Operator’s Manual
Copyright Information CG Triumvirate is a trademark of Agfa Corporation. CG Times based upon Times New Roman under license from the Monotype Corporation. Windows is a registered trademark of the Microsoft Corporation. Ethernet is a registered trademark of Xerox Corporation. All other brand and product names are trademarks, service marks, registered trademarks, or registered service marks of their respective companies.
Agency Compliance and Approvals C US Listed UL60950 Information Technology Equipment C22.2 No. 950-M93 EN60950 For 230 Volt Operation (Europe): Use a cord set, marked “HAR,” consisting of a min H05VV-F cord which has a minimum 0.
Important Safety Instructions The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance instructions in the literature accompanying this unit. This unit has been carefully designed to provide years of safe, reliable performance.
Contents 1 Overview................................................................................................. 1 1.1 About the Printer ............................................................................... 1 1.1.1 Standard Features .................................................................... 1 1.1.2 Optional Features ..................................................................... 2 2 Getting Started ................................................................................
4.1.3 Menu Mode: Configuration ....................................................... 20 4.1.4 Test Mode: Printing Test Labels ................................................ 21 4.2 The System Menu............................................................................ 22 4.2.1 Entrance and Exit Prompts ....................................................... 22 4.2.2 Media Settings ....................................................................... 23 4.2.3 Print Control ..........................
5.3 Reset Methods ................................................................................ 70 5.3.1 Soft Reset.............................................................................. 70 5.3.2 Level One Reset ..................................................................... 70 5.3.3 Level Two Reset ..................................................................... 70 5.4 Printhead Assembly Adjustments ....................................................... 71 5.4.
7.2 Approved Media and Ribbon ............................................................100 7.2.1 Controlling Print Quality ..........................................................100 7.2.2 Media and Ribbon Requirements ..............................................101 7.3 Serial Cable Requirements ...............................................................103 Appendix A.............................................................................................. 105 Module Assignments ...........
1 Overview 1.1 About the Printer Congratulations on your purchase of an I-Class printer (hereafter referred to as “the printer”). This manual provides information regarding printer setup, operation, and care. To print label formats, refer to the instructions provided with your labeling software; or if you wish to write custom programs, a copy of the Class Series 2 Programmer’s Manual can be found on the Accessories CD and at our web site at http://www.datamax-oneil.
Standard Features I-Class Model Feature 4206 4208 4212 4308 4406 4604 Direct Thermal Printing X X X X X X Fan-Fold Media Handling X X X X X X 1MB 1MB 2MB 2MB 2MB 2MB Liquid Crystal Display X X X X X X Media Tear Bar X X X X X X Multi-Language Support X X X X X X On-Demand and Batch Printing X X X X X X 203 203 203 300 406 600 X X X X X X 8MB 8MB 16MB 16MB 16MB 16MB Scalable Font Engine X X X X X X Serial & Parallel Ports X X
External Keyboard (specify voltage & country requirement when ordering) A portable terminal for stand-alone printing. External Media Rewinder (specify voltage requirement when ordering) A feature-dependant bidirectional label rewinding device: • DMXREW1 – rewinds widths up to 4.5 inches (114 mm) into eight-inch (203 mm) outer diameter rolls on one to four inch (25 to 101 mm) diameter cores at up to ten inches per second. • DMXREW2 – rewinds widths up to 9.
RFID An integrated Radio Frequency Identification tag encoding and reading device with data capture capabilities, available for immediate or future use: • Factory Installed – complete, ready to use. • Ready – factory installed antenna, requiring installation of additional hardware. RS-422 Serial Interface (unavailable for I-4206 and I-4208 models) Single-drop interface hardware for greater printer to host serial communication distances (at up to 38,400 baud).
Option Installations (continued) I-Class Option Recommended Installer Peel and Present Mechanism Operator Present Sensor Operator RFID-Ready DMX Certified Technician RS-422 Serial Interface DMX Certified Technician Thermal Transfer Operator Twinax/Coax Interface DMX Certified Technician USB Port DMX Certified Technician 5
6 I-Class
2 Getting Started 2.1 Unpacking the Printer The printer has been carefully packaged to prevent transit damage. (Inspect the container for damage; if evident, notify the shipping company before acceptance.) Complete the steps below to ready the printer for use: A. With the arrow pointing upward, open the box. B. Remove Accessories Box. C. Tilt the box sideways and then slide out the printer. D. Place the printer in an upright position and remove the packing foam, bag, and tape.
2.1.1 Inspection After removing the packaging, check the contents of the shipment. The following items should be included: • Printer • Power Cord • Accessories CD • Any special or additionally purchased items. 2.1.2 Additional Requirements Other items can also be needed for operation: 8 • An interface cable; see Section 3.1.1. • Applicable media; see Section 7.3.
3 Setting up the Printer 3.1 Installation Interface and connect power to the printer: A. Place the printer on a firm, level surface. B. Turn OFF the Host Computer then, depending upon your system, connect an appropriate interface cable from the host to the printer; see Section 3.1.1. C. Turn ON the Host Computer. D. Ensure that the printer’s Power On/Off Switch is in the OFF position. Connect the AC Power Cord to the AC Power Connector, and then plug the AC Power Cord into a properly grounded AC Outlet.
3.1.1 Communications Following power-up (or after a period of inactivity), interface port selection occurs automatically upon detection of valid data. If the incoming (received) data flow stops and the Host Timeout Value (see Section 4.2.6) is exceeded, partially received formats will be ignored and the port detection process repeated. Notes: 1) To change an active port immediately, cycle the power OFF and ON. 2) For alternate data processing options, see SYSTEM SETTINGS / INPUT MODE - Section 4.2.5.
3.2 Media Loading Load media according to its type: A. Raise the cover. B. Rotate the Printhead Latch then raise the Printhead Assembly. C. Slide the Media Guide outward and then rotate it downward. D. If using roll media on a 1.5-inch (38mm) core, grasp then pull firmly outward to remove the 3-Inch Media Hub; otherwise, go to Step E. Printhead Assembly 3 Inch Media Hub 1.5 Inch Media Hub Printhead Latch Media Guide E. Proceed according to the media type: I-Class • For Roll Media, see Section 3.2.
