Brady Bradyprinter Models 2461 and 3481 Operator’s Manual (TEMP COVER) (DO NOT PRINT)
(DO NOT PRINT)
Copyright Information: CG Triumvirate is a trademark of Agfa Corporation. CG Times based upon Times New Roman under license from The Monotype Corporation. Firmware (Software) Agreement The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and is licensed for used only on a single printer in the user’s Trade or Business.
Agency Compliance and Approvals: UL1950 Information Technology Equipment C22.2 No. 950-M93 C US Listed EN60950 For 230 Volt Operation (Europe): Use a cord set, marked "HAR," consisting of a min H05VV-F cord which has a minimum 0.
Important Safety Instructions: This printer has been carefully designed to give you many years of safe, reliable performance. As with all electrical equipment, there are some basic precautions you should take to avoid hurting yourself or damaging the printer: ¾ Before using the printer, carefully read all the installation and operating instructions. ¾ Observe all warning instruction labels on the printer. ¾ Install the printer on a flat, firm, solid surface.
Printer Overview 1.0 Introduction........................................................................ 1 1.1 About this Printer............................................................... 2 1.1.1 Standard Features .................................................... 2 1.1.2 Optional Features .................................................... 3 1.2 Option Installation ............................................................. 5 Getting Started 2.0 Before using the Printer .........................
4.1 The Menu System ............................................................ 30 4.1.1 Media Settings....................................................... 31 4.1.2 Print Control.......................................................... 32 4.1.3 Printer Options ...................................................... 33 4.1.4 System Settings ..................................................... 34 4.1.5 Communications ................................................... 38 4.1.6 Diagnostics ...............
Troubleshooting 6.0 6.1 6.2 6.3 Introduction...................................................................... 73 General Troubleshooting ................................................. 73 Error and Warning Messages........................................... 77 Hex Dump Mode ............................................................. 83 Specifications 7.0 Printer Specifications....................................................... 85 Appendix A ASCII Control Code Chart............................
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1.0 Introduction Congratulations on your purchase of the Bradyprinter Model 2461 or 3481. This printer family, hereafter referred to as ‘the printer’, blends the rugged durability of solid-frame construction with other innovative design features to redefine the standard in industrial thermal printers. The printer incorporates highly specialized electronics, including a powerful 32-bit processor and up to 16 megabytes* of on-board memory.
1.1 About this Printer To meet all of your printing needs this unit is easily configurable. This section lists the available standard and optional hardware features. 1.1.1 Standard Features This printer offers the following standard features: Standard Features Table Feature Printhead Density (Dots Per Inch) Direct Thermal Printing On-Demand and Batch Printing Media Hanger for 1.5” and 3.0” I.D. rolls Rotating Media Hub for 1.5” or 3.0” I.D.
1.1.2 Optional Features (available except as noted) This printer offers the following optional features: Light-Duty Cutter A rotary-type cutter for cutting material with a maximum thickness of .005” (.127mm). Standard Cutter A rotary-type cutter for cutting labels and tags with a maximum thickness of .010” (.254mm). Cutter Tray For use with the optional cutter, this tray collects the cut labels and tags. External Keyboard Support Allows the connection of the Passport™ external keyboard.
LAN Interface A slide-in circuit card assembly that provides network connectivity, allowing multiple users on various platforms to share the same printer. Peel and Present Mechanism (requires the Internal Rewind option) A device used to automatically separate printed labels from the backing material on-demand. Present Sensor A device to control the printer’s output, where subsequent printing occurs only after the removal of a previously print label.
1.2 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 sales support representative or Technical Support.
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2.0 Before using the Printer Unpacking 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 packaging materials (i.e., tape and foam) placed there for shipment. Complete the following steps prior to connecting power or attempting to load media.
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: ¾ ¾ ¾ ¾ Printer Power Cord Accessories CD Any special or additionally purchased items. Additional Requirements The following items are necessary for generating and printing labels. Contact your customer support representative for advice on which media and software may best suit your needs.
2.1 Choosing Media and Ribbon The following is a limited overview of media characteristics. For complete information and advice regarding your specific application needs, always consult a qualified media specialist or a Media Representative. Media Selection – Direct Thermal Consider three important factors when selecting direct thermal stock: • The abrasive qualities of the material that covers the thermal reactive layer of the paper.
• The second method, if only subtle contrast changes are desired, would be to change the ‘Custom Adjustments / Darkness’ menu setting. • The next method would be to change the ‘Print Control / Heat’ menu setting (also selectable as ‘Heat’ in most software programs). Increasing this value causes more energy to be transferred to the media, resulting in a darker image.
3.0 Introduction This chapter explains how to connect the printer and load media and ribbon. 3.1 ; Note: Connecting the Printer When connecting the AC power cord or data cables to the printer, ensure the power switch is in the ‘Off’ position. Connect the AC power cord to the receptacle located on the back of the printer, then plug the cord into a properly grounded outlet.
3.1.1 Interfacing The interface selection process in the printer occurs by data detection. Once detected, the receiving port is set ‘active’. It will remain active, as long as data flow continues; however, if data inactivity occurs and the Host Timeout Value (see Section 4.1.5) is exceeded the selection process will automatically be repeated. When timeout occurs before a complete label format has been received, all data will be lost and the format must be sent again.
