Brady Printer 203X PLUS User Manual

Bradyprinterä THT Models  
300X-PLUS, 600X-PLUS,  
203X-PLUS, and 360X-PLUS  
Thermal Transfer Printers  
User’s Guide  
Customer order # 48025L-12  
Manufacturer part # 48025LB-12 Rev. 1  
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I have determined that the Brady printers identified as the  
BradyprinterX-PLUS Series Printers  
203X-PLUS, 300X-PLUS, 360X-PLUS, and 600X-PLUS  
manufactured by:  
Zebra Technologies Corporation  
333 Corporate Woods Parkway  
Vernon Hills, Illinois 60061-3109 U.S.A.  
have been shown to comply with the applicable technical standards of the FCC  
for Home, Office, Commercial, and Industrial use  
if no unauthorized change is made in the equipment,  
and if the equipment is properly maintained and operated.  
Brady X-PLUS Series User’s Guide  
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Table of Contents  
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Introduction  
Hello!  
Thank you for purchasing this high-quality Bradyprinter X-PLUS Series  
printer!  
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This manual provides all of the information you will need to operate  
your printer.  
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The ZPL II Programming Guide Volume I and Volume II  
(part # 45540L) show you how to create the perfect label format for your  
application.  
The ZebraNetâ Networking: PrintServer IIä Installation and User’s  
Guide (part # 45537L) explains how you can quickly set up your printer  
on an IP network (optional ZebraNet PrintServer II required).  
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There is also a maintenance manual for this printer. This manual  
(part # 48152L) contains the information you will need to maintain your  
printer.  
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Unpacking and Inspection  
Inspect the printer for possible damage incurred during shipment.  
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Check all exterior surfaces.  
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Raise the media access door and inspect the media compartment.  
In case shipping is required, save the carton and all packing material.  
Reporting Damage  
If you discover shipping damage:  
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Immediately notify and file a damage report with the shipping company.  
Brady USA, Inc. is not responsible for any damage incurred during  
shipment of the equipment and will not repair this damage under  
warranty.  
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Keep the carton and all packing material for inspection.  
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Notify your local Brady distributor.  
Storage and Reshipping  
If you are not placing the printer into operation immediately, repackage it  
using the original packing materials. The printer may be stored under the  
following conditions:  
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Temperature: -4° to +140° F (-20° to +60° C)  
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Relative humidity: 5 to 85% non-condensing  
To ship the printer, carefully pack it in a suitable container to avoid damage  
during transit. Whenever possible, use the original container from the  
factory. If you use a different container, package the printer carefully to  
avoid damage. Brady will not be responsible for shipping damage incurred  
due to improper packaging!  
CAUTION! When packaging the printer in a rigid container, use  
shock mounts or shock-absorbing packing material to  
prevent damage to the printer. Before packing, remove  
all ribbon and media from the supply and  
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take-up/rewind spindles to prevent damage to the  
printer.  
Media and Ribbon Requirements  
Since print quality is affected by media and ribbon, printing speeds, and  
printer operating modes, it is very important to run tests for your  
applications.  
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Continuous roll media, fanfold media, or card stock with optional  
perforations and registration holes may be used.  
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Printhead life may be reduced by the abrasion of exposed paper fibers  
when using perforated media.  
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The ribbon MUST be as wide as or wider than the media being used. If  
the ribbon is narrower than the media, areas of the printhead will be  
unprotected and subject to premature wear. (When printing in direct  
thermal mode, ribbon is not used and should not be loaded in the  
printer.)  
Power Cord  
WARNING! For personnel and equipment safety, always use a  
three-prong plug with a ground (earth) connection.  
NOTE: Depending on how your printer was ordered, a power cord may or  
may not be included. If one is not included, or if the one included  
is not suitable for your requirements, refer to “Power Line Cord  
Specifications” on page 92.  
The power cord connector must be plugged into the mating connector on  
the rear of the printer.  
Make sure that the POWER on/off switch (located at the back of the printer)  
is in the off position before connecting the power cable to an electrical  
outlet.  
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Printer Anatomy 101  
Depending on the options you have selected, your printer may look slightly  
different.  
Ribbon take-up  
spindle  
Printhead  
lever  
Ribbon supply  
spindle  
Media  
supply  
guide  
Platen  
roller  
Dancer  
roller  
assembly  
Snap  
plate  
Media  
supply  
hanger  
Tear-off/  
peel-off  
bar  
Lower  
roller  
Media  
guide  
Rewind  
spindle  
(optional)  
Spindle  
hook  
Only on select models  
Figure 1  
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Calibrating the Printer  
This chapter of the user’s guide is so important that we’ve printed it on a  
different color paper! That way, it will be easy for you to find when you  
must calibrate (set up) the printer for your particular application.  
Purpose  
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To calibrate the printer.  
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To verify that the printer is properly set up by printing a test label.  
NOTE: This procedure must be performed when the printer is first  
installed or when it cannot properly detect the top of the label.  
To calibrate the printer, you must do the following (all of the instructions  
are contained in this chapter):  
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Determine the type of media (labels) being used.  
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Choose the print method.  
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Position the media sensors (if necessary).  
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Configure the printer and software or driver based on the label being  
used.  
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Perform a media and ribbon calibration.  
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Print a test label.  
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Types of Media  
Non-Continuous Web Media  
Non-continuous web media (refer to Figure 2) refers to individual labels  
that are separated by a gap, notch, or hole. When you look at the media,  
you can tell where one label ends and the next one begins.  
Notch  
Hole  
Non-continuous media with a hole or notch  
Label gap (2-4 mm)  
Label gap (2-4 mm)  
Non-continuous media with gaps between the labels  
(individual labels on a continuous liner)  
Figure 2  
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Non-Continuous Black Mark Media  
Non-continuous black mark media has black marks printed on the back that  
indicate the start and end of each label (refer to Figure 3).  
Black mark  
Black mark  
Non-continuous media for black mark sensing  
Figure 3  
Continuous Media  
Continuous media (refer to Figure 4) is one uninterrupted roll of material  
that allows the image to be printed anywhere on the label.  
Continuous media (no gaps, holes, notches, or black marks)  
Figure 4  
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Choosing the Print Mode  
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Tear-off mode allows you to tear off each label, or a strip of labels, after  
it is printed.  
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In Peel-off mode, backing material is peeled away from the label as it is  
printed. After this label is removed from the printer, the next one is  
printed.  
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When in cutter mode, the printer automatically cuts the label after it is  
printed.  
In rewind mode, the media and backing are rewound onto a core as the  
labels are printed.  
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Loading the Media  
Figure 5 illustrates one method of media loading. For more detailed  
instructions, as well as information about how to load the different types of  
media and the various printing modes, refer to the instructions that begin on  
page 27.  
Printhead lever  
Media  
supply  
Open  
guide  
Media  
Closed  
Media  
guide  
Tear-off/  
peel-off  
bar  
Figure 5  
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Positioning the Media Sensors  
The correct positioning of the media sensors is important. It can make the  
difference between a perfect label and a call to Technical Support!  
Transmissive Sensor  
The web or gap sensor, better known as the “transmissive sensor,” detects  
the gap between labels.  
The transmissive sensor actually consists of two sections: a light source  
(the lower media sensor) and a light sensor (the upper media sensor). The  
media passes between the two.  
The upper media sensor must be positioned:  
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Directly over the hole or notch, or  
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Anywhere along the width of the media if there is a gap between labels.  
NOTE: If you are using continuous media, position the upper media sensor  
over the media so that the printer can detect an out-of-paper  
condition.  
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Adjusting the Upper Media Sensor  
Refer to Figure 6. (For clarity, not all printer parts are shown.)  
1. Remove the ribbon (if it is installed).  
2. Locate the upper media sensor. The upper media sensor “eye” is  
directly below the adjustment screw head.  
3. Slightly loosen the upper media sensor adjustment screw (Phillips  
head).  
4. Using the tip of the screwdriver, slide the upper sensor along the slot to  
the desired position.  
5. Secure the upper media sensor adjustment screw.  
Upper media sensor  
adjustment screw  
Figure 6  
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Adjusting the Lower Media Sensor  
Position the lower media sensor (refer to Figure 7) by sliding it in its slot  
until it is positioned under the upper media sensor.  
Lower  
media sensor  
Figure 7  
Black Mark Sensor  
The black mark sensor is in a fixed position and enabled via the front panel  
(details in “Configuring the Printer” on page 15).  