3.2.1 Loading Roll Media A. Slide the Roll Media onto the Media Hub until it reaches the Backstop. Backstop Roll Media Media Hub Media Guide B. Route the Media under the Media Idler, through the Media Sensor, and then straight out the front of printer. Media Idler Media Media Sensor Media Guide C. Raise then slide the Media Guide over so that it rests lightly against the edge of the media. D. Position the Media Sensor; see Section 3.3.
E. If using thermal transfer media, load ribbon (see Section 3.4); otherwise, go to Step F. F. Lower the Printhead Assembly and rotate the Printhead Latch into the locked position. Close the cover then turn ON the printer. After READY is displayed, press and hold the FEED Key until at least one label gap (or mark) is advanced; see Section 3.5. Printhead Assembly Printhead Latch Note: Adjust the Leveling Cam if using narrow media; see Section 5.4.1. 3.2.2 Loading Fan-Fold Media A.
B. Route the Media under the Media Idler (also, if equipped over the Internal Rewinder; and, if through the Rear Media Slot, over the Media Hub). Media Idler Media Media Sensor Media Hub Media Guide Internal Rewinder (Optional Equipment) C. Pass the media through the Media Sensor then straight out the front of the printer. D. Raise then slide the Media Guide over so that it rests lightly against the edge of the media. E. Position the Media Sensor; see Section 3.3. F.
3.3 Media Sensor Adjustment The Media Sensor detects media presence, and top-of-form (except when using continuous stock). Adjust the Media Sensor as follows: A. With media loaded and the Printhead Assembly raised for visual access, grasp the Slide Tab of the Media Sensor. B. According to your Media Type, use the Slide Tab to position the Sensor Eye Mark as described in the table below. (Afterward, if necessary, return to the previous section to complete the setup.
3.4 Ribbon Loading The Thermal Transfer Option type determines the applicable ribbon type [Coating Side In (CSI) or Coating Side Out (CSO)]. Depending upon the option type, load ribbon as follows: A. Unlock the Printhead Latch and raise the Printhead Assembly. Following the Directional Arrows on the Thermal Transfer Option, orient the Ribbon Roll accordingly and then slide it completely onto the Ribbon Supply Hub. B.
Removing Used Ribbon When the Ribbon Roll is depleted, pull the empty core from the Ribbon Supply Hub. Grasp the used roll on Ribbon Take-Up Hub then pull and squeeze to remove the spent ribbon. (To remove partially depleted rolls, cut the ribbon then remove the roll and discard any used ribbon as described above.) 3.5 Quick Calibration The printer is calibrated to sense a wide range of media. Calibration fine-tunes these settings for your die-cut, notched, or reflective application.
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4 Using the Control Panel 4.1 Operation The Control Panel is composed of a display, indicators, and mode-dependant keys for easy access to printer functions. 4.1.1 Display and Indicator Lights Liquid Crystal Display (LCD) The LCD provides textual information: • • • • • Following initialization, the READY message; The time and date; Label counts during batch jobs; When in Menu Mode, the System Menu; and, Displayed Messages.
4.1.2 Ready Mode: Normal Operation (Ready Light ON) The PAUSE Key temporarily suspends printing, and pressing it again returns normal operation. The FEED Key advances labels, and clears any corrected faults. Pressing and holding it initiates calibration; see Section 3.5. The CANCEL Key cancels the current print job and then pauses the printer. Pressing and holding it four seconds initiates a soft reset; see Section 5.3.1.
The ESCAPE Key moves through previous menu levels to Ready Mode. The TEST Key terminates printing then restores Menu Mode. 4.1.4 Test Mode: Printing Test Labels The DOWN ARROW Key scrolls to the previous test function. The UP ARROW Key scrolls to the next test function. The ENTER Key changes the selected test label quantity (except the Configuration Label, always one), and holding down the key scrolls the quantities. The ESCAPE Key exits the Test Mode.
4.2 The System Menu The MENU Key accesses seven system branches: • MEDIA SETTINGS • PRINT CONTROL • PRINTER OPTIONS • SYSTEM SETTINGS • COMMUNICATIONS • DIAGNOSTICS • MCL OPTIONS Notes: (1) Entering the menu takes the printer offline and halts the processing of new data. (2) Selected Menu items are indicated with an asterisk (*) next to the displayed setting, while items designated with a section symbol (§) require a reset to become effective.
Displayed Message MENU MODE Details The Menu Key has been pressed, where: ENTER PASSWORD 0000 KEEP HOST CHANGES? ENTER=YES SAVE CHANGES? ENTER = YES Requires entry of the correct security password for menu access. Requires a decision regarding existing host commands that have affected the configuration of the printer, where pressing ENTER will save these changes or pressing ESC will discard them.
Media Settings (continued) Menu Item SENSOR TYPE Details Selects the Top Of Form (TOF) sensing method used to determine the leading edge of the label, where: GAP Senses the gaps or notches in the media. CONTINUOUS TOF sensing is not used; see LABEL LENGTH. REFLECTIVE Senses the reflective (black) marks on the underside of the media. LABEL LENGTH 04.00in (0-99.99) MAXIMUM LABEL LENGTH 16.00in (0-99.
Media Settings (continued) Menu Item PAUSE ON RIBBON LOW Details Sets the printer to pause when the RIBBON LOW DIAMETER setting is met, where: ENABLED Forces the user to press the PAUSE Key to proceed with the print job. DISABLED Allows printing to continue until ribbon empty is declared. SENSOR CALIBRATION Selects the method used to calibrate the media sensor (see Section 5.2), where: PERFORM CALIBRATION Sets the values via printer calculations.
4.2.3 Print Control The Print Control menu contains print quality, throughput, formatting, and custom setup functions: Menu Item HEAT 10 Details Controls the burn-time of the printhead (selectable as “Heat” in most labeling programs), where: (0 - 30) PRINT SPEED Controls the rate of label movement during printing, where: (X - XX) XXin/sec Is the number based on duration, corresponding to print darkness. Is the speed setting; see Appendix A for the model dependant default and range.