Serial Interface Cable Listing (all models except as noted) Null Modem (MXM) “PC” (DB9P) to Printer Part Number 556000 Cable used for typical connection to other DCE equipment with Xon/Xoff flow control. Part Number 556001 “PC” (DB25P) to Printer Part Number 556002 Cable used for connection to a PC compatible with DB25 communication ports. Flow control can be either Xon/Xoff or CTS/DTR. Cable used for connection to a PC compatible with DB9P communication ports.
3.2 Loading Media The following procedures explain the preliminary media loading steps. n o p q r Raise the Access Cover. Rotate the Printhead Latch forward to raise the printhead. Slide the Media Guide out away from the frame and then lower it to the down position. Referencing the drawings on the next page, determine the type of media mounting device in the printer: Media Hanger or Rotating Media Hub.
Media Hanger equipped printer Rotating Media Hub equipped printer 15
3.2.1 n Roll Media Media Hanger equipped: place Roll Media onto the hanger as shown, sliding it over against the Backstop; then raise the Media Retainer and slide it over to rest firmly against the roll. Rotating Media Hub equipped: place Roll Media onto the hub, sliding it over against the Backstop. o p q r Route the media through the printer as shown below: under the Media Idler, through the Media Sensor and out the front of the printer.
3.2.2 n o p q r s Fan-Fold Media Bring the media in through the Bottom or the Rear Media Slot. Route the media as shown below: over the Media Hanger (or Rotating Media Hub) when entering through the Rear Media Slot; or if entering through the Bottom Media Slot, route the media over the Media Rewind Hub. Continue routing the media under the Media Idler, through the Media Sensor and out the front of the printer.
3.3 Loading the Media Rewinder With the Media Rewinder option, the printer can wind labels and backing material. When equipped with the Peel and Present option, labels can be separated automatically. The following subsections illustrate both set-ups: 3.3.1 ;Note: n o p q r Winding Labels When winding labels, the outer diameter of the wound stock cannot exceed 6”. Remove the Front Fascia. Remove the Tear Plate by first removing the Thumbscrew.
s t u Route the media back to the Media Rewind Hub as shown below. Insert the edge of the labels into the Slot on the Rewind Hub and then insert the Media Retainer into the Slot. Slide the Media Retainer over the media and onto a Slot on the Media Rewind Hub and rotate the hub to remove any slack in the Media. ) After loading, close the Access Cover and then press the FEED key to secure the media.
3.3.2 Winding with the Peel and Present Option The printer can separate the labels from the backing material “on-demand” when equipped with the Peel and Present Mechanism. Complete the following steps for automatic separation: n o p q With media loaded as described in Section 3.2, and the Peel and Present Mechanism installed on the printer, loosen the two Thumbscrews on the front of the Roller Bracket, allowing the bracket to swing down.
r Route the Label Backing back to and around the Media Rewind Hub, as shown. s Insert the edge of the Label Backing into the Slot on the Rewind Hub and then insert the Media Retainer, into the Slot on the Rewind Hub. Rotate the Rewind Hub to remove any slack in the Label Backing. ) After loading, close the Access Cover and then push the FEED key to secure the backing material. ;Note: To print on-demand, load the media as described above, and enable the Present Sensor as detailed in Section 4.1.3.
3.4 ;Note: Loading Ribbon Always use ribbon slightly wider than the media backing material; this helps protect against printhead wear. To produce an image on the label, thermal transfer media requires ribbon. Ribbon types are available with the ‘ink’ layer on the outside (coating side out) or with the ‘ink’ layer on the inside (coating side in). These types cannot be interchanged in the printer.
‘Coated Side In’ Ribbon routing path ‘Coated Side Out’ Ribbon routing path 23
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4.0 Front Panel Operation The front panel is equipped with five keys, 3 indicators and a Liquid Crystal Display (LCD). The key functions differ depending upon the selected mode. The selectable modes are Ready, Menu and Quick Test. 4.0.1 Ready Mode: Normal Operation (Ready Light ‘On’) n Pressing the PAUSE key temporarily suspends printing. Pressing again returns the printer to normal operation. o The FEED key advances one label, and clears any faults that have been corrected.
4.0.2 Menu Mode: Configuration (Ready Light ‘Flashing’) n The DOWN ARROW key moves to the previous (reverse) menu item; also, decrements numerical values within certain menu selections. o The UP ARROW key moves to the next (forward) menu item; also, increments numerical values within certain menu selections. p The ENTER key selects function or value displayed in the LCD (selection is indicated with an ‘*’); also, moves between selections in multiple parameter fields.
4.0.3 Quick Test Mode: Print Test Labels n Pressing the DOWN ARROW key scrolls to the previous test function. o Pressing the UP ARROW key scrolls to the next test function. p Pressing the ENTER key will change the selected test label quantity of 2, 100, 1000, or 9999 (the ‘Configuration Label’ is always one). Holding down the key scrolls to the desired quantity. q Pressing the ESCAPE key will exit the Quick Test Mode without printing.
4.0.4 Indicators n ‘On’ indicates READY Mode. ‘Slow Flashing’ indicates MENU Mode. ‘Fast Flashing’ indicates received data is being processed. o ‘On’ indicates a ‘Paused’ state. p ‘Slow Flashing’ indicates a Warning. ‘Fast Flashing’ indicates an Error. Section 6.2 lists the corresponding display messages. 4.0.5 LCD (Display) n Liquid Crystal Display The display provides several types of information: • After the power on sequence is complete, the READY message.