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Loading the Ribbon  
To load ribbon, refer to Figure 8 (for the 300X-PLUS, 600X-PLUS, and  
203X-PLUS) and Figure 9 (for the 360X-PLUS). For more detailed  
information, refer to the instructions that begin on page 39.  
Ribbon  
take-up  
spindle  
Ribbon  
supply  
spindle  
Printhead  
lever  
Open  
Closed  
Figure 8  
Ribbon  
take-up  
spindle  
Ribbon  
supply  
spindle  
Printhead  
lever  
Open  
Closed  
Figure 9  
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Operator Controls  
POWER Switch  
The POWER switch is located at the back of the printer above the power  
cord and fuse. Turn on the printer.  
Front Panel  
The step-by-step instructions in this  
section tell you which keys to press  
and what appears on the liquid crystal  
display (LCD) during the calibration  
procedure.  
For a more detailed explanation of the  
front panel keys and lights (as shown  
in Figure 10), refer to the instructions  
that begin on page 24.  
Figure 10  
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Configuring the Printer  
The configuration procedure in the next table contains the information you  
need to get your printer up and running, but it is not comprehensive. Refer  
to page 43 for more information.  
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Enter the configuration mode by pressing the SETUP/EXIT key at the  
“PRINTER READY” display.  
NOTE: You will need to press the NEXT/SAVE key more than once to  
advance to some of the displays.  
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To increase the value, answer “yes,” indicate “on,” or move to the next  
selection, use the RIGHT BLACK OVAL key.  
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To decrease the value, answer “no,” indicate “off,” or return to the  
previous selection, use the LEFT BLACK OVAL key.  
NOTE: When changing parameters, an asterisk (*) in the upper left-hand  
corner of the display indicates that you have changed this setting  
from what is currently stored in memory.  
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Press  
Display Shows  
Action/Explanation  
Normal printer operation.  
-
PRINTER READY  
Press the BLACK OVAL keys to increase or decrease the print  
darkness setting. (You may need to change this setting when  
you print your label.)  
DARKNESS  
Press the BLACK OVAL keys to select tear-off, peel-off, cutter,  
or rewind mode.  
PRINT MODE  
MEDIA TYPE  
Press the BLACK OVAL keys to select continuous or  
non-continuous media type. (If you choose continuous  
media, you must also include a label length instruction in  
your label format.)  
Press the BLACK OVAL keys to select transmissive or black  
mark sensing mode. Unless your media has black marks on  
the back, leave your printer at the default setting (web).  
SENSOR TYPE  
PRINT METHOD  
Press the BLACK OVAL keys to select thermal transfer (if you  
are using ribbon) or direct thermal (no ribbon).  
MAXIMUM  
LENGTH  
Press the BLACK OVAL keys to set the value that is closest to,  
but not less than, the length of the label you are using.  
Press the BLACK OVAL keys to select:  
PERMANENT -- saves the changes when the power is turned  
off.  
SAVE SETTINGS  
PRINTER READY  
Press NEXT/SAVE to accept the selection.  
You have exited the configuration mode and are now ready  
to calibrate the printer.  
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Configuring the Software or Printer Driver  
Many printer settings may also be controlled by your printer’s driver or  
label preparation software. Refer to the driver or software documentation  
for more information.  
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Media and Ribbon Calibration  
NOTE: All steps must be performed in the following procedure, even if  
only one sensor needs to be adjusted.  
1. Press the SETUP/EXIT key.  
2. Press the NEXT/SAVE key until “MEDIA AND RIBBON  
CALIBRATE” displays.  
3. To start the calibration procedure, press the RIGHT BLACK OVAL  
key. “LOAD BACKING CANCEL CONTINUE” displays.  
4. Open the printhead. Remove approximately 8” (203 mm) of labels  
from the media roll, enough so that only the backing material is  
threaded between the media sensors when the media is loaded  
(refer to Figure 11).  
TM  
Remove  
labels  
Figure 11  
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5. Press the RIGHT BLACK OVAL key. The front panel display will  
show “REMOVE RIBBON CANCEL CONTINUE.”  
6. Either remove the ribbon or slide it as far from the printer frame as  
possible.  
7. Close the printhead, trapping the ribbon in this position.  
8. Press the RIGHT BLACK OVAL key. The front panel will show  
“CALIBRATING PLEASE WAIT.”  
9. When this part of the calibration process is completed, the display will  
read “RELOAD ALL CONTINUE.”  
10. Open the printhead. Pull the backing material until a label is positioned  
between the media sensors.  
11. Either load the ribbon or return the ribbon to its proper position.  
12. Close the printhead. Press the RIGHT BLACK OVAL key to perform  
the next part of the calibration sequence. “MEDIA AND RIBBON  
CALIBRATE” displays. The printer is calibrated when the media stops  
feeding.  
13. Press the SETUP/EXIT key to leave the programming mode. Choose  
“permanent” when SAVE CHANGES displays.  
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Printing a Test Label  
To print a test label:  
1. Turn off the printer.  
2. Press and hold the CANCEL key  
while turning on the printer.  
A configuration label, which shows the  
printer’s currently stored parameters,  
will print (similar to the one shown in  
Figure 12).  
Figure 12  
If you encounter any problems while you are configuring or calibrating the  
printer or printing a test label, refer to Troubleshooting, which starts on  
page 75. Otherwise, refer to Establishing Communication on page 21 to set  
up the communication parameters.  
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Establishing Communication  
System Considerations  
Interfaces  
The method of interfacing this printer to a data source depends on the  
communication options installed in the printer. The standard interfaces are  
an RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port.  
The optional ZebraNet PrintServer II enables printers to be connected to  
10 BaseT Ethernet networks. In addition, the IBM® Twinax or IBM Coax  
option is available for those applications that require them.  
Data Specifications  
Printer  
Computer  
When communicating via an  
asynchronous serial data port (refer  
to Figure 13), the baud rate, number  
of data and stop bits, parity, and  
handshaking are user selectable.  
Parity only applies to data  
Male  
25  
transmitted by the printer since the  
parity of received data is ignored.  
25  
Male  
25  
9
Female  
Null modem adapter  
(if using a standard  
modem cable)  
50’ maximum  
Figure 13  
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When communicating via the parallel  
port (refer to Figure 14), the  
Printer  
Computer  
previously mentioned parameters are  
not considered. Refer to page 53 to  
configure the communication  
36-pin  
male  
parameters for the printer. The  
values selected must be the same as  
those used by the host equipment  
connected to the printer.  
PC  
25-pin  
female  
For serial and parallel pinout and  
technical information, refer to the  
Appendix on page 93.  
25-pin  
male  
10’ maximum  
Figure 14  
Cabling Requirements  
Data cables must be fully shielded and fitted with metal or metalized  
connector shells. Shielded cables and connectors are required to prevent  
radiation and reception of electrical noise.  
To minimize electrical noise pickup in the cable:  
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Keep data cables as short as possible.  
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Do not bundle the data cables tightly with the power cords.  
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Do not tie the data cables to power wire conduits.  
NOTES: Brady X-PLUS printers comply with FCC “Rules and  
Regulations”, Part 15, for Class B Equipment, using fully  
shielded data cables. Use of unshielded cables may increase  
radiated emissions above the Class B limits.  
RS-422 and RS-485 applications should use twisted shielded  
pairs as recommended in the Appendix of the TA/EA.-485  
Specification.  
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Printer Basics  
Operator Controls  
This section discusses the functions of the various controls and indicators  
on the printer. The operator should become familiar with each of these  
functions.  
POWER Switch  
This switch is located at the back of the printer above the power cord and  
fuse. The POWER switch should be turned off before connecting or  
disconnecting any cables.  
External influences, such as lightning storms or noise on the power or data  
cables, may cause erratic printer behavior. Turning the printer’s power off  
and back on may re-establish proper printer operation.  
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Front Panel Display  
The front panel display communicates operational status and programming  
modes and parameters.  
Figure 15  
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Front Panel Keys  
Key  
Function  
Starts and stops the printing process.  
• If the printer is not printing: no printing can occur.  
• If the printer is printing: printing stops once the current label is complete.  
Press to remove error messages from the display.  
NOTE: Pause mode can also be activated via ZPL II (~PP, ^PP).  
Forces the printer to feed one blank label each time the key is pressed.  