Print Control (continued) Menu Item PRESENT DISTANCE 0.00in (0 - 4.00) MOTOR THROTTLING Details Sets the label stop position, where: Is the label travel distance at output. Controls the current to the stepper motor, where: ENABLED Counts labels versus time and, if needed, pauses printing to maintain a cooler motor temperature. DISABLED Applies motor current normally.
4.2.4 Printer Options The Printer Options menu contains module, file-handling, and option functions: Menu Item Details MODULES Controls memory handling functions, where: PRINT DIRECTORY Prints a listing of available space, files, and types; see Appendix A. PRINT FILE Prints from a list of available files. FORMAT MODULE Formats the selected module, erasing all data. DELETE FILE Removes selected files from the module directory.
Printer Options (continued) Menu Item CUT BEHIND Details Allows a number of small labels to queue before a cut is performed, increasing throughput, where: Note: This mode can be used without a cutter to allow the presentation of an extra label, with retraction occurring upon the next job or feed operation. 0 (0 – 2) Is the queue number.
Printer Options (continued) Menu Item Details BARCODE COUNT Specifies a number of bar codes per label and generates a fault when the number present is incorrect, where: (0 - 99) Sets the number of bar codes to count, where 00 (Auto Mode) allows a variable number. 00 Note: If bar codes are bitmaps, enter the minimum number to be read on each label (check your software application if questioning the bar code generation method).
Printer Options (continued) Menu Item RFID Controls the RFID operation, where: RFID MODULE Sets the mode of RFID operation, where: DISABLED Disables RFID. HF Selects the Securakey option. UHF CLASS 1 Selects the Alien option. UHF MULTI-PROTOCOL Selects the UHF cross-platform option. RFID POSITION 1.10in (110 - 4.00) HF SETTINGS Is the inlay location, as referenced from the leading edge of the tag moving in the direction of print.
Printer Options (continued) Menu Item DSFID LOCK Locks the DSFID value, where: DISABLED Is not protected. ENABLED Is write-protected. EAS VALUE 00 Selects the Electronic Article Surveillance value, where: (HEX) Is the value (00 - FF). AUDIO INDICATOR N/A ERASE ON FAULT Allows tag data erasure when errors are detected, where: DISABLED Keeps data. ENABLED Erases bad data.
Printer Options (continued) Menu Item KILL CODE Code to permanently deactivate the tag, where: 00 00 00 00 ACCESS CODE 00 00 00 00 GEN 2 LOCK ACTION Is the code, in the form B3, B2, B1, B0. Code to protect tag memory contents, where: Is the code, in the form B3, B2, B1, B0. Sets the lock for Gen 2 tags, where: NONE Does not lock the tag. PERMALOCK Locks data permanently. PWD-READ/WRITE Locks data with password-protection for writing data. BOTH Allows both Permalock and PWD-Lock to be used.
Printer Options (continued) Menu Item RETRY ATTEMPTS 3 (0 - 9) Details Sets the number of retry attempts, where: Is the retry count before a fault is declared. AUTO DETECT TAG Allows the printer to establish the tag to transducer distance setting. CALIBRATING RFID will appear as media is scanned for the tag location. Upon completion, the media will be retracted to the TOF position with the positioning results (along with a brief SUCCESS or FAILURE message).
Printer Options (continued) Menu Item START OF PRINT Selects the type of input signal required to initiate printing, where: ACTIVE HIGH Triggers printing with a high signal. EDGE Triggers printing with a signal edge transition. LOW PULSE Triggers printing with a low pulse. HIGH PULSE Triggers printing with a high pulse. ACTIVE LOW Triggers printing with a low signal.
Printer Options (continued) Menu Item BACKUP LABEL Details Positions a presented label for printing (provided the PRESENT DISTANCE setting is greater than zero), where: DISABLED Disables backup positioning. ACTIVE LOW Positions the label when a logic low is received. ACTIVE HIGH Positions the label when a logic high is received. ERR ON PAUSE (APP2) Sets the output when a service required fault occurs, where: ENABLED Enables the output signal. DISABLED Disables the output signal. 4.2.
System Settings (continued) Menu Item INTERNAL MODULE D 1024 K (XXX - XXXX) DEFAULT MODULE D SCALEABLE FONT CACHE 0312 K (100 - 5120) SINGLE BYTE SYMBOLS PC–850 MULTILINGUAL DOUBLE BYTE SYMBOLS Details Allocates a number of 1KB memory blocks for internal Memory Module D; where: Is the memory allocation; see Appendix A for the memory ranges, types, and availability. Designates the memory module for storage when no other location is specified; where: Is the module; see Appendix A for availability.
System Settings (continued) Menu Item MEDIA COUNTERS Details Provides a recorded count of inches printed and time; where: ABSOLUTE COUNTER Shows the total number of inches printed and the set date. (Non-resettable) RESETTABLE COUNTER Shows the number of inches printed and the last reset date. RESET COUNTER Returns the RESETTABLE COUNTER to zero.
System Settings (continued) Menu Item UNLOCK FEATURE 000000 SET FACTORY DEFAULTS SET FACTORY DEFAULT? CANCEL KEY = YES Details Unlocks a corresponding feature with the entry of the correct code. Returns the printer settings to the factory-programmed values or the Factory Setting File values, where: Overwrites the current configuration and restores the default configuration (), or if selected the Factory Setting File. Otherwise, press the ESC Key to keep the current configuration.
System Settings (continued) Menu Item PEEL MODE Details Allows the SOP signal to initiate (via GPIO option) the feeding of the labels, where: DISABLED Feeds regardless of SOP. ENABLED Feeds only when SOP is received. SECURITY SELECT SECURITY Allows menu password protection, where: Enables or disables the security feature, where: Note: The default password must be changed to activate. DISABLED Allows entry. SECURE MENU Sets a password requirement for menu entry.
System Settings (continued) Menu Item AUTO Details Identifies then activates the appropriate emulation parser for the data. Note: Correct identification can be dependant upon the HOST SETTINGS / HOST TIMEOUT (see Section 4.2.6). Also, extraneous characters may, in some cases, render the data unrecognizable, thus requiring manual selection of the mode.