4.0.6 Factory Default Resetting Depending upon the method used, there are two factory default reset levels possible: ;Note: See Section 4.1 for the factory default settings. Level 1: To return the printer to factory default settings only: press and hold the PAUSE and CANCEL keys; continue to depress the keys until the ‘SYSTEM RESET’ message flashes.
4.1 The Menu System The printer operation can be controlled through the menu system user interface, allowing the operator access to these six menu branches: • • • • • • Media Settings Print Control Printer Options System Settings Communications Diagnostics Changes made in the menu system can be saved, so that the configuration will not be lost if power is removed. And as a security feature, and to prevent accidental changes, the user interface has a password protection feature.
4.1.1 Media Settings From Ready Mode, press the ; Note: key to enter the Menu Mode. Entering the menu will clear memory of any settings sent from the host – unless the host has reset the printer. Selects a print method. MEDIA TYPE For use with heat sensitive media. DIRECT THERMAL THERMAL TRANSFER For use with media requiring a ribbon to create an image. SENSOR TYPE GAP CONTINUOUS REFLECTIVE Selects the top-of-form (TOF) sensing method for the media.
4.1.2 Print Control HEAT 10 (0-30) Controls the printhead ‘burn-time’. See Section 2.1.1 for more on print quality control. PRINT SPEED 2-12 in/sec Controls the rate of label movement during the printing process; see Appendix C. FEED SPEED 2-12 in/sec Controls the rate of label movement between printing areas; see Appendix C. REVERSE SPEED 2-6 in/sec Controls the rate of label movement during backup positioning for start of print, cutting or present distance; see Appendix C. ROW OFFSET 00.
4.1.3 Printer Options MODULES PRINT DIRECTORY PRINT FILE FORMAT MODULE DELETE FILE PACK MODULE PRESENT SENSOR ENABLE DISABLE NOT INSTALLED CUTTER ENABLE DISABLE NOT INSTALLED The physical presence of the respective memory module must be detected to show the module function selections for that module in the menu system. Prints a label directory of all available modules, the available space on these modules, the files present, and the type of module and files.
4.1.4 System Settings MEMORY SETTINGS ♦ Allows user to allocate use of printer memory. Sets the number of 1K blocks allocated for the internal RAM ‘D’ module. Available memory dependent upon model; see Appendix C. SCALEABLE FONT CACHE 0312 KB (100-16384) Sets the number of 1K blocks allocated for the scaleable font engine. Available memory dependent upon model; see Appendix C.
System Settings (continued) CONFIGURATION LEVEL PRINTER KEY Note: Reserved for future use – current printer configuration does not allow these values to be modified. This information may change at a later date. To upgrade the application (resident software) of the printer, the hardware and software compatibility levels must match for the update to be accepted. This information is displayed here and can also be found printed on the configuration label.
System Settings (continued) SET FACTORY DEFAULTS Parameters in this menu listing with the ‘ ’ symbol are the designated defaults. Overwrite the current settings and restore SET FACTORY to the factory defaults. DEFAULTS Note: The printer will reset automatically. ALL menu settings will be restored except the CUSTOM ADJUSTMENTS section.
System Settings (continued) PAUSE MODE ENABLE DISABLE SECURITY ♦ SELECT SECURITY ENABLE DISABLE MODIFY PASSWORD UNITS OF MEASURE METRIC IMPERIAL SELECT LANGUAGE ♦ ENGLISH FRENCH GERMAN SPANISH ITALIAN When enabled, PAUSE MODE suspends printing between each label until the PAUSE key is pressed. Printer requires operator to press the PAUSE key after each label. Printer completes label batch without pausing between labels.
4.1.5 Communications SERIAL PORT ♦ BAUD RATE 38400 28800 19200 9600 4800 2400 PROTOCOL BOTH SOFTWARE HARDWARE NONE PARITY NONE ODD EVEN DATA BITS 7 8 STOP BITS 1 2 PARALLEL PORT ♦ PORT DIRECTION UNI-DIRECTIONAL BI-DIRECTIONAL (Continued next page) 38 Controls serial communications port settings. Determines the serial communication rate. 9600 bits per second Sets the flow control (handshaking) method.
Communications (continued) HOST TIMEOUT VALUE ♦ 10 (1-60) The number of seconds an active 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 download. CONTROL CODES ♦ Allows the operator to change the prefix of the commands listed in the Programmer’s Manual, as they are interpreted by the printer.
4.1.6 Diagnostics HEX DUMP MODE ENABLE DISABLE OPTIONS TESTING TEST PRESENT SENSOR TEST CUTTER PERFORM TEST TEST INPUT/OUTPUT Mode most commonly used to troubleshoot communications and format related problems. See Section 6.3 for details. Prints raw ASCII data received from the host rather than executing the commands. Executes and prints label formats (normal operating mode). Tests currently installed options Performs a functional test of the Present Sensor circuitry.