• Printer not printing: one blank label immediately feeds.  
• Printing: one blank label feeds after the current batch of labels is complete.  
NOTE: Equivalent to the Slew to Home Position (~PH, ^PH) ZPL II instruction.  
When in the pause mode, this key will cancel print jobs.  
• Print job in queue: press once for each print job to be deleted.  
• Press and hold for several seconds to cancel all print jobs in the printer’s  
memory. The DATA light will turn off.  
When in Pause mode, this key will calibrate the printer for:  
• Media length.  
• Media type (continuous or non-continuous).  
• Print mode (direct thermal or thermal transfer).  
• Sensor values.  
NOTE: The keys below are used only when configuring the printer. Specific uses of these keys  
are explained in Configuration, starting on page 43.  
• Scrolls back to the previous parameter.  
• Press and hold to quickly go backward through parameter sets.  
• Scrolls forward to the next parameter. (Saves any changes you’ve made in the  
configuration and calibration sequence.)  
• Press and hold to quickly advance through parameter sets.  
Enters and exits the configuration mode.  
These keys change the parameter values. They are used in different ways  
depending on the parameter displayed. Common uses are: to increase/decrease  
a value, answer “yes” or “no,” indicate “on” or “off,” scroll through several  
choices, input the password, or set up the printer for a firmware download.  
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Front Panel Lights  
NOTE: If two operating conditions occur simultaneously (for example,  
one that causes a light to be on constantly and one that causes the  
same light to flash), the light will flash.  
Light  
Status  
Indication  
Off  
On  
Off  
The printer is off or power is not applied.  
POWER  
The printer is on.  
Normal operation.  
TAKE LABEL  
ERROR  
(Peel-off mode only.) The label is available. Printing is paused until  
the label is removed.  
Flashing  
Off  
Normal operation — no printer errors.  
A printer error exists. Check the display screen for more  
information.  
Flashing  
Off  
Normal operation — ribbon (if used) is properly loaded.  
CHECK  
RIBBON  
Printing is paused, the front panel displays a warning message, and  
the PAUSE light is on.  
• If the printer is in direct thermal mode: Ribbon is loaded.  
• If the printer is in thermal transfer mode: No ribbon is loaded.  
On  
Off  
On  
Off  
Normal operation — media is properly loaded.  
PAPER OUT  
PAUSE  
No media is under the media sensor. Printing is paused, the display  
shows an error message, and the PAUSE light is on.  
Normal operation.  
The printer has stopped all printing operations. Either the PAUSE  
key was pressed, a pause command was included in the label  
format, the on-line verifier detected an error, or a printer error was  
detected. Refer to the display screen for more information.  
On  
Off  
On  
Normal operation. No data being received or processed.  
Data processing or printing is taking place. No data is being  
received.  
DATA  
The printer is receiving data from or sending status information to  
the host computer. Flashing slows when the printer cannot accept  
more data, but returns to normal once data is again being received.  
Flashing  
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Roll Media Loading  
NOTE: A calibration must be performed when media and ribbon (if used)  
are first installed in the printer, or when a different type of media  
or ribbon is being used.  
Tear-Off Mode  
Refer to Figure 16.  
1. Open the printhead.  
2. Slide the media guide and media supply guide as far from the printer  
frame as possible. Flip down the media supply guide.  
3. Load media as shown.  
4. Flip up the media supply guide. Slide in the media guide and media  
supply guide so they just touch, but not restrict, the edge of the roll.  
5. Close the printhead.  
Printhead lever  
Media  
supply  
Open  
guide  
Media  
Closed  
Media  
guide  
Figure 16  
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Peel-Off Mode  
NOTE: Rewind option required.  
Refer to Figure 17.  
1. Remove the rewind plate from the front of the printer (if installed).  
Store it on the two mounting screws on the inside of the front panel.  
2. Open the printhead.  
3. Slide the media guide and media supply guide as far from the printer  
frame as possible. Flip down the media supply guide.  
4. Load media as shown.  
5. When loading media, allow approximately 36” (914 mm) of media to  
extend past the tear-off/peel-off bar. Remove all labels from this  
portion to create a leader.  
6. Remove the hook from the rewind spindle. If you are using a core,  
slide it onto the rewind spindle until it is flush against the guide plate.  
7. Wind the label backing around either the 3” (76 mm) core or the rewind  
spindle and reinstall the hook.  
8. Flip up the media supply guide. Slide in the media guide and media  
supply guide so they just touch, but not restrict, the edge of the roll.  
Before closing the printhead, make sure:  
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The media is positioned against the inside guides.  
n
The media is taut and parallel with itself and the pathway when wound  
onto the rewind spindle/core.  
9. Close the printhead.  
10. To discard the label backing from the rewind spindle, refer to  
“Removing the Label Backing Material” on page 38.  
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Printhead lever  
Open  
Media  
supply  
guide  
Media  
Label  
Closed  
Media  
guide  
Tear-off/  
peel-off  
bar  
Label  
backing  
Rewind  
spindle  
Rewind  
plate  
Hook  
Guide  
plate  
Figure 17  
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Rewind Mode (for Printers Without the Cutter Option)  
NOTE: Rewind option required.  
Refer to Figure 18.  
1. Remove the rewind plate from its storage location in front of the print  
mechanism inside the media compartment.  
2. Invert the rewind plate so that the lip on the attached hook plate points  
down.  
3. Insert the hook plate lip a short distance (½"/13 mm) into the lower  
opening in the side plate.  
4. Align the upper end of the rewind plate with the corresponding opening  
in the side plate. Slide in the rewind plate so that it stops against the  
printer’s main frame.  
5. Open the printhead.  
6. Slide the media guide and media supply guide as far from the printer  
frame as possible. Flip down the media supply guide.  
7. Load media as shown.  
8. When loading media, allow approximately 36” (914 mm) of media to  
extend past the printhead. Remove all labels from this portion to create  
a leader.  
9. Remove the hook from the rewind spindle. If you are using a core,  
slide it onto the rewind spindle until it is flush against the guide plate.  
10. Wind the label backing around either the 3” (76 mm) core or the rewind  
spindle and reinstall the hook.  
11. Flip up the media supply guide. Slide in the media guide and media  
supply guide so they just touch, but not restrict, the edge of the roll.  
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Before closing the printhead, make sure:  
n
The media is positioned against the inside guides.  
n
The media is taut and parallel with itself and the pathway when wound  
onto the rewind spindle/core.  
12. Close the printhead.  
Printhead lever  
Media  
supply  
Open  
guide  
Media  
Closed  
Media  
guide  
Side  
plate  
Rewind  
spindle  
Rewind  
plate  
Guide  
plate  
Hook  
Figure 18  
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Cutter Mode  
NOTE: Cutter option required.  
Refer to Figure 19.  
1. Open the printhead.  
2. Slide the media guide and media supply guide as far from the printer  
frame as possible. Flip down the media supply guide.  
3. Load media as shown.  
4. Flip up the media supply guide. Slide in the media guide and media  
supply guide so they just touch, but not restrict, the edge of the roll.  
5. Close the printhead.  
6. The printer will automatically feed out and cut one label when the  
printer is turned on.  
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Printhead lever  
Open  
Media  
supply  
guide  
Media  
Closed  
Media  
guide  
Cutter  
Figure 19  
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Rewind Mode (for Printers With the Cutter Option)  
NOTE: Cutter and rewind options required.  
Refer to Figure 20.  
1. Remove the rewind plate from its storage location in front of the print  
mechanism inside the media compartment.  
2. Invert the rewind plate so that the lip on the attached hook plate points  
down.  
3. Insert the hook plate lip a short distance (½"/13 mm) into the lower  
opening in the side plate. Slide in the rewind plate so that it stops  
against the printer’s main frame.  
4. Insert the two small tabs on the rewind plate into the corresponding  
slots in the cutter support bracket. (The rewind plate should spring into  
the proper position.)  
5. Open the printhead.  
6. Slide the media guide and media supply guide as far from the printer  
frame as possible. Flip down the media supply guide.  
7. Load media as shown.  
8. When loading media, allow approximately 36” (914 mm) of media to  
extend past the printhead. Remove all labels from this portion to create  
a leader.  
9. Remove the hook from the rewind spindle. If you are using a core,  
slide it onto the rewind spindle until it is flush against the guide plate.  
10. Wind the label backing around either the 3” (76 mm) core or the rewind  
spindle and reinstall the hook.  