System Settings (continued) Menu Item MODE Details Repositions media, where: DISABLED Moves media only when the next label is ready to print, minimizing edge curling. ENABLED Moves media according to BACKUP DELAY timing after a cut, cleared sensor, or SOP signal to allow fastest throughput. BACKUP DELAY 000 (1/50s) (0 – 255) FONT EMULATION Determines repositioning timing, where: Is the specified lapse (in fiftieths of a second) between new format processing and label retraction.
System Settings (continued) Menu Item FAULT HANDLING LEVEL Details Determines the label disposition and user action if a fault occurs, where: Sets the printer response upon declaration of a fault, where: STANDARD Stops printing and declares a fault. Then, following correction of the problem, the FEED Key must be pressed to clear the fault and reprint the label in process.
System Settings (continued) Menu Item VOID DISTANCE 0.50in (10 – 2.00) Details Sets the distance to print VOID on a faulted label, where: Is the distance, measured from the trailing edge, which establishes the text size. Note: VOID will not be printed if insufficient text space exists or if the fault occurred after printing completed. Also, the text can be customized; see the Class Series 2 Programmer’s Manual.
Communications (continued) Menu Item 9600 BPS 19200 BPS 28800 BPS 38400 BPS 57600 BPS 115000 BPS 1200 BPS 2400 BPS 4800 BPS PROTOCOL Details Is the speed in Bits Per Second. Sets the data flow control (handshaking) method. BOTH Uses XON/XOFF and CTS/DTR flow control. SOFTWARE XON/XOFF HARDWARE CTS/DTR NONE Flow control is not used. PARITY Sets word parity, where: NONE Uses parity. ODD Uses odd parity. EVEN Uses even parity.
Communications (continued) Menu Item SERIAL PORT D Details Controls the RS-232 communications settings for optional Serial Port D; see SERIAL PORT A. Note: The maximum baud is 38.4K BPS. PARALLEL PORT A PORT DIRECTION Controls the communications settings for Parallel Port A, where: Allows data return from the printer, where: UNIDIRECTIONAL Returns no data; communication is one-way. BIDIRECTIONAL Returns data (compliant back-channel operation).
Communications (continued) Menu Item WLAN ADHOC? CANCEL KEY = YES Details Restores the WiFi defaults and initiates infrastructure mode with an SSID of “Any.” All existing access point associations will be deleted then established with the closest available. (Useful when moving the printer to a geographically distant location.) Note: Press the ESC Key to exit the menu item without changing the current settings.
Communications (continued) Menu Item SNMPTRAP DESTINATION 000.000.000.000 Details Specifies the SNMP Trap Address, where: Is the address in standard octet format where SNMP traps will be sent when SNMP service is installed on your receiver. Note: When zeroed, no traps are sent. IP DISCOVERY ENABLED Controls IP Address discovery, where: Broadcasts over the network at startup to receive addresses from the responsible server.
Communications (continued) Menu Item MTU 01500 (512 - 65515) GRATUITOUS ARP 0000 (0 - 2048) PORT NUMBER 09100 (1 - 65535) DUPLEX CAPABILITY Details Sets the Maximum Transmission Unit packet size, where: Is the packet size, in bytes. Sets the Address Resolution Protocol notification rate, where: Is the time, in minutes. Sets the network communications port, where: Is the Port Number. Sets the communication capability for the Wired network, where: AUTO-NEGOTIATE Automatically selects the best type.
Communications (continued) Menu Item Details SET FACTORY DEFAULTS Returns the NIC to factory-programmed values, where: SET FACTORY DEFAULTS? Restores the default settings. CANCEL KEY = YES Note: Press the ESC Key to exit the menu item without changing the current settings.
Communications (continued) Menu Item HEAT COMMAND Determines how a host software Heat command is handled, where: ENABLED Processes commands normally. DISABLED Ignores commands; instead, Heat is controlled via the menu setting; see Section 4.2.3. SPEED COMMANDS Determines how host software Print, Feed, Reverse, and Slew commands are handled, where: ENABLED Processes commands normally. DISABLED Ignores commands; instead, the speeds are controlled via the menu setting; see Section 4.2.3.
Communications (continued) Menu Item MAX LENGTH COMMAND Details Determines how a host software Maximum Label Length (M) command is handled, where: ENABLED Processes commands normally. DISABLED Controls the setting via the menu; see Section 4.2.2.
4.2.7 Diagnostics The Diagnostics menu contains testing functions: Menu Item Details HEX DUMP MODE Allows raw code received from the host to print, where: DISABLED Executes commands and prints label formats normally. ENABLED Prints received data without processing; see Section 6.2.
Diagnostics (continued) Menu Item Details LOOPBACK Not Supported PRINT SIGNAL INFO Prints signal names, pin assignments, settings, and current states for reference.
Diagnostics (continued) Menu Item SENSOR READINGS THR TRAN RIBM 24V 127 159 093 175 Details Displays A-D sensor values (0 – 255), where: Are the sensor readings, where: • THR = Printhead thermistor sensor; • TRAN = Media sensor when set to Gap or Continuous, or REFL when to Reflective; PS HD 000 254 RANK 000 • • • • • RIBM = Ribbon sensor; 24V = 24 VDC sensor; PS = Present sensor; HD = Printhead position sensor; and, RANK = Printhead ranking resistor.
4.3 The Test Menu The TEST Key accesses six resident format selections that are printed at selected heat and speed settings (see Section 4.1.4 for printing details). Notes: (1) With the exception of the Configuration Label, all test labels require full width media to capture the entire format. (2) During a test, press the Key or the Key to stop printing. (3) Use PRINT TEST RATE (Section 4.2.7) to delay printing. 4.3.
4.3.3 Ribbon Test Label The Quick Ribbon Test Label can be used to verify thermal transfer functions. 4.3.4 Validation Label The Validation Label can be used to verify print quality. 4.3.5 Print Last Label The Print Last Label function reprints the most recent test label, format received from the host, or format recalled from a memory module. Note: If a job was cancelled or if power was removed since the last job and the request for this label, no reprint will occur. 4.3.