Diagnostics (continued) All Analog Sensor readings displayed SENSOR READINGS THR TRAN RIBM 24V-> Live sensor values may be viewed. View is toggled with forward and reverse keys. 255 255 255 255 Maximum values are shown here (actual values may vary) for the following: thermistor sensor, transmissive (gap) media sensor, ribbon motion sensor, 24 volt power supply sensor (Continued) present sensor, head down <- PS HD RANK sensor (n/a), printhead ranking resistor.
4.2 Display Messages The printer generates and displays four different categories of information (if not in the Menu system or Quick Test Mode): ¾ ¾ ¾ ¾ User Prompts and Condition Messages Download Messages (see Section 5.7) Error Messages (see Section 6.2) Warning Messages (see Section 6.2) 4.2.1 User Prompts and Condition Messages User Prompts indicate a required user operation. Condition Messages indicate a current printer operation or state, when outside the menu system.
Displayed Message Description Condition(s) " The printer is paused or / offline. The printer is in a paused condition. The print job is being processed. Batch status indication, updated with each label printed. READY Mode. Normal operating mode. The printer is ready to receive and process label formats. The Present Sensor option is enabled and a printed label is awaiting removal. A label blocks the Present Sensor; remove it to continue printing.
4.3 The Quick Test Mode This section explains the functions of the resident Quick Tests, accessible by pressing the key on the Front Panel. ; Notes: With the exception of the Configuration Label, all Quick Test labels require 4-inch (102mm) wide media to capture all format information. When using less than full width media, change the Label Width setting to the width of the material to avoid printing on the platen (see Section 4.1.2).
4.3.2 Configuration Label ;Notes: To print all Configuration Label information, the media cannot be less than 2 inches wide (51mm) and the Label Width setting must match the width of the media being used (see Section 4.1.2). The Configuration Label can vary with the application version and model of the printer. The Configuration Label provides valuable printer database information, as detailed in Section 4.1. To print a Configuration Label: n Press the o Use the key.
4.3.3 Quick Ribbon Test Label The Quick Ribbon Test Label features a compliant 4” wide, picket-fence bar code that can be used to verify ribbon and print quality functions. To print a Quick Ribbon Test Label: n Press the o Use the p Use the q Press the 46 key. key to scroll to ‘Ribbon Test Label’. key to select a quantity; see Section 4.0.3. key to start printing.
4.3.4 Dot Test Pattern Label The Dot Test Pattern Label tests printhead and can be used to determine the condition of each thermal element. Pattern examples are shown below. To print a Dot Test Pattern Label: n Press the o Use the p Use the q Press the key. key to scroll to ‘Dot Test Pattern’. key to select a quantity; see Section 4.0.3. key to start printing. Good Test Pattern Label: Indicates that the printhead is operating normally.
4.3.5 Validation Label The Validation Label is another useful tool for evaluating print quality. To generate a Validation Label: n Press the o Use the p Use the q Press the 4.3.6 key. key to scroll to ‘Validation Label’. key to select a quantity; see Section 4.0.3. key to start printing. User Defined Label The User Defined Label will reprint the last label printed (unless the printer was powered-off between the printing of the last label and the request to print a user defined label).
5.0 Introduction Correct hardware adjustments, regular maintenance, and calibrations will ensure continued peak printer performance. 5.1 Media Sensor Adjustment The laterally adjustable Media Sensor is used to detect media; it also detects label TOF for all media types, except continuous stock (where TOF is determined by the label format). To properly detect TOF, the gap, notch, or black mark must pass under the Sensor Eye Mark, as noted in the table below.
p q r s Lower the printhead and rotate the Printhead Latch back to the locked position. Close the Access Cover. If you are using die-cut media proceed to Step 6; otherwise, from READY mode, enter the Media Settings menu and verify that the correct ‘Sensor Type’ is selected for your media; see Section 4.1.1. Exit the Media Settings menu and return to READY mode. Press and hold the FEED key until 2-3 labels are advanced (approximately 4 seconds) to set the TOF; see Section 5.2.
5.2 Positioning Calibration The Positioning Calibration sets the TOF and calculates the label length of the media. This process also calibrates the ribbon sensor on printers equipped with the thermal transfer option. If using die-cut and reflective media, this procedure is recommended: 1) When a ‘Position Fault’ or ‘Ribbon Fault’ message is displayed. 2) After changing media. 3) Following a Media Sensor Calibration. If using continuous media, TOF and label length parameters are set by the label format.
position that can become critical when using reflective or notched stock with a small TOF mark. Three required readings are: Empty: No media in the Media Sensor. Mark or Gap: Only the backing (liner) material, notch, or reflective mark in the sensor. Paper: With an unmarked label area (a space without pre-printing) in the sensor. To perform a Standard Calibration: Step 1 Operator Action Turn ‘On’ the printer. 2 Press the Menu Mode.
Step 6 Operator Action Displayed Message Press the key. Use " " # " the key to scroll to ‘Sensor Calibration’. Comment See Section 4.1.1 for details. Press the key to abort this procedure. 7 Press the 8 Press the key. "# Ensure no label media is in " ]<<<_ the Media Sensor then press any key. key. " # " " # " See Section 4.1.1 for details. Sets the parameter for the ‘out of stock’ condition.
Step 9 Operator Action Displayed Message Comment Proceed according to media " #" " ]<<<_ type: Sets the parameter for the ‘gap’ or ‘mark’ value. -ORDie-cut stock: remove approximately six inches of label material from the " " " ]<<<_ backing (liner) and place the backing under the Sensor Eye Mark. Notched stock: place the notched area in the sensor and adjust the Sensor Eye Mark over the notch.