11. Flip up the media supply guide. Slide in the media guide and media  
supply guide so they just touch, but not restrict, the edge of the roll.  
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Before closing the printhead, make sure:  
n
The media is positioned against the inside guides.  
n
The media is taut and parallel with itself and the pathway when wound  
onto the rewind spindle/core.  
12. Close the printhead.  
Printhead lever  
Media  
supply  
Open  
guide  
Media  
Closed  
Media  
guide  
Side  
plate  
Cutter  
Rewind  
spindle  
Rewind  
plate  
Guide  
plate  
Hook  
Figure 20  
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Fanfold Media Loading  
NOTE: A calibration must be performed when media and ribbon (if used)  
are first installed in the printer, or when a different type of media  
or ribbon is being used.  
Fanfold media feeds through either the bottom or rear access slot from  
outside the printer.  
Refer to Figures 21 and 22.  
1. Open the printhead.  
2. Slide the media guide as far from the printer frame as possible.  
3. Load media as shown. If in cutter mode, route media through the  
cutter.  
4. Slide in the media guide so it just touches, but not restricts, the edge of  
the roll.  
5. Close the printhead.  
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Bottom supply  
Printhead lever  
Open  
Closed  
Media  
guide  
Media  
Figure 21  
Rear supply  
Printhead lever  
Open  
Closed  
Media  
guide  
Media  
Figure 22  
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Removing the Label Backing Material  
Since the rewind spindle holds the backing from a standard-size media roll,  
we recommend that you perform this procedure whenever you change the  
media.  
To remove the backing material from the rewind spindle, follow these steps  
(you don’t need to turn off the printer for this procedure).  
1. Unwind approximately 36” (914 mm) of backing from the rewind  
spindle. Cut it off at the spindle.  
2. Pull out the hook. Slide the backing material off of the rewind spindle  
and discard.  
3. Wind the media around the rewind spindle once or twice and reinstall  
the hook. Continue winding to remove any slack in the media.  
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Ribbon Loading  
To load ribbon, refer to Figure 23 (for the 300X-PLUS, 600X-PLUS, and  
203X-PLUS) and Figure 24 (for the 360X-PLUS) and follow the procedure  
below.  
NOTE: Use ribbon that is at least as wide as the media. The smooth  
backing of the ribbon protects the printhead from wear and  
premature failure due to excessive abrasion. (For direct thermal  
print mode, ribbon is not used and should  
not be loaded in the printer.)  
1. Align the segments of the ribbon supply spindle.  
2. Place the ribbon roll on the ribbon supply spindle.  
NOTE: Make sure that the core is pushed up against the stop on the ribbon  
supply spindle and that the ribbon is aligned squarely with its core.  
If this is not done, the ribbon may not cover the printhead entirely  
on the inside, exposing print elements to potentially damaging  
contact with the media.  
3. Open the printhead.  
4. (Optional) To make ribbon loading and  
unloading easier, make a leader for your  
ribbon roll if it doesn’t already have one.  
Ribbon  
Label  
Strip of media  
6-12” long  
5. Tear off a strip of media (labels and  
backing) about 6-12” (152-305 mm) long  
from the roll. Peel off a label from this  
strip. Apply half of this label to the end  
of the strip and the other half to the end  
of the ribbon. This acts as a ribbon  
leader.  
6. Thread the ribbon (with leader, if used) as shown without creasing or  
wrinkling it.  
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7. Before wrapping the ribbon around the ribbon take-up spindle, ensure that  
the arrow on the knob aligns with the indented notch (see Figure 25  
inset).  
NOTE: Do not tape the ribbon to the ribbon take-up spindle!  
8. Place the ribbon (with leader, if used) around the ribbon take-up spindle  
and wind counterclockwise for several turns.  
9. Close the printhead.  
Ribbon  
take-up  
spindle  
Ribbon  
supply  
spindle  
Printhead  
lever  
Open  
Closed  
Figure 23  
Ribbon  
take-up  
spindle  
Ribbon  
supply  
spindle  
Printhead  
lever  
Open  
Closed  
Figure 24  
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Ribbon Removal  
1. Break the ribbon as close to the ribbon take-up spindle as possible.  
2. Refer to Figure 25. While holding the ribbon take-up spindle, turn the  
knob (1) clockwise until it stops. This will cause the ribbon release bars  
to pivot down (2), easing the spindle’s “grip” on the wound ribbon.  
3. Slide the ribbon off of the ribbon take-up spindle. Once the spent  
ribbon has been removed, ensure that the arrow on the knob aligns with  
the indented notch in the ribbon take-up spindle (see Figure 25 inset).  
4. Remove the empty core from the ribbon supply spindle.  
5. Follow the ribbon loading procedure on page 39 to load the new ribbon.  
2
1
Figure 25  
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Configuration  
After you have installed the media and ribbon and the power-on self test  
(POST) is complete, the front panel display will show “PRINTER READY.”  
(If the printer fails its POST, refer to page 81.) You may now set printer  
parameters for your application using the front panel display and the five keys  
directly below it.  
NOTE: Printers that are operating on an IP network can be quickly  
configured via ZebraNet WebView (optional ZebraNet  
PrintServer II required). For information, refer to ZebraNet  
Networking: PrintServer II Installation and User’s Guide.  
If it becomes necessary to restore the initial printer defaults, see “FEED  
Key and PAUSE Key Self Test” on page 85.  
NOTE: Unless otherwise noted, all parameters are listed in the order they  
are displayed, starting with “DARKNESS.”  
Entering the Setup Mode  
To enter the programming mode, press the SETUP/EXIT key. Press either  
the NEXT/SAVE key or PREVIOUS key to scroll to the parameter you  
wish to set.  
NOTE: You may also press and hold the NEXT/SAVE and PREVIOUS  
keys to quickly advance through the configuration parameters.  
Parameters in this section are shown in the order displayed when pressing  
the NEXT/SAVE key. Throughout this process, press the NEXT/SAVE  
key to continue to the next parameter, or press the PREVIOUS key to return  
to the previous parameter in the cycle.  
An asterisk (*) in the upper left-hand corner of the display indicates that the  
value displayed is different than the currently stored value.  
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Changing Password-Protected Parameters  
Certain parameters are password-protected by factory default.  
CAUTION: Do not change password-protected parameters unless  
you are sure you know what you are doing! If they are  
set incorrectly, these parameters could cause the  
printer to function in an unpredictable way.  
The first attempt to change one of these parameters (pressing one of the  
BLACK OVAL keys) will require you to enter a four-digit password. This  
is done via the “ENTER PASSWORD” display. The LEFT BLACK  
OVAL key changes the selected digit position. The RIGHT BLACK  
OVAL key increases the selected digit value. After entering the password,  
press the NEXT/SAVE key. The parameter you wish to change will be  
displayed. If the password was entered correctly, you can now change the  
value.  
The default password value is 1234. The password can be changed using  
the ^KP (Define Password) ZPL II instruction or through ZebraNet  
WebView (optional ZebraNet PrintServer II required).  
NOTE: Once the password has been entered correctly, it will not have to  
be entered again unless you leave and re-enter the programming  
mode using the SETUP/EXIT key.  
NOTE: You can disable the password protection feature so that it no  
longer prompts you for a password by setting the password to  
ØØØØ via the ^KPØ ZPL/ZPL II command. To re-enable the  
password-protection feature, send the ZPL/ZPL II command ^KPx,  
where “x” can be any number, one to four digits in length,  
except Ø.  
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Leaving the Setup Mode  
You can leave the program mode at any time by pressing the SETUP/EXIT  
key. The “SAVE CHANGES” display will appear. There are five choices,  
described below. Pressing the LEFT or RIGHT BLACK OVAL key  
displays other choices and pressing the NEXT/SAVE key selects the  
displayed choice.  
n
PERMANENT - Permanently saves the changes. Values are stored in  
the printer even when power is turned off.  
n
TEMPORARY - Saves the changes until changed again or until power is  
turned off.  
n
CANCEL - Cancels all changes since pressing the SETUP/EXIT key  
except the darkness and tear-off settings (if they were changed).  
n
LOAD DEFAULTS - Loads factory defaults. The factory defaults are  
shown on the following pages.  
NOTE: Loading factory defaults will require printer calibration.  
n
LOAD LAST SAVE - Loads values from the last permanent save.  