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5 Operating, Adjusting and Maintaining the Printer 5.1 Displayed Messages During operation the printer (when not in Menu or Test Mode) displays several types of information: • Prompts and Condition Messages (see Section 5.1.1); and, • Fault and Warning Messages (see Section 6.1.2). 5.1.1 Prompts and Condition Messages Prompts are alerts to required actions, while Condition Messages are indicators of an operational state.
Prompts and Condition Messages (continued) Displayed Message Action The MENU Key is being pressed and held, and now the LCD contrast is being adjusted. Release the MENU Key when the desired contrast is achieved. The network card is initializing, a normal condition following powerup or a reset. No action is required. Depending upon the settings, it may take a few minutes. The selected option or feature cannot be found. Verify that the option or feature is correctly installed. If so, call for service.
Prompts and Condition Messages (continued) Displayed Message Description Action SYSTEM INITIALIZING The power switch has been turned ON or a reset has occurred. No action is required. Wait briefly while the process completes. SYSTEM RESET IN PROGRESS A reset has occurred. No action is required. Wait briefly while the process completes. UNCALIBRATED The Media Sensor is not calibrated. Perform calibration; see Section 5.2.
Three samples are required: • Empty: Nothing in the sensor. • Gap (or Mark): The media liner, notch, or reflective mark in the sensor. • Paper: The label (and liner, if any) in the sensor. With the correct SENSOR TYPE selected (see Section 4.2.2), perform a Standard Calibration as follows: Step 1 2 Action Displayed Message Turn ON the printer. Key, and Press the then raise the printhead assembly. Key. 3 Press the 4 Key then Press the scroll to SENSOR CALIBRATION. 5 Press the 6 62 Key.
Standard Calibration (continued) Step Action Displayed Message Comment Proceed according to your media: Die-cut – remove a label from the backing material then place the backing in the sensor. Adjust the Sensor Eye Mark over the center of the backing. 7 Notched – load media in the printer then adjust the Sensor Eye Mark over the center of the notch. Reflective – load media in the printer (black mark facedown) then adjust the Sensor Eye Mark over the center of the black mark. See Section 3.
Standard Calibration (continued) Step 9 Action Observe the LCD. Displayed Message GAP MODE CALIBRATION COMPLETE Or, for reflective media: REFLECTIVE MODE CALIBRATION COMPLETE Or, for continuous media: CONTINUOUS MODE CALIBRATION COMPLETE Comment The calibration was successful if CALIBRATION COMPLETE appears. (If, however, another message was displayed see Note 1, below.) The printer is ready. If this calibration was unsuccessful, go to Section 5.2.2.
5.2.2 Advanced Entry Calibration Advanced Entry is the alternate calibration method for special-case media types. In the procedure, sensor readings for the label and TOF values are taken using different sampling algorithms. From this compiled list of values the best algorithm is selected and then used to generate new readings for manual entry into memory. Note: Use this method only when Standard Calibration has proven unsuccessful. With the correct SENSOR TYPE selected (see Section 4.2.
Advanced Entry Calibration (continued) Step Action Press the 7 Displayed Message Key. Place the label under the Sensor Eye Mark, and then lower the printhead assembly. Use the Key to scroll to the 00 GAIN setting and Key. then press the 8 Record the sensor reading as a Label Value in a table similar to the one shown below. GAIN TRAN *00 <0 - 31> Or, for reflective media: GAIN REFL *00 <0 - 31> GAIN TRAN *00 <0 - 31> Or, for reflective media: Comment See Section 3.
Advanced Entry Calibration (continued) Step Action Displayed Message Comment Proceed according to your media type: Die-cut – remove a label from the backing material then place the backing into the sensor. Adjust the Sensor Eye Mark over the center of the backing. 10 Notched – adjust the Sensor Eye Mark over the center of the notch. Reflective – adjust the Sensor Eye Mark over the center of the facedown black mark.
Advanced Entry Calibration (continued) Step Action GAIN TRAN *31 11 Press the Key to increment the Gain Number Key then press the and record the resulting TOF Value. Repeat this step for each of the remaining Gain Numbers (01-31). GAIN REFL *31 12 Displayed Message From the collected data, where both the values are above 20, subtract the Label Value from the corresponding TOF Value to find the Difference Value. Note the Gain Number of the largest Difference Value.
Advanced Entry Calibration (continued) Step Action a) Place the media in the sensor. Record the reading and label it “P” (paper). 14 b) Place the backing, notch, or mark in the sensor. Record the reading and label it “G” or “M” (Gap or Mark). c) Remove media. Record the reading and label it “E” (Empty). 15 Press the then press the Key, and Key.
Advanced Entry Calibration (continued) Step Action Displayed Message 17 After all entries have been Key made, press the to back out of the menu and Key then press the to save the settings and return to the Ready Mode. SAVE CHANGES? ENTER KEY = YES Comment From READY, press the FEED Key to advance to the next label TOF. Note: If the Advanced Entry Calibration fails, enter MEDIA SETTINGS / CALIBRATION / ADVANCED ENTRY / SENSOR GAIN and lower the selected Gain Number by one.
5.4 Printhead Assembly Adjustments Mechanical adjustments ensure consistent print quality across a wide range of media types and sizes. 5.4.1 Leveling Cam Adjustment Adjust the Leveling Cam for even pressure distribution when using less than full width media [4 inches (102mm)]; in addition, perform the adjustment when changing to a different width of media: A. With media loaded, download a batch of labels (or use a test format) and begin printing. B.
Example 2 – Correct adjustment produces a complete image, with even print contrast across the label. Note: Under-adjustment can cause ribbon wrinkling, lateral label movement, and excessive wear on printer components. 5.4.2 Burn Line Adjustment Adjust the Burn Line only after trying the print quality improvement suggestions in Section 5.4.1 and 7.2.1.
C. Equally turn each Adjustment Screw counter-clockwise until the burn line is positioned past the platen roller apex. Print a Validation Label; see Section 4.3.4. (The print on the label should have a light, uneven appearance.) D. Tighten the Locking Screws just enough to remove any play in the printhead assembly, while leaving them loose enough to allow for adjustment. E.