Step Operator Action 10 Place the label (and backing) under the Sensor Eye Mark. Displayed Message " " " ]<<<_ Press any key to continue. 11 Depending upon the ‘Sensor Type’ selection, observe the display for the calibration message. Comment Calculates the parameter settings for the ‘Paper’ value. ‘yyy’ is a numerical value representing the current sensor reading.
Calibration Problems: When problems occur during calibration, one of the following messages will be displayed. The ‘Comment’ column addresses the most likely cause and the corrective action to be taken (if any) for each situation. Displayed Message " " #" Action Comment Press any key. The printer measured only a small difference between the ‘empty’ and ‘gap’ readings. Transparent backing or notched type media typically gives this indication.
5.3.2 Advanced Entry Calibration The second calibration method is the Advanced Entry Calibration. This method overrides all previous settings and should be used only when the other method has failed. The procedure has two parts: 1) Sensor Gain: Different algorithms are used for sampling, to produce different measurements for the media. 2) Sensor Levels: At a selected gain, values are directly input for ‘Paper’, ‘Mark’ or ‘Gap’, and ‘Empty’ variables.
Step 6 Operator Action Press the key. key to Use the scroll to ‘Sensor Calibration’. Press the Displayed Message " " # " Comment See Section 4.1.1 for details. Press the key to abort this procedure. key. 7 Use the key to scroll to ‘Advanced Entry’. Press the key. " # " " " See Section 4.1.1 for details. 8 Press the " " " See Section 4.1.1. 9 Place the label under the Sensor Eye Mark and lower the printhead.
Step Operator Action 10 Proceed according to media type: Die-cut stock: remove approximately six inches of label material from the backing and place the backing under the Sensor Eye Mark. Lower the printhead. Displayed Message " " JQQ ]<<<_ HQ L RVI -OR " JQQ ]<<<_ HQ L RVI Comment ‘yyy’ is a numerical value representing the current sensor reading. Notched stock: place the notched area in the sensor and adjust the Sensor Eye Mark over the notch. Lower the printhead.
Step Operator Action 11 Using the Gain Number data collected from Steps 9 and 10, subtract each Label Value from the TOF Value. From the resulting list of Difference Values, select the largest number. Its associated Gain Number is the best selection for the media. See example below.
Step Operator Action 13 Using the ‘Gain Number’ set in Step 12, complete the following steps: Displayed Message " " JQY n Place the label under the Media Sensor. Record the sensor reading and label it “P” (paper). ]<<<_ HQ L RVI -OR " JQY ]<<<_ HQ L RVI Comment ‘yyy’ is a numerical value representing the current sensor reading. o Place the backing, mark, or notch under the Media Sensor. Record the sensor reading and label it “G” or “M” (gap or mark). p Remove all media.
5.4 Printhead Adjustments To ensure even and consistent print quality across a wide range of media types, widths and thickness, the printhead is equipped with two adjustments: the Leveling Cam and the Burn Line. 5.4.1 Leveling Cam Adjustment The Printhead Leveling Cam raises and lowers the right side of the Printhead Assembly. Make this important adjustment when using media that is less than the full width of the Platen Roller. n o p q Load the printer with media.
5.4.2 Burn Line Adjustment The row of heat elements running the length of the thermal printhead is referred to as the Burn Line. At the factory, the burn line has been adjusted to meet strict print and bar code compliance requirements, using 6.5-mil (.0065″) media, enabling the printer to accommodate the majority of media types in use today.
r s Turn each Adjustment Screws clockwise about ¼ a turn (or 1/8 a turn for finer adjustments). Print another Validation Label and examine the print quality. Repeat this step until labels with even print contrast (darkness) and acceptable print quality are produced. Tighten the Locking Screws. Print a final Quick Test label to verify the adjustment. ;Note: When the Locking Screws are ‘snug’, turning the Adjustment Screws counter-clockwise will not move the printhead outward.
5.5 Printhead Replacement Locating pins in the printhead assembly eliminate the need for an alignment following the installation of a new printhead. n o p q r s t u v Touch a metal part of the printer’s frame to discharge any static electricity that may be present on your body. Turn ‘Off’ and unplug the printer. Open the Access Cover, rotate the Printhead Latch forward and raise the printhead. Remove the ribbon, if installed. Lower and rotate the Printhead Latch to the locked position.
5.6 Cleaning Schedule A clean printer operates efficiently. The following list of cleaning items and table below provides the recommended schedule and technique for cleaning the various parts of your printer safely and effectively. • • • • • • Isopropyl alcohol Cotton swabs A clean, lint-free cloth Soft-bristle brush Soapy water/mild detergent Compressed air For your continued safety and to avoid damage, always turn ‘Off’ and unplug the printer before cleaning.
5.6.1 Cleaning the Printhead If print quality begins to decline, indicated by symptoms including noncompliant bar codes, print dropouts, streaking and smudging, the typical cause is debris build-up on the surface of the printhead (see Section 4.3.4). Furthermore, if this build-up is not removed it may lead to premature element failures, greatly reducing the life of the printhead. To clean the printhead: n o p q r Turn ‘Off’ and unplug the printer. Open the access cover.