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Configuration and Calibration Sequence  
Press  
Display Shows  
Action/Explanation  
Normal printer operation.  
----  
PRINTER READY  
Setting Print Parameters  
Adjusting Print Darkness Press the RIGHT BLACK OVAL key to  
increase darkness. Press the LEFT BLACK OVAL key to decrease  
darkness.  
Default: +10  
Range: 0 to +30  
Darkness settings are dependent upon a variety of factors  
including ribbon type, media, and the condition of the printhead.  
You may adjust the darkness for consistent high-quality printing.  
If printing is too light, or if there are voids in printed areas, you  
should increase the darkness. If printing is too dark, or if there is  
spreading or bleeding of printed areas, you should decrease the  
darkness.  
DARKNESS  
The FEED key self test on page 84 can also be used to determine  
the best darkness setting. Since the darkness setting takes effect  
immediately, you can see the results on labels that are currently  
printing.  
CAUTION: Set the darkness to the lowest setting that provides  
good print quality. Darkness set too high may cause  
ink smearing and/or it may burn through the ribbon.  
Darkness settings also may be changed by the driver or software  
settings.  
Adjusting the Tear-Off Position Press the RIGHT BLACK OVAL  
key to increase the value, press the LEFT BLACK OVAL key to  
decrease the value. Each press of the key adjusts the tear-off  
position by four dot rows.  
Default: +0  
TEAR OFF  
Range: -120 to +120  
This parameter establishes the position of the media over the  
tear-off/peel-off bar after printing. The label and backing can be  
torn off or cut between labels.  
Selecting Print Mode Press the RIGHT or LEFT BLACK OVAL key  
to display other choices.  
Default: Tear-off  
Selections: Tear-off, peel-off, cutter, rewind, applicator*  
PRINT MODE  
Print mode settings tell the printer the method of media delivery  
that you wish to use. Be sure to select a print mode that your  
hardware configuration supports since some selections displayed  
are for optional printer features.  
* Option required  
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Press  
Display Shows  
Action/Explanation  
Setting Media Type Press the RIGHT or LEFT BLACK OVAL key  
to display other choices.  
Default: Continuous  
Selections: Continuous, non-continuous  
This parameter tells the printer the type of media you are using.  
Selecting continuous media requires that you include a label  
length instruction in your label format (^LLxxxx if you are using  
ZPL or ZPL II).  
MEDIA TYPE  
When non-continuous media is selected, the printer feeds media  
to calculate label length (the distance between two detections of  
the inter-label gap, webbing, or alignment notch or hole).  
Setting the Sensor Type Press the RIGHT or LEFT BLACK OVAL  
key to display other choices.  
Default: Web  
Selections: Web, mark  
SENSOR TYPE  
This parameter tells the printer whether you are using media with  
a web (gap/space between labels, notch, or hole) to indicate the  
separations between labels or if you are using media with a black  
mark printed on the back. If your media does not have black  
marks on the back, leave your printer at the default (web).  
Selecting Print Method Press the RIGHT BLACK OVAL key for  
the next value; press the LEFT BLACK OVAL key for the previous  
value.  
Default: Thermal transfer  
Selections: Thermal transfer, direct thermal  
PRINT METHOD  
The print method parameter tells the printer the method of  
printing you wish to use: direct thermal (no ribbon) or thermal  
transfer (using thermal transfer media and ribbon).  
NOTE: Selecting direct thermal when using thermal transfer  
media and ribbon creates a warning condition, but  
printing will continue.  
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Press  
Display Shows  
Action/Explanation  
Setting Print Width Press the RIGHT BLACK OVAL key to  
increase the value, press the LEFT BLACK OVAL key to decrease  
the value. To change the unit of measurement, press the LEFT  
BLACK OVAL key until the unit of measurement is active, then  
press the RIGHT BLACK OVAL key to toggle to a different unit of  
measure (inches, mm, or dots).  
PRINT WIDTH  
Default:, Range: The default and range of acceptable values vary  
depending on what printer you have. Refer to “Printing  
Specifications” on page 90 for further information about the  
ranges available for your model.  
Print width determines the printable area across the width of the  
label.  
Setting Maximum Length Press the LEFT BLACK OVAL key to  
decrease the value, press the RIGHT BLACK OVAL key to  
increase the value.  
Default:, Range: The default and range of acceptable values vary  
depending on your printer’s configuration. Values are adjustable  
in 1” (25.4 mm) increments.  
MAXIMUM  
LENGTH  
Maximum length is used in conjunction with the calibration  
procedure. The value of this setting determines the maximum  
label length that will be used during the media portion of the  
calibration process. Only a few labels are required to set media  
sensors. Always set the value that is closest to, but not lower  
than, the length of the label you are using. For example, if the  
length of the label is 14.5 inches (368 mm), set the parameter for  
15.0 inches (381 mm).  
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Listing Printer Information  
Press  
Display Shows  
Action/Explanation  
List Fonts Press the RIGHT BLACK OVAL key to print a label  
listing all of the available fonts.  
This selection is used to print a label that lists all of the fonts  
currently available in the printer, including standard printer fonts  
plus any optional fonts. Fonts may be stored in RAM, FLASH  
memory, font EPROMs, or font cards.  
LIST FONTS  
List Bar Codes Press the RIGHT BLACK OVAL key to print a label  
listing all of the available bar codes.  
LIST BAR CODES  
LIST IMAGES  
This selection is used to print a label that lists all of the bar codes  
currently available in the printer.  
List Images Press the RIGHT BLACK OVAL key to print a label  
listing all of the available images.  
This selection is used to print a label that lists all of the images  
currently stored in the printer’s RAM, FLASH memory, optional  
EPROM, or optional memory card.  
List Formats Press the RIGHT BLACK OVAL key to print a label  
listing all of the available formats.  
LIST FORMATS  
LIST SETUP  
LIST ALL  
This selection is used to print a label that lists all of the formats  
currently stored in the printer’s RAM, FLASH memory, optional  
EPROM, or optional memory card.  
List Setup Press the RIGHT BLACK OVAL key to print a label  
listing the current printer configuration.  
This selection is used to print a label that lists the current printer  
configuration information. (Same as CANCEL key self test.)  
List All Press the RIGHT BLACK OVAL key to print a label listing  
all of the available fonts, bar codes, images, formats, and the  
current printer configuration.  
This selection is used to print a label that lists the five previous  
selections, as described.  
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Press  
Display Shows  
Action/Explanation  
Initialize Memory Card  
CAUTION: Perform this operation only when it is necessary to  
erase all previously stored information from the optional memory  
card. Press the NEXT//SAVE key to bypass this function.  
1. Press the RIGHT BLACK OVAL key to select “YES.”  
If your printer is set to require a password, you will  
now be prompted to enter the password. Enter the  
password and then press the NEXT/SAVE key.  
2. The display will ask “INITIALIZE CARD?”. Press the RIGHT  
BLACK OVAL key “YES.”  
3. The front panel LCD will ask “ARE YOU SURE?”.  
4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.  
or  
INITIALIZE CARD  
Press the LEFT BLACK OVAL key “NO” to cancel the request  
and return to the “INITIALIZE CARD” prompt.  
5. Press the SETUP/EXIT key followed by the NEXT/SAVE key.  
If initialization is still in process, the front panel display  
will flash back and forth between the two phrases  
“CHECKING B: MEMORY” and “PRINTER IDLE.”  
When initialization is complete, the printer will  
automatically exit the configuration mode and the  
front panel will display “PRINTER READY.”  
NOTE: Depending on the amount of memory in the memory  
card, initialization may take up to five minutes to  
complete.  
Initialize Flash Memory  
CAUTION: Perform this operation only when it is necessary to  
erase all previously stored information from the FLASH memory.  
Press the NEXT//SAVE key to bypass this function.  
1. Press the RIGHT BLACK OVAL key to select “YES.”  
If your printer is set to require a password, you will  
now be prompted to enter the password. Enter the  
password and then press the NEXT/SAVE key.  
2. The display will ask “INITIALIZE FLASH?”. Press the RIGHT  
BLACK OVAL key “YES.”  
3. The front panel LCD will ask “ARE YOU SURE?”.  
4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.  
or  
INIT FLASH MEM  
Press the LEFT BLACK OVAL key “NO” to cancel the request  
and return to the “INITIALIZE FLASH” prompt.  