C. With the printhead locked in the down position, loosen the Printhead Mounting Screw (it will remain in the assembly). D. Rotate the printhead latch forward and, while supporting the Printhead, raise the Printhead Assembly. Disconnect the Cables and then remove the Printhead. E. Install the Printhead by securely connecting both Cables. F. Position the Printhead onto the Locating Pins in the Printhead Assembly and secure it with the Printhead Mounting Screw. (Do not over-tighten the screw.
5.6 Maintenance The following list and table detail the recommended items, techniques, and schedules to help you safely and effectively maintain the printer: Isopropyl alcohol • • • • • • • Cotton swabs A clean, lint-free cloth Soft-bristle brush Soapy water/mild detergent Compressed air Printhead Cleaning Cards or Printhead Cleaning Film CAUTION For your safety and to avoid damage, always turn OFF and unplug the printer before cleaning.
5.6.1 Cleaning the Printhead NEVER use a sharp, hard or abrasive object on the printhead. CAUTION If print quality declines the typical cause can be traced to debris buildup on the printhead; left unattended, the printhead service life can be reduced. The printer can be programmed to remind you to perform cleaning (see Section 4.2.2.) Depending upon the media and printing parameters used, different cleaning methods are recommended. Note: Streaks can indicate a dirty or faulty printhead.
B. Move media (and ribbon, if present) away from the printhead, as necessary. Using a cotton swab moistened (not soaked) with isopropyl alcohol, gently wipe away buildup on the Printhead while paying special attention to cleaning the Burn Line. Allow the printhead to dry. C. Reposition media (and ribbon, if present). Lower and lock the Printhead Assembly. D. Plug in and turn ON the printer. Close the cover then run a few sample labels and examine them.
5.6.2 Cleaning the Platen Roller NEVER use a sharp object to clean the Platen. CAUTION Grit, adhesive, and ink buildup can cause a decline in print quality and, in extreme cases, cause labels to stick and wrap around the roller. Clean the platen roller as follows: A. Turn OFF and unplug the printer. B. Open the access cover. Unlock the Printhead Latch and raise the Printhead Assembly. Remove media and ribbon. C.
5.6.3 Cleaning Interior and Exterior Surfaces Interior Surfaces – Turn OFF and unplug the printer. Remove all media. Then, using a soft bristle brush or compressed air, remove all dust particle buildup inside the printer. Exterior Surfaces – Turn OFF and unplug the printer. Remove all media. Then, using a soft cloth or sponge dampened with general-purpose cleanser (never abrasive cleansers or solvents) wipe the exterior surfaces until clean. 5.
5.7.1 Updating from Ready Mode Application Version 2.091 (or greater) Update Procedure Step 1 Displayed Message READY Action Using the DOS copy command (where “filename” is the program to be loaded and “lpt1” is the selected interface port), enter the following: copy filename lpt1: Comment(s) As an example, this would be entered as: copy i4212_1105.zg lpt1 (Where “lpt1” can differ to include another port, as equipped.) The Ready Indicator will flash as data is received.
5.7.2 Updating from Download Mode Application Version 2.08 (or less) Update Procedure* Step Displayed Message Action Turn OFF the printer. 1 BOOT–PA10 02.08 2/11/00 Press and hold the PAUSE Key and TEST Key while turning ON the printer. Comment(s) The Boot Loader version is displayed. Note: This information will vary with the printer model and Boot Loader version. The printer is ready to accept the new application version.
5.7.3 Possible Problems The following is list of possible error messages when downloading updates: Application Update Error Messages Displayed Message Descriptions / Causes / Solutions DECOMPRESSION ERROR The printer detected an error during the decompression and transfer of file data from cache storage into the Flash memory. Confirm the version and retry in Download Mode; however, if the problem continues call for service. ERROR ERASING FLASH The printer could not successfully erase Flash memory.
5.8 Boot Loader Updates The printer stores its Boot Loader program in Flash memory on the main logic card. As available, updates can be found on our web site at ftp://ftp.datamax-oneil.com and then installed in the printer. If power is lost while UPGRADING SOFTWARE is displayed, the printer will become non-functional and will require factory programming or a main logic WARNING card. Before updating, identify the current program version by printing a Configuration Label (see Section 4.3.2).
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6 Troubleshooting 6.1 Problem Resolution When a problem is encountered, the information in this section will help resolve it. Locate the description of the problem to find an appropriate solution. For problems that are accompanied by a displayed message, see Section 6.1.2. Note: If you have questions, or if problems persist, contact a qualified technician or Datamax-O’Neil Technical Support. 6.1.
General Resolutions (continued) If experiencing this problem… Erratic media movement: Erratic printing (instead of the label format, strange characters are printed): Intellifont will not print: Light print on the right side of the label (as it exits the printer): Missing printed information: Missing print on left or right side of the label: 86 Try this solution… The printer may require a calibration – See Section 3.5. • The printer may be in Hex Dump Mode – See Section 6.2.
General Resolutions (continued) If experiencing this problem… The LCD is off, but indicator lights are illuminated: The LCD is off and no indicator lights are illuminated: Try this solution… The Display Contrast may set too low – Press and hold the MENU Key; see Section 4.1.1. • Verify that the AC power cord is connected to the outlet and the printer, and that the power switch is ON. • Verify that the AC outlet is functioning, or try moving the printer to another location with a different AC circuit.
General Resolutions (continued) If experiencing this problem… Nothing happens when printing from your software program: Try this solution… • Ensure that the printer is at READY. • Send the job again while observing the Ready Indicator (see Section 4.1.1.) – If the indicator does not flash, check the printer and host for protocol and port settings. • Ensure the interface cable meets the requirements found in Section 3.1.1. • The printhead may need cleaning – See Section 5.6.1.
6.1.2 Warning and Fault Messages The printer displays messages when the possibility of a problem or an actual fault occurs. Depending upon the displayed message, find the possible action or solution in the tables below. Note: Warning and Fault Messages do not appear in Menu or Test Mode. Warning Messages: Displayed for about three seconds, Warning Messages assume a low priority and indicate a pending change in printer configuration, or an operating condition that could lead to a fault.