5.6.2 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, even cause labels to stick and wrap around the roller. To clean the platen roller: n o p q r s Turn ‘Off’ and unplug the printer. Open the access cover. Unlock the Printhead Latch and raise the Printhead Assembly. Remove media and ribbon.
5.6.3 Interior and Exterior Surfaces Cleaning Interior Surfaces: During normal operation, dust particles can buildup inside the printer and find their way onto the media to cause voids in the print. To prevent this, turn ‘Off’ and unplug the printer. Then use a soft bristle brush or compressed air to clean the interior of the printer. Cleaning Exterior Surfaces: The outer surfaces of the printer should be cleaned using a general-purpose cleanser. Turn ‘Off’ and unplug the printer.
p Downloading: Using the DOS copy command (where ‘filename’ is the program to download, e.g., 4206pa10_102.zs), enter the following: copy filename lpt1: ; Note: Printer Key hardware and software compatibility must at a minimum level to accept the file download. In the example above, the hardware compatibility level must be ‘pa’, while the software compatibility level must be ‘10’ or higher; see Section 4.1.4, ‘Configuration Level’ for details.
Download Error Messages: Displayed Message " " " " Descriptions / Causes / Solutions The printer detected an error in the download. The possible causes include: • An invalid or corrupted file was downloading. • Communications error. • Application downloading was not compatible with the Printer Key hardware or software level; see Section 4.1.4, System Settings/Configuration Level. " " " The printer could not successfully erase Flash memory.
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6.0 Introduction If a problem arises with the printer, the information in this section will help you resolve it. Use this as a starting point in troubleshooting. If you have questions, or if problems persist, contact a qualified service technician or a Technical Support Representative. 6.1 General Troubleshooting The following are problems that will not necessarily generate a message (see Section 6.2 for Error and Warning Messages).
If experiencing this problem… Try this solution… Intellifont will not print: Intellifont format is Little/Big Endian specific. The printer uses Big Endian. Refer to your font supplier for information. Light print on the right side (facing the printer) of the label: • The Printhead Leveling Cam may be incorrectly adjusted; see Section 5.1.4. Missing information in the printed label: • The Platen Roller may be dirty or worn; see Section 5.6.2.
If experiencing this problem… Try this solution… No power (all indicator lights are ‘Off”): • Verify that the AC power cord has been made at both the outlet and the printer; also, ensure the power switch is ‘On’. • Verify that the AC outlet is functioning, or try moving the printer to another AC circuit. • The AC cord may be damaged; replace it. • The power switch may be defective or the line fuse blown; call for service.
If experiencing this problem… Nothing happens when trying to print using a software program: Try this solution… • 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 I/O cable meets requirements found in Section 3.1.1. Poor print quality: the • The printhead may need cleaning; see Section 5.6.1.
6.2 Error and Warning Messages When the printer detects a (potential) problem, a message is displayed and an Error indicator (see Section 4.0.4) will be illuminated. There are two types of indicators: • Error Indication – the Error indicator ‘fast flashes’ with message. • Warning Indication – the Error indicator ‘slow flashes’ with message. The Error and Warning Messages are listed in the following two tables, including a brief description of each and possible solution(s).
Error Messages (continued): Displayed Message Description The printer cannot detect media. Possible Solution(s) 1) Reload media. 2) Ensure that the labels are passing through the Media Sensor. 3) Readjust the Media Sensor over the TOF mark; see Section 5.1. 4) Calibrate the printer; see Section 5.3. The printer has determined that the media is not correctly positioned to print. Press and hold the FEED key for 4 seconds; see Section 5.2.
Error Messages (continued): Displayed Message ## " Description The ribbon sensor detects no or only sporadic ribbon supply hub movement; or the sensor values may have changed. ; Note: The ribbon sensor calibration can be performed only after a Level 2 reset has cleared the previously entered values. # " " " Possible Solution(s) 1) Ensure that ribbon is correctly loaded with the printhead locked down.
Error Messages (continued): Displayed Message " Description The printer could not find the TOF mark within the maximum label length setting or it found a TOF in an unexpected place. Possible Solution(s) If media is moving: 1) Press the FEED key. It may be necessary to recalibrate the printer; see Section 5.3. 2) The Media Sensor may be out of position. Readjust its position; see Section 5.1. 3) The media may not be properly loaded.
Warning Messages: Displayed Message " " # " " ## " " Description Action The printer has detected burnedout printhead elements. Replace the printhead when print quality degrades or if bar codes are noncompliant. The printer missed detecting a label gap. Readjust the media sensor and recalibrate. Power has been removed and shutdown is in progress.
Warning Messages (continued): Displayed Message Description Action " " A high printhead temperature has been detected. Allow printhead to cool. " The previous warning condition has been corrected. No further action is necessary.
6.3 Hex Dump Mode The hex dump mode is a useful tool for diagnosing problems, including communication and DPL syntax errors, allowing a comparison of input strings (sent by host) to output data (received by printer). To decode this information, the Programmer’s Manual is an essential reference. This output can be used for debugging the label format. And by repeatedly sending a format, this mode can uncover handshaking problems (if they exist).