5. Press the SETUP/EXIT key followed by the NEXT/SAVE key.  
If initialization is still in process, the front panel display  
will flash back and forth between the two phrases  
“CHECKING E: MEMORY” and “PRINTER IDLE.”  
When initialization is complete, the printer will  
automatically exit the configuration mode and the  
front panel will display “PRINTER READY.”  
NOTE: Depending on the amount of free FLASH memory,  
initialization may take up to one minute to complete.  
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Media and Ribbon Sensor Calibration  
NOTE: Before you begin this procedure, make sure that the maximum length is set to a value  
equal to or greater than the length of the labels you are using. If the maximum length is set to a  
lower value, the calibration process will assume that continuous media is in the printer. See  
page 48 for more information.  
There are two different types of calibration that can be performed by the printer:  
1) Standard Calibration. Pressing the CALIBRATE key on the printer’s front panel causes the  
printer to feed media and ribbon and set the values it detects for media, media backing material  
(the spaces between labels), media out, and ribbon or no ribbon (which determines the print  
mode — thermal transfer or direct thermal). This type of calibration also occurs as part of the  
sensor profile and media and ribbon calibration procedures.  
2) Media and Ribbon Sensor Sensitivity Calibration. Performing the media and ribbon  
calibration procedure first resets the sensitivity of the sensors to better detect the media and  
ribbon you are using. With the sensors at their new sensitivity, the printer then performs the  
standard calibration described above. Changing the type of ribbon and/or media may require  
resetting the sensitivity of the media and ribbon sensors. Indications that the sensitivity may  
need to be reset would be a CHECK RIBBON light on with the ribbon properly installed or  
non-continuous media being treated as continuous media.  
Press  
Display Shows  
Action/Explanation  
Sensor Profile Press NEXT/SAVE to skip this standard calibration  
procedure and continue with the media and ribbon calibration  
parameter which follows. Press the RIGHT BLACK OVAL key to  
initiate this standard calibration procedure and print a media  
sensor profile.  
SENSOR PROFILE  
See Figure 26. The media sensor profile may be used to  
troubleshoot registration problems that may be caused when the  
media sensor detects preprinted areas on the media or  
experiences difficulty in determining web location. If the  
sensitivity of the media and/or ribbon sensors MUST be adjusted,  
use the media and ribbon sensor sensitivity procedure.  
Figure 26  
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Press  
Display Shows  
Action/Explanation  
Media and Ribbon Sensor Sensitivity Press NEXT/SAVE to skip  
the calibration procedure and continue with the host port  
selection parameters that follow. Press the RIGHT BLACK OVAL  
key to start the calibration procedure.  
MEDIA AND  
RIBBON  
CALIBRATE  
This procedure is used to adjust the sensitivity of the media and  
ribbon sensors.  
NOTE: The procedure must be followed exactly as presented.  
All steps must be performed even if only one of the  
sensors requires adjustment.  
Media and Ribbon Calibration Procedure  
Press the LEFT BLACK OVAL key to cancel the operation, or do  
the following:  
1) Open the printhead.  
LOAD BACKING  
2) Remove approximately 8” (203 mm) of labels from the media  
roll, enough so that only the backing material is threaded  
between the media sensors when the media is loaded.  
Press the LEFT BLACK OVAL key to cancel the operation or do  
the following:  
REMOVE RIBBON 1) Remove the ribbon (sliding it as far to the right as possible will  
have the same effect as removing it).  
2) Close the printhead.  
The printer automatically adjusts the scale (gain) of the signals it  
receives from the media and ribbon sensors based on the  
CALIBRATING  
specific media and ribbon combination you are using. On the  
PLEASE WAIT  
sensor profile, this essentially corresponds to moving the graph  
up or down to optimize the readings for your application.  
When “RELOAD ALL” is displayed:  
1) Open the printhead and pull the media forward until a label is  
positioned under the media sensor.  
2) Move the ribbon back to its proper position.  
3) Close the printhead.  
----  
RELOAD ALL  
Now that the scale has changed, the printer performs a  
calibration equivalent to pressing the CALIBRATE key. During  
this process, the printer checks the readings for the media and  
ribbon based on the new scale you have established, determines  
the label length, and determines whether you are in direct  
thermal or thermal transfer print mode. The process is now  
complete! To see the new readings on the new scale, print a  
sensor profile.  
MEDIA AND  
RIBBON  
CALIBRATE  
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Setting Communication Parameters  
Communication parameters must be set correctly for the printer to communicate with the host.  
These parameters make sure that the printer and host are “speaking the same language.” All  
communications parameters are password protected.  
Press  
Display Shows  
Action/Explanation  
Setting Parallel Communications Press the RIGHT or LEFT  
BLACK OVAL key to display other choices.  
PARALLEL  
COMM  
Default: Parallel  
Selections: Parallel, twinax/coax  
Select the communications port that matches the one being used  
by the host computer.  
Setting Serial Communications Press the RIGHT or LEFT  
BLACK OVAL key to display other choices.  
Default: RS232  
SERIAL COMM  
Selections: RS232, RS422/485, RS485 multidrop  
Select the communications port that matches the one being used  
by the host computer.  
Setting Baud Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: 9600  
Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200,  
28800, 38400, 57600  
BAUD  
The baud setting of the printer must match the baud setting of  
the host for accurate communications to take place. Select the  
value that matches the one being used by the host.  
Setting Data Bits Press the RIGHT or LEFT BLACK OVAL key  
to display other choices.  
Default: 7-bits  
Selections: 7-bits, 8-bits  
DATA BITS  
The data bits of the printer must match the data bits of the host  
for accurate communications to take place. Set the data bits to  
match the setting being used by the host.  
NOTE: Must be set to 8 data bits to use Code Page 850.  
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Press  
Display Shows  
Action/Explanation  
Setting Parity Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: Even  
PARITY  
Selections: Even, odd, none  
The parity of the printer must match the parity of the host for  
accurate communications to take place. Select the parity that  
matches the one being used by the host.  
Setting Stop Bits Press the RIGHT or LEFT BLACK OVAL key  
to display other choices.  
Default: 1 stop bit  
STOP BITS  
Selections: 1 stop bit, 2 stop bits  
The stop bits of the printer must match the stop bits of the host  
for accurate communications to take place. Select the stop bits  
that match the one being used by the host.  
Setting Host Handshake Press the RIGHT or LEFT BLACK  
OVAL key to display other choices.  
Default: XON/XOFF  
HOST  
HANDSHAKE  
Selections: XON/XOFF, DTR/DSR  
The handshake protocol of the printer must match the handshake  
protocol of the host for communications to take place. Select the  
handshake protocol that matches the one being used by the host.  
Setting Protocol Press the RIGHT or LEFT BLACK OVAL key  
to display other choices.  
Default: None  
Selections: None, Zebra, ACK/NACK  
Protocol is a type of error checking system. Depending on the  
selection, an indicator may be sent from the printer to the host  
signifying that data has been received. Select the protocol that is  
requested by the host. Further details on protocol can be found  
in the ZPL II Programming Guide Volume I.  
PROTOCOL  
NOTE: Zebra is the same as ACK/NACK except that with Zebra  
the response messages are sequenced.  
NOTE: If Zebra is selected, printer must use “DTR/DSR” host  
handshake protocol.  
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Press  
Display Shows  
Action/Explanation  
Setting Network ID  
Press the LEFT BLACK OVAL key to  
move to the next digit position, press the RIGHT BLACK OVAL  
key to increase the value of the digit.  
Default: 000  
Range: 000 - 999  
NETWORK ID  
Network ID is used to assign a unique number to a printer used in  
an RS-422/RS-485 network. This gives the host the means to  
address a specific printer. If the printer is used in a network, you  
must select a network ID number. This does not affect TCP/IP or  
IPX networks.  
Setting Communications Mode Press the RIGHT or LEFT  
BLACK OVAL key to display other choices.  
Default: Normal mode  
Selections: Normal mode, diagnostics  
The communication diagnostics mode is a troubleshooting tool  
for checking the interconnection between the printer and the  
host. When “diagnostics” is selected, all data sent from the host  
to the printer will be printed as straight ASCII hex characters. The  
printer prints all characters received including control codes, like  
CR (carriage return). A sample printout is shown in Figure 36 on  
page 85.  
COMMUNI-  
CATIONS  
NOTES on diagnostic printouts:  
• An FE indicates a framing error.  
• An OE indicates an overrun error.  
• A PE indicates a parity error.  