Warning Messages (continued) Warning Messages Displayed Message Description Action(s) • Possible low or fluctuating line LOW VOLTAGE The printer has detected a low operating voltage. voltage level – Try moving the printer to another AC outlet; if the condition persists, call for service. • If printing black over more than 50% of the total label area, try reducing the HEAT setting or the size of the black area. RTC RAM FAILURE The printer was unable to save settings in permanent memory.
Fault Messages (continued) Fault Messages Displayed Message Description Action(s) WARNING! Use extreme care. Turn OFF and unplug the printer before proceeding. CUTTER FAULT The printer has detected a cutter mechanism fault. Examine the cutter for obstructions and ensure its cable is properly connected. Plug in and turn ON the printer. Press the FEED Key. If the fault does not clear, call for service. DMA FAULT The printer has detected a Direct Memory Access failure.
Fault Messages (continued) Fault Messages Displayed Message Description Action(s) Try the following procedures: • Load media. Ensure that the OUT OF STOCK The printer cannot detect media. labels are passing through the Media Sensor and, if necessary, readjust the Media Sensor over the TOF mark; see Section 3.3. Also, if using media with large gaps, adjust the PAPER OUT DISTANCE (see Section 4.2.2); or, • Calibrate the printer; see Section 5.2.
Fault Messages (continued) Fault Messages Displayed Message Description Action(s) Press any key to continue. REFLECTIVE MODE CANNOT CALIBRATE Consistently low sensor readings were detected. Ensure that the reflective mark is inserted facedown in the media sensor during calibration; also, ensure that the reflective mark is made of carbon based ink; and, that the sensor is free of debris. Retry calibration. If the problem persists, try Advanced Entry Calibration; see Section 5.2.2.
Fault Messages (continued) Fault Messages Displayed Message Description Action(s) Press the FEED Key to clear. If the bar code is free from anomalies (e.g., voids, insufficient quiet zones, etc.) yet the fault continues, try the following: 1) Ensure that the bar code is capable of being read by the scanner; see the option’s documentation or the Class Series 2 Programmer’s Manual. 2) Adjust the Heat value. The Scanner could not pass a bar code.
Fault Messages (continued) Fault Messages Displayed Message Description Action(s) If media is moving: 1) Press the FEED Key. It may be necessary to re-calibrate the printer; see Section 5.2. 2) The Media Sensor may be out of position. Readjust it; see Section 3.3. The printer could not find the TOF within the maximum label length setting, or TOF occurred in an unexpected place. TOP OF FORM FAULT Note: When using reflective media, this fault is given for an Out of Stock condition.
6.2 Hex Dump Mode 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 Class Series 2 Programmer’s Manual is an essential reference. To begin, go to DIAGNOSTICS and enable HEX DUMP MODE; see Section 4.2.7. Exit the menu and save your changes.
7 Specifications 7.1 General Bar Codes Code 39, Interleaved 2 of 5, Code 128 (subsets A, B and C), Codabar, LOGMARS, UPC-A, UPC-E, UPC 2 & 5 digit addendums, EAN-8, EAN-13, EAN 2 & 5 digit addendums, UPC Random Weight, Code 93, Plessey, Universal Shipping Container Symbology, Code 128 MOD 43, Postnet, USS/EAN-128 Random Weight, Telepen, USD-8 (Code 11), UPS MaxiCode (modes 2 & 3), PDF417, Data Matrix, QR Code, Aztec, and MicroPDF417. (See the Class Series 2 Programmer’s Manual for details.
Environmental 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 inches (322.6 mm) Width: 12.62 inches (320.6 mm) Depth: 18.60 inches (472.5 mm) Weight: 45 pounds (20.
Printing (continued) Maximum Print Width: 4.10” 4.16” 4.10” 4.16” (104.0 (105.7 (104.0 (105.7 mm): mm): mm): mm): I-4206, I-4208, I-4212 I-4308 I-4406 I-4604 Print Length Range: .25”- 99” (6.4 - 2514.6 mm): I-4206, I-4208, I-4212, I-4308 .25”- 84” (6.4 - 2133.6 mm): I-4406 .25”- 55” (6.4 - 1397 mm): I-4604 with cutter: 1.25”- 99” (31.8 - 2514.6 mm): I-4206,I-4208, I-4212, I-4308 1.25” - 84” (31.8 - 2133.6 mm): I-4406 1.25” - 55” (31.8 - 1397 mm): I-4604 with peel & present: 1.50” - 99” (38 – 2514.
7.2 Approved Media and Ribbon To achieve optimum print quality and maximum printhead life, DATAMAX-O’NEIL brand media and ribbons must be used. These supplies are specially formulated for use in this printer. The use of non-Datamax-O’Neil supplies may affect the print quality, performance, and life of the printer or its components (see the Warranty Statement). For a current list of approved media and ribbons, contact a Media Representative at (407) 523-5650.
7.2.
Dimensional Requirements are listed in the following table: Side View Top View G F I H J D K E A B C Media Dimensional Requirements Designator Description Minimum [1] Maximum [1] A Label width 1.00 4.65 B Liner width 1.00 4.65 C Gap (or notch) between labels[3] .10 – D Label length[3] .25 – E Media thickness .0025 .010 F Notch opening width .20 .500 G Media edge to sensor aperture distance .20 2.25 H Reflective (black) mark width[2] .50 4.
7.3 Serial Cable Requirements Wiring diagrams, suggested applications, and part numbers for serial interface cables are given in the table below. (Contact a reseller for ordering information.) Applicable Serial Interface Cables Null Modem (MXM) “PC” (DB9P) to Printer Part Number 556000 Part Number 556001 For connection to other DCE equipment. Flow control is only Xon/Xoff. For connection to a PC compatible with DB9P communication ports. Flow control can be either Xon/Xoff or CTS/DTR.
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Appendix A Module Assignments Memory Module Designator Module Size Volatile* Location / Use D 1024 KB (default size) Yes Main logic card SDRAM – for graphics, fonts, and formats F 4 MB No Optional GPI/O Multi-Expansion Card – for graphics, fonts, and formats G 256 KB No Main logic card Flash – for graphics, fonts, and formats (all models except I-4206 and I-4208).