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7.0 Printer Specifications Bar Codes (See the Programmer’s Manual for details. See Appendix B for visual samples.) Code 39, Interleaved 2 of 5, Code 128 (subsets A, B and C), Codabar, LOGMARS, UPC-A, UPC-E, UPC 2 & 5 digit addendums, EAN-8, EAN-13, EAN 2 & 5 digit addendums, UPC Random Weight, Code 93, Plessey, Universal Shipping Container Symbology, Code 128 MOD 43, Postnet, USS/EAN-128 Random Weight, Telepen, UPS MaxiCode (modes 2 & 3), PDF417, Data Matrix.
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” (322.6mm) Width: 12.62” (320.6mm) Depth: 18.60” (472.5cm) Weight: 45 lbs. (20.5 kg) Printing Specifications Printing Type: Direct Thermal or optional Thermal Transfer Print Speed: 2 – 6 IPS (50.
Media and Ribbon Media Types: Roll-Fed, Die-Cut, Continuous, Fan-Fold. Flat on the printable side with no more than .0007" (.018mm) protrusions on the opposite side. 4.65" (118.1 mm) 1" (25.4 mm) .0025" - .01" (.06 mm – .25 mm) 8" (203.2 mm) Outer Diameter 1.5" or 3.0" (38 mm – 76.2 mm) Inner diameter 1.010 ± .006" (25.65 ± .15 mm) Inner diameter size. Core not to protrude beyond ribbon edge. 1.0 – 4.5" (25.4 – 114.
Approved Media To achieve optimum print quality and maximum printhead life, we recommend the use of our media and ribbons. These supplies are specially formulated for use in our printers; use of other supplies may affect the print quality, performance, and life of the printer or its components. For a current list of approved media and ribbons for use in direct thermal and thermal transfer applications consult Section 2.1.1 or contact a Media Representative.
ASCII Control Code Chart Ctrl @ Ctrl A Ctrl B Ctrl C Ctrl D Ctrl E Ctrl F Ctrl G Ctrl H Ctrl I Ctrl J Ctrl K Ctrl L Ctrl M Ctrl N Ctrl O Ctrl P Ctrl Q Ctrl R Ctrl S Ctrl T Ctrl U Ctrl V Ctrl W Ctrl X Ctrl Y Ctrl Z Ctrl [ Ctrl \ Ctrl ] Ctrl ^ Ctrl _ Char Dec Hex NUL SOH STX EXT EOT ENQ ACK BEL BS HT LF VT FF CR SO SI DLE DC1 DC2 DC3 DC4 NAK SYN ETB CAN EM SUB Esc FS GS RS US 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 00 01 02 03 04 05 06 07 08 09 0A 0B 0C 0D 0
Char Dec Hex Char Dec Ç ü é â ä à å ç ê è è ï î ì Ä Å É Æ Æ ô ö ò û ù ÿ Ö Ü Ø £ Ø x ƒ 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 80 81 82 83 84 85 86 87 88 89 8A 8B 8C 8D 8E 8F 90 91 92 93 94 95 96 97 98 99 9A 9B 9C 9D 9E 9F á í ó ú ñ Ñ a ° ¿ ® 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 90 1/2 1/4 ¡ – 2 3 ´ Á Â À © 1 » ¢ ¥ Hex
Available Fonts and Bar Codes All character fonts and bar codes available with the printer are described in this section. Each font and bar code has a name associated with it for use in programming. Human-readable fonts have numeric names, while bar code fonts have alpha names. Consult the Programmer's Manual for detailed information. Fonts Fonts 0 through 8 use the slash zero (Ø) convention for distinguishing between the number zero and the letter O.
The table below lists the font sizes; the numbers indicate the number of dots. FONT Font 0 Font 1 Font 2 Font 3 Font 4 Font 5 Font 6 Font 7 Font 8 HEIGHT 7 13 18 27 36 52 64 32 28 WIDTH 5 7 10 14 18 18 32 15 15 SPACING 1 2 2 2 3 3 4 5 5 Font 0 96-character alphanumeric, upper and lower case. Font 1 145-character upper and lower case alphanumeric w/ descenders and ascenders. Font 2 138-character alphanumeric, upper and lower case. Font 3 62-character alphanumeric, uppercase.
Font 4 62-character alphanumeric, uppercase. Font 5 62-character alphanumeric, uppercase. Font 6 62-character alphanumeric, uppercase.
Font 7 OCR-A, size I. Font 8 OCR-B, size III. Font 9 Internal Triumvirate font. Point sizes are selected by the number in the bar code height. Larger point sizes can be obtained by increasing the height and width multipliers.
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. Barcode ID Type Length Checksum Valid ASCII Characters, decimal value representation 32, 36, 37, 42, 43, 4557, 65-90 48-57 Numeric only.
