0039 in. 0.084 mm x 0.099 mm 0.0033 in. x 0.0039 in. 0.084 mm x 0.099 mm 600 dots/in. 0.0016 in. x 0.0016 in. 0.
112 Specifications Printing Specifications Printing Specifications BBP81 (4”) BBP81 (6”) Programmable constant print speeds 203 dots/in. • 2.4 in. (61 mm) per second • 3 in. through 10 in. per second in 1-in. increments (76 mm through 254 mm per second in 25-mm increments) • 2.4 in. (61 mm) per second • 3 in. through 10 in. per second in 1-in. increments (76 mm through 254 mm per second in 25-mm increments) 300 dots/in. • 2.4 in. (61 mm) per second • 3 in. through 8 in. per second in 1-in.
Specifications Media Specifications Media Specifications Media Specifications Label length Minimum BBP81 (4”) BBP81 (6’) Tear-off 0.5 in. 13 mm 0.5 in. 13 mm Peel-off 0.5 in. 13 mm 0.5 in. 13 mm Rewind 0.5 in. 13 mm 0.5 in. 13 mm Cutter 1 in. 25.4 mm 1.0 in. 25.4 mm 200 or 300 dots/in. 32 in. 812.80 mm 32 in. 812.80 mm 600 dots/in. 20 in. 508 mm N/A N/A 1 in. 25.4 mm 2 in. 51 mm Tear/Cutter 4.5 in. 114 mm 7.0 in. 178 mm Peel/Rewind 4.25 in. 108 mm 6.75 in.
114 Specifications Ribbon Specifications Ribbon Specifications Ribbon is wound with the coated side on the outside. The ribbon used must match the Thermal Transfer option installed. The standard Thermal Transfer option (black ribbon spindle) uses ribbon coated on the outside. For more information, see Ribbon Overview on page 28. Ribbon Specifications BBP81 (4”) BBP81 (6”) Ribbon width (Brady recommends using ribbon at least as wide as the media to protect the printhead from wear.) Minimum >2 in.
Specifications Printer Options Printer Options Printer options that are currently available include the BBP81 Thermal Transfer 300 dpi, 4inch wide printer. This printer is avaialble with Internal or External (field-installable) Ethernet 10/100 Print Server. Please check with your Brady representative to learn more about Brady printers.
116 Specifications Printer Options Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________________
Index A adhesive test for ribbon coating 28 adjustments left position 72 print darkness 54 printhead pressure 44 tear-off position 57 auto calibration 43 B backfeed setting 71 bar codes list available codes 64 battery disposal 78 baud setting 67 before you begin setup 16 bitmap scaling factor 73 C calibration media and ribbon sensor 55 setting for head close 56 setting for media power up 56 troubleshooting problems 94 CANCEL button CANCEL self test 100 description 11 checklist before you begin 16 5/13/08
118 Index characteristics of wireless connection 20 internal wired connection and configuration 23 wired and wireless connector locations 8 exit Setup mode 48 external view of printer 8 lights described 12 location 8 overview and illustration 10 parameters 53 control prefix setting 70 customer service 3 cutter loading media for Cutter mode 34 selecting Cutter mode 61 F D darkness setting 54 data bits setting 68 data cables 21 data source connections 20 site selection 19 date setting 74 default password
Index inspect for shipping damage 17 international safety organization marks 25 INVALID HEAD message 87 L label length maximum setting 60 label top printer cannot detect 98 setting 72 labels did not print 95 language changing from unreadable language 97 selection 75 LCD messages error messages 87 language selection 75 Setup mode 53 Liner Take-Up mode description 32 loading media 34 Linerless Peel or Linerless Rewind selecting 61 list settings all settings 65 bar codes 64 fonts 64 formats 64 images 64 netw
120 Index setting password level 74 PAUSE button description 11 FEED and PAUSE self test 105 PAUSE self test 101 Peel-Off mode loading media 34 selecting 61 power connect to power source 24 power cord specifications 25 power switch and connector locations 8 site selection 19 Power-On Self Test (POST) 99 print configuration label CANCEL self test 100 List Setup command 64 print darkness setting 54 print modes described 32 load media for different print modes and options 34 media paths 33 selecting 61 print
Index ribbon adhesive test 28 determining coated side 28 loading 38 ordering 3 removing 42 ribbon LED setting 73 scratch test 29 specifications 114 when to use 28 RIBBON IN message 88 RIBBON OUT message 87 Ribbon S.
122 Index print quality problems 91 types of media continuous roll media 27 fanfold media 27 non-continuous roll media 27 U unpack the printer 17 USB port characteristics of USB connection 20 connection and configuration 22 connector location 8 W Web S.
Brady Worldwide Inc. 6555 West Good Hope Road Milwaukee, WI 53223 U.S.A. Telephone: 414-358-6600 USA Domestic Facsimile: 414-438-6958 Websites USA: Canada: Mexico: Asia: Europe: www.bradyid.com. www.bradycanada.com www.bradylatinamerica.com www.bradycorp.com www.bradyeurope.com Part Number: Y882746 © 2008 Brady Worldwide Inc.