• An NE indicates noise.  
For any errors, check that your communication parameters are  
correct. Set the print width equal to or less than the label width  
used for the test. See page 48 for more information.  
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Selecting Prefix and Delimiter Characters  
Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to  
the printer. The printer uses the last prefix and delimiter characters sent to it, whether from a  
ZPL II instruction or from the front panel.  
NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The  
printer needs to see different characters to function properly.  
Press  
Display Shows  
Action/Explanation  
Control Prefix Character Press the LEFT BLACK OVAL key to  
move to the next digit position, press the RIGHT BLACK OVAL  
key to increase the value of the digit.  
Default: 7E (tilde - displayed as a black square)  
Range: 00-FF  
CONTROL PREFIX  
The printer looks for this 2-digit hex character to indicate the start  
of a ZPL/ZPL II control instruction.  
Format Prefix Character  
Press the LEFT BLACK OVAL key to  
move to the next digit position, press the RIGHT BLACK OVAL  
key to increase the value of the digit.  
FORMAT  
PREFIX  
Default: 5E (caret)  
Range: 00 - FF  
The printer looks for this 2-digit hex character to indicate the start  
of a ZPL/ZPL II format instruction.  
Delimiter Character  
Press the LEFT BLACK OVAL key to  
move to the next digit position, press the RIGHT BLACK OVAL  
key to increase the value of the digit.  
Default: 2C (comma)  
Range: 00 - FF  
DELIMITER CHAR  
The delimiter character is a 2-digit hex value used as a parameter  
place marker in ZPL/ZPL II format instructions. Refer to the ZPL II  
Programming Guide Volume I for more information.  
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Selecting ZPL Mode  
Press Display Shows  
Action/Explanation  
Selecting ZPL Mode Press the RIGHT or LEFT BLACK OVAL  
key to display other choices.  
Default: ZPL II  
Selections: ZPL II, ZPL  
The printer will remain in the selected mode until it is changed by  
this front panel instruction or by using a ZPL/ZPL II command. The  
printer accepts label formats written in either ZPL or ZPL II. This  
eliminates the need to rewrite any ZPL formats you already have.  
Refer to the ZPL II Programming Guide Volume II for more  
information on the differences between ZPL and ZPL II .  
ZPL MODE  
Power-Up and Head Close Parameters  
Media Power-Up Press the RIGHT or LEFT BLACK OVAL key  
to display other choices.  
Default: Feed  
Selections: Feed, calibration, length, and no motion  
This parameter establishes the action of the media when the  
printer is turned on.  
MEDIA POWER  
UP  
• Calibration: Recalibrates the media and ribbon sensors.  
• Feed: Feeds the label to the first web.  
• Length: Determines the length of the label.  
• No Motion: Media does not move.  
Head Close Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: Feed  
Selections: Feed, calibration, length, no motion  
Determines the action of the media after the printhead has been  
opened and then closed.  
HEAD CLOSE  
• Calibration: Recalibrates the media and ribbon sensors.  
• Feed: Feeds the label to the first web.  
• Length: Determines the length of the label.  
• No Motion: Media does not move.  
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Label Positioning Parameters  
Press  
Display Shows  
Action/Explanation  
Backfeed Sequence Press the RIGHT or LEFT BLACK OVAL  
key to display other choices.  
Default: Default (90%)  
Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%,  
60%, 70%, 80%, off  
This parameter establishes when and how much label backfeed  
occurs after a label is removed or cut in the peel-off, cutter, and  
applicator modes. It has no effect in rewind or tear-off modes.  
This parameter setting can be superseded by the ~JS instruction  
when received as part of a label format (refer to the ZPL II  
Programming Guide Volume I).  
BACKFEED  
NOTE: The difference between the value entered and 100%  
establishes how much backfeed occurs before the next  
label is printed. For example, a value of 40 means that  
40% of the backfeed takes place after the label is  
removed or cut. The remaining 60% takes place before  
the next label is printed. A value of “before” means that  
all backfeed will take place before the next label is  
printed.  
Adjusting Label Top Position Press the RIGHT BLACK OVAL key  
to increase the value, press the LEFT BLACK OVAL key to  
decrease the value. The displayed value represents dots.  
Default: +0  
LABEL TOP  
Range: -120 to +120 dot rows  
The label top position adjusts the print position vertically on the  
label. Positive numbers adjust the label top position further down  
the label (away from the printhead), negative numbers adjust the  
position up the label (toward the printhead).  
Adjusting Left Position Press the LEFT BLACK OVAL key to  
move to the next position, press the RIGHT BLACK OVAL key to  
change between + and - and to increase the value of the digit.  
The displayed value represents dots.  
Default: 0000  
Range: -9999 to +9999  
LEFT POSITION  
NOTE: For a negative value, enter the value before changing to  
the minus sign.  
This parameter establishes how far from the left edge of a label  
the format will begin to print by adjusting horizontal positioning  
on the label. Positive numbers adjust the printing to the left by  
the number of dots selected, negative numbers shift printing to  
the right.  
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Press  
Display Shows  
Action/Explanation  
Setting the Head Test Count Press the LEFT BLACK OVAL  
key to move to the next digit position, press the RIGHT BLACK  
OVAL key to change the value of the digit.  
Default: 0000 (disables the test)  
Range: 0000 to 9999  
HEAD TEST  
COUNT  
The printer periodically performs a test of the printhead  
functionality, called a “printhead test” or “head test.” This  
parameter establishes how many labels are printed between  
these internal tests.  
Setting the Head Resistor Value  
Press the LEFT BLACK  
OVAL key to move to the next digit position, press the RIGHT  
BLACK OVAL key to increase the value of the digit.  
CAUTION: This parameter should only be changed by qualified  
personnel!  
Initial Value: Factory-set to match the printhead shipped with  
your printer.  
Default Value: 0500  
Range: 0500 to 1175  
HEAD RESISTOR  
This value has been pre-set at the factory to match the resistance  
value of the printhead. It will not need to be changed unless the  
printhead is replaced.  
CAUTION: DO NOT set the value higher than that shown on the  
printhead. Setting a higher value may damage the  
printhead!  
Before replacing a printhead, look on the bottom of the printhead  
element for the label that shows the resistance value (ohm value).  
Setting the Verifier Port Press the RIGHT or LEFT BLACK  
OVAL key to display other choices.  
Default: Off  
Selections: Off, 1 VER-RPRNT, 2 VER-THRUPUT  
The auxiliary port is used to determine how the printer will react  
to the on-line verifier. There are currently three operating  
conditions for this port:  
• Off: The verifier port is off.  
• 1 VER-RPRNT ERR: Label reprinted if verifier detects an error.  
If a bar code is near the upper edge of the label, the label will be  
fed out far enough to be verified and then backfed to allow the  
next label to be printed and verified.  
VERIFIER PORT  
• 2 VER-THRUPUT: Allows greatest throughput but may not  
indicate a verification error immediately upon detection. May  
print from one to three labels before an error is recognized and  
printing stops.  
For more information on the operation of the optional verifier,  
refer to the documentation provided with that option.  
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Press  
Display Shows  
Action/Explanation  
Setting the Applicator Port Press the RIGHT or LEFT BLACK  
OVAL key to display other choices.  
Default: Off  
Selections: Off, mode 1, mode 2, mode 3, mode 4  
Determines the action of the verifier port.  
• Off: The applicator port is off.  
• Mode 1: Asserts the ~END_PRINT signal low while the printer  
is moving the label forward.  
APPLICATOR  
PORT  
• Mode 2: Asserts the ~END_PRINT signal high while the printer  
is moving the label forward.  
• Mode 3: Asserts the ~END_PRINT signal low for 20  
milliseconds when a label has been completed and positioned.  
Not asserted during continuous printing modes.  
• Mode 4: Asserts the ~END_PRINT signal high for 20  
milliseconds when a label has been completed and positioned.  
Not asserted during continuous printing modes.  
WEB S.  
MEDIA S.  
RIBBON S.  
MARK S.  
These parameters are automatically set during the calibration  
procedure. They should only be changed by a qualified service  
technician. Refer to the maintenance manual for more  
information on these parameters.  
MARK MED S.  
MEDIA LED  
RIBBON LED  
MARK LED  
Press the NEXT/SAVE key repeatedly to skip these parameters.  