Bar Code A Code 3 of 9 Bar Code B UPC-A Bar Code D Interleaved 2 of 5 Bar Code C UPC-E Bar Code E Code 128 Bar Code F EAN-13 Bar Code H Health Industry Bar Code (HBIC) Bar Code G EAN-8 96
Bar Code I Codabar Bar Code J Interleaved 2 of 5 w/module 10 checksum Bar Code K Plessey Bar Code L Interleaved 2 of 5 w/module 10 checksum and shipping bearer bars Bar Code M 2 Digit UPC addendum Bar Code N 5 Digit UPC addendum Bar Code p Postnet Bar Code O Code 93 97
Bar Code Q UCC/EAN Code 128 Bar Code R UCC/EAN Code 128 KMART NON EDI Bar Code S UCC/EAN Code 128 Random Weight 98
Barcode T Telepen Barcode u UPS MaxiCode Barcode z PDF-417 Barcode v FIM Barcode W1c DataMatrix 99
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Module Assignments Consult the Programmer's Manual for detailed programming information. Module Designator D F Y Z Module Internal SDRAM (in 1KB blocks) 2461: 100-8192; 3481:100-16384 Optional User Flash Internal Flash Optional ILPC protected Flash Print Resolutions and Maximum Widths Model 2461 3481 Printhead Resolutions and Widths Maximum Print Printhead Resolution Width Inches Millimeters 203 dots/inch 4.09 103.9 (8 dots/mm) 300 dots/inch 4.16 105.6 (11.8 dots/mm) Factory Default Setting 4.10 4.
Speed Settings and Defaults Consult the Programmer's Manual for detailed information. Function Print Feed Reverse Function Print Feed Reverse 102 2461 Speed Range IPS MMPS 2-6 50.8 – 152.4 2-6 50.8 – 152.4 2-6 50.8 – 152.4 Default Setting IPS MMPS 6.0 152.4 6.0 152.4 4.0 101.6 3481 Speed Range IPS MMPS 2-8 50.8 – 203.2 2-8 50.8 – 203.2 2-6 50.8 – 152.4 Default Setting IPS MMPS 6.0 152.4 6.0 152.4 4.0 101.
Brady Products Limited Warranty Statement Bradyprinter Models 2461 and 3481 Printer Brady warrants to Purchaser that under normal use and service, the 2461, 3481 and 6441 Printers, (with the exception of the thermal printhead) purchased hereunder shall be free from defects in material and workmanship for a period of (365) days from the date of shipment by Brady. Expendable and/or consumable items or parts such as lamps, fuses, labels and ribbons are not covered under this warranty.
Thermal Printhead This warranty is limited to a period of one year, (365 days), or 1,000,000 linear inches of use, whichever comes first, for the 2461, 3481 or 6441 thermal printhead. This one year (365 days) warranty is valid only if a Brady - approved thermal label media is used, as defined in the then current Brady list of approved thermal/thermal transfer media, a copy of which is available from Brady.
General Warranty Provisions Brady makes no warranty as to the design, capability, capacity or suitability of any of its hardware, supplies, or software. Software is licensed on an “as is” basis without warranty. Except and to the extent expressly provided in this warranty and in lieu of all other warranties, there are no warranties, expressed or implied, including, but not limited to, any warranties of merchantability or fitness for a particular purpose.
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Glossary of Terms alphanumeric Consisting of alphabetic, numeric, punctuation and other symbols. backing material The silicon-coated paper carrier material to which labels with adhesive backing are affixed. Also referred to as “liner”. bar code A representation of alphanumeric information in a pattern of machine-readable marks. The basic categories are divided into one-dimensional (UPC, Code 39, Postnet, etc.) and twodimensional barcodes (Data Matrix, MaxiCode, PDF417, etc.).
direct thermal The printing method that uses a heat sensitive media and only the heat of the thermal printhead to create an image on the label. direct thermal media Media coated with special chemicals that react and darken with the application of heat. DPI (dots per inch) A measurement of print resolution, rated in the number of thermal elements contained in one inch of the printhead. Also referred to as “resolution”.
media Generalized term for all types of printing stocks, including: roll fed, continuous, die-cut, and fanfold. media hub Device in the printer used to support roll media. media sensor An electronic device equipped with photosensors to detect media and the top-of-form on die-cut, notched or reflective media. MMPS (millimeters per second) Metric measurement of printer speeds. notched stock Media, typically tag stock, with holes or notches in the material that is used to signal the top-of-form.
tag stock A heavy paper or synthetic printing material, typically featuring a notch or reflective mark and without an adhesive backing. thermal transfer The printing method that creates an image by transferring ink from a ribbon onto the media using the heat from the thermal printhead. TOF (top-of-form) The start of a new label. void An undesirable blank space in a printed image.
Index A Advanced Entry Calibration, 57 alphanumeric, 92, 93, 107, 108 ASCII, 40, 83, 89, 91, 95 B backing material, 3, 4, 9, 18, 20 - 22, 52, 87, 107, 109 bar code, 46, 63, 76, 85, 91, 94 - 98, 107 black mark, 49, 54, 59, 87 boot loader, 107 burn line, 62, 63, 76 C cable listing, 13 calibration, 29, 31, 43, 51, 55 - 57, 76, 107 calibration problems, 55, 56 checksum, 95, 97, 107 cleaning schedule, 66 communications, 38, 39, 71, 85.
M media, 1 - 4, 7 - 11, 14 - 22, 31, 41, 44, 49 - 54, 56, 57 - 69, 75, 76, 78 81, 87, 88, 104, 107 - 110 media rewinder, 18 media selection, 9 media sensor adjustment, 49 media sensor calibration, 51 media settings. See Menu Settings memory settings, 34 menu mode, 26, 31, 52, 57 menu system, 30 MMPS, 102, 109 module, 33, 101 N notched stock, 51, 109 P parallel port, 12, 73 peel and present, 3, 4, 5, 18, 20 perforation, 109 positioning calibration, 51 present sensor, 33, 40 print control.