Available Speeds and Default Settings Printer Speed Ranges and Defaults* Model Function I-4206 Print Feed Reverse Slew I-4208 I-4212 I-4308 I-4406 I-4604 Speed Range IPS 2 2 2 2 – – – – 6 8 4 6 Default Setting MMPS 51 51 51 51 – – – – IPS MMPS 152 203 102 152 6.0 6.0 4.0 6.0 152 152 102 152 Print 2–8 51 – 203 8.0 203 Feed Reverse 2–8 2–4 51 – 203 51 – 102 8.0 4.0 203 102 Slew 2–8 2 – 12 2 – 12 2–4 2 – 12 2–8 2–8 2–4 2–8 2–6 2–6 2–4 2–6 2–4 2–4 2–4 2–4 51 – 203 8.
Appendix B Custom Adjustment Ranges Row, Column, and Present Adjust Ranges (in dots) Model Row Adjust Column Adjust, and Present Adjust I-4206, I-4208, & I-4212 -100 – 2030 -100 – 100 I-4308 -150 – 3000 -150 – 150 I-4406 -200 – 4060 -200 – 200 I-4604 -300 – 6000 -300 – 300 Default Setting 000 Column & Row Emulation Ranges Emulation Range (in dots) Model Column Row Default Setting I-4206, I-4208, & I-4212 153 – 203 103 – 303 203 I-4308 250 – 300 200 – 400 300 I-4406 356 – 406 3
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Appendix C Menu Multi-Language Support The printer allows new menu languages and / or replacement of the Datamax-O’Neil provided translations. A Microsoft Excel Spreadsheet defines the menu dictionary and a new language column is added or an existing column modified. Then, by clicking on the “Generate DPL file(s)” radio button, the generated DPL file(s) is sent to the printer.
Creating a Menu Language: Invoke Excel and open the gemmsglst.xls file. Excel opens the file and the following screen appears. Click the “Enable Macro” box and the following appears: Click On Column J and enter your new language, or modify an existing one. Tips: A) Message Size – When entering new messages, reference the “MAX” column: this is the maximum number of characters allowed for this field. Warnings are displayed when the number of characters is exceeded or when trying to modify the MAX value.
C) Comments – This field can be modified with no effect. When editing has been completed, highlight all of the columns you desire to create (more than one language may be selected) by pressing the letter above the column. Press the Generate DPL File(s) radio button. A file will be generated for each of the selected columns and Excel will provide confirmation. (Example: small.ls) Download the generated files to the printer – one method is the DOS copy command: copy small.
Contact Datamax-O’Neil Technical Support if problems continue (be prepared to provide the Gemmsglst.xls and the DPL download file that you have created). Other possible error messages are as follows: Menu Language Error Message Description Please select the entire column(s) or the desired language(s), by clicking on the column letter(s) After pressing the Generate DPL File(s) radio button, the languages to convert were not correctly selected.
Appendix D Configuration Files With application version 5.01 and above, the printer can save and restore complete printer settings, including media calibration parameters, in internal Configuration Files. Here are the highlights and restrictions of the feature: • Eliminates the need to repeat the manual steps of a special printer setup, making future changeovers faster and easier.
Follow the steps below to save a manually entered setup as a configuration file: Step Displayed Message Action Comment You are entering MENU MODE. 1 READY 2 MENU MODE SYSTEM SETTINGS Key to Use the scroll to SYSTEM SETTINGS then press it once again to select it. Key can also The be used. You are entering SYSTEM SETTINGS. 3 SYSTEM SETTINGS CONFIGURATION FILE Key to Press the select CONFIGURATION FILE. You are entering the CONFIGURATION FILE submenu.
Appendix E Printer Driver and Port Setup Install the Printer Driver and Port software according to the host’s operating system. The example below highlights the driver installation for Windows XP; other installations will be similar. Windows XP Driver and Port Installation 1 Start the Windows “Add Printer Wizard.” The following screen should appear. Click Next>. 2 Ensure that Local Printer is selected and then click Next.
Windows XP Driver and Port Installation (continued) 5 In the Printer Name or IP Address field enter the IP address of your printer. The Port Name field does not need to be changed. When finished click “Next”. 6 Ensure Standard is selected and then click Next. 7 Confirm your settings and then click Finish. 8 Click on Have Disk. 9 Insert the Accessories CDROM and click Browse. 10 Browse to the “\DRIVERS\Seagull” folder on the CDROM, ensure the file “for 95, 98, ME, 2000, and xp.
Windows XP Driver and Port Installation (continued) 11 Click OK. 12 Select your printer from the list and then click Next. 13 Name your printer in the Printer name: field. Next select whether or not to set this printer as your default printer. Then Click Next. 14 Select whether or not to share this printer on your network. Then Click Next. 15 Select No then Click Next. 16 Confirm your settings and then click Finish.
Windows XP Driver and Port Installation (continued) 17 118 If prompted with the "Digital Signature Not Found" window, click “Continue Anyway” to continue installation. 18 Your computer will now copy the necessary files from the CD-ROM. The driver and port installation is now complete. The printer can be selected through any Window’s application.
Glossary alphanumeric Consisting of alphabetic, numeric, punctuation and other symbols. backing material The silicon-coated paper carrier material to which labels with adhesive backing are affixed (also referred to as “liner”). bar code A representation of alphanumeric information in a pattern of machine-readable marks. The basic categories are divided into one-dimensional (UPC, Code 39, Postnet, etc.) and two-dimensional bar codes (Data Matrix, MaxiCode, PDF417, etc.).
DPI (dots per inch) A measurement of print resolution, rated in the number of thermal elements contained in one inch of the printhead (also referred to as “resolution”). DPL (Datamax-O’Neil Programming Language) programming commands used specifically for control of and label production in Datamax-O’Neil printers. A complete listing of commands can be found in the Class Series 2 Programmer’s Manual.
on demand An output regulator (i.e., the Present Sensor) that inhibits printing when a label is already present. preprinted media Label stock that contains borders, text, or graphics, floodcoating, etc. perforation Small cuts extending through the backing and/or label material to facilitate their separation (also referred to as “perf”). print speed The speed at which the media moves under the printhead during the printing process.