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Press  
Display Shows  
Action/Explanation  
LCD Display Adjustment Press the LEFT BLACK OVAL key to  
decrease the value (reduce brightness), press the RIGHT BLACK  
OVAL key to increase the value (increase brightness).  
LCD ADJUST  
Range: 00 to 19  
This parameter allows you to adjust the brightness of your  
display if your display is difficult to read.  
Format Convert Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: None  
FORMAT  
CONVERT  
Selections: None, 150 300, 150 600, 200 600, 300 600  
Selects the bitmap scaling factor. The first number is the original  
dots per inch (d.p.i.) value; the second, the d.p.i. to which you  
would like to scale.  
Idle Display Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: Firmware version  
Selections: mm/dd/yy (24 hour), mm/dd/yy (12 hour),  
dd/mm/yy (24 hour), dd/mm/yy (12 hour)  
IDLE DISPLAY*  
This parameter selects the LCD display options for the real time  
clock (if installed).  
NOTE: If the default value is not selected, pressing either BLACK  
OVAL key will briefly display the firmware version of the  
printer.  
RTC Date  
Press the LEFT BLACK OVAL key to move to the  
next digit position, press the RIGHT BLACK OVAL key to increase  
the value of the digit.  
RTC DATE*  
This parameter allows you to set the date following the  
convention selected in “IDLE DISPLAY.”  
RTC Time  
Press the LEFT BLACK OVAL key to move to the  
next digit position, press the RIGHT BLACK OVAL key to increase  
the value of the digit.  
RTC TIME*  
This parameter allows you to set the time following the  
convention selected in “IDLE DISPLAY.”  
* Option required  
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Press  
Display Shows  
Action/Explanation  
IP Resolution Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: Dynamic  
Selections: Dynamic, permanent  
IP RESOLUTION*  
Depending on the selection, allows either the user (”permanent”)  
or the server (”dynamic”) to select the IP address. For more  
information, refer to ZebraNet Networking: PrintServer II  
Installation and User’s Guide.  
IP Protocols Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: All  
Selections: All, gleaning only, RARP, BOOTP, DHCP,  
DHCP/BOOTP  
IP PROTOCOLS*  
If “dynamic” was chosen in the previous parameter, this selection  
determines the method(s) by which the PrintServer II will receive  
the IP address from the server. For more information, refer to  
ZebraNet Networking: PrintServer II Installation and User’s  
Guide.  
IP Address  
Press the LEFT BLACK OVAL key to move to the  
next digit position, press the RIGHT BLACK OVAL key to increase  
the value of the digit.  
This parameter allows you to select the IP address if “permanent”  
was chosen in “IP RESOLUTION.” (If “dynamic” was chosen, the  
user cannot select the address.) For more information, refer to  
ZebraNet Networking: PrintServer II Installation and User’s  
Guide.  
IP ADDRESS*  
Subnet Mask Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: Permanent (user must set)  
Selections: Dynamic (user may set, but server can assign),  
permanent  
SUBNET MASK*  
This parameter selects the part of the IP address that is  
considered to be part of the local network It can be reached  
without going through the default gateway.  
Default Gateway  
Press the LEFT BLACK OVAL key to move  
to the next digit position, press the RIGHT BLACK OVAL key to  
increase the value of the digit.  
DEFAULT  
GATEWAY*  
This parameter allows you to select the IP address that the  
network traffic is routed through if the destination address is not  
part of the local network.  
* Option required  
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Press  
Display Shows  
Action/Explanation  
Selecting the Display Language Press the RIGHT or LEFT BLACK  
OVAL key to display other choices.  
Default: English  
Selections: English, Spanish, French, German, Italian,  
Norwegian, Portuguese, Swedish, Danish,  
Spanish 2, Dutch, Finnish, Custom  
LANGUAGE  
This parameter allows you to change the language used on the  
front panel display.  
You have now completed the entire configuration and calibration sequence. You may either  
press the NEXT/SAVE key or the SETUP/EXIT key.  
You are now back at the first parameter in the configuration  
sequence.  
DARKNESS  
NOTE: If you pressed the NEXT/SAVE key but are through  
programming the printer configuration, you may press  
the SETUP/EXIT key and continue with the “SAVE  
SETTINGS” function.  
Save Settings Press the RIGHT or LEFT BLACK OVAL key to  
display other choices.  
Default: Permanent  
Selections: Permanent, temporary, cancel, load defaults,  
load last save.  
This display appears when you attempt to exit the configuration  
mode.  
• Permanent: Permanently saves the changes, even when printer  
power is turned off.  
SAVE SETTINGS  
• Temporary: Saves the changes until changed again or until  
power is turned off.  
• Cancel: Cancels all changes since you entered the  
configuration mode except for darkness and tear-off position (if  
they were changed).  
• Load defaults: Loads factory defaults.  
NOTE: Loading factory defaults will require calibration and  
resetting the head resistor value.  
• Load last save: Loads the values from the last permanent save.  
Press the NEXT/SAVE key to activate the displayed choice.  
PRINTER READY  
You have exited the configuration and calibration sequence and  
are now ready for normal printer operation  
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Routine Care and Adjustment  
Cleaning  
The following table provides a brief cleaning schedule. Specific cleaning  
procedures are provided on the following pages.  
Area  
Method  
Solvent*  
Interval  
Printhead  
Direct thermal print mode:  
After every roll of media (or  
500’/152 m of fanfold media).  
Platen roller  
Solvent*  
Air blow  
Air blow  
Solvent*  
Air blow  
Air blow  
Solvent*  
Solvent*  
Solvent*  
Transmissive sensor  
Black mark sensor  
Media path  
Thermal transfer print mode:  
After every roll of ribbon.  
Ribbon sensor  
Label available sensors  
Tear-off/peel-off bar  
Snap plate  
Monthly  
As needed  
Cutter  
* Brady recommends using a solvent containing 90% isopropyl alcohol.  
CAUTION: Use only the cleaning agents indicated.  
Brady USA, Inc. will not be responsible for any other  
fluids being used on this printer.  
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Cleaning the Exterior  
The exterior surfaces of the printer may be cleaned with a lint-free cloth.  
Do not use harsh or abrasive cleaning agents or solvents. If necessary, a  
mild detergent solution or desktop cleaner may be used sparingly.  
Cleaning the Interior  
Inspect this area after every four rolls of media. Remove any dirt and lint  
from the interior of the printer using a soft bristle brush and/or vacuum  
cleaner.  
Cleaning the Printhead and Platen Roller  
Inconsistent print quality, such as voids in the bar code or graphics, may  
indicate a dirty printhead. For best results, perform the following cleaning  
procedure after every roll of ribbon.  
NOTE: You do not need to turn off the printer before cleaning the  
printhead. If power is turned off, all label formats and images, as  
well as any temporarily saved parameter settings stored in the  
printer’s internal memory, will be lost. When power is turned back  
on, you will need to reload these items.  
To clean the printhead, refer to Figure 27 and follow these steps:  
1. Open the printhead.  
2. Remove the media and ribbon (if loaded).  
3. Moisten an applicator tip with Brady-recommended solvent and wipe  
along the print elements from end to end. (The print elements are on  
the brown strip just behind the chrome strip on the printhead.) Allow a  
few seconds for the solvent to evaporate.  
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4. Rotate the platen roller and clean thoroughly with solvent and an  
applicator.  
5. Brush/vacuum any accumulated paper lint and dust away from the  
rollers.  
6. Reload ribbon and/or media, and close and the printhead.  
Printhead  
lever  
Printhead  
Black  
mark  
sensor  
Ribbon  
sensor  
Label  
available  
sensors  
Platen  
roller  
Tear-off/peel-off  
bar  
Figure 27  
Cleaning the Sensors  
The media, ribbon, and label available sensors should be cleaned on a  
regular basis to ensure proper operation of the printer. To locate these  
sensors, refer to Figure 27, Figure 6 on page 11, and Figure 7 on page 12.  
Brush/vacuum any accumulated paper lint and dust off of these sensors.  
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Cleaning the Snap Plate  
Clean the snap plate to remove label adhesive or a label that has adhered to  
the underside of the snap plate.  
Refer to Figure 28.  
1. Insert a small-blade screwdriver or similar tool into the loop on the left  
side of the snap plate. Lift the snap plate.  
CAUTION: Use care to not bend, twist, or otherwise deform the  
loops!  
2. Repeat step one on the right side of the snap plate.  
3. Remove the snap plate from the printer.  
4. Clean the snap plate with cleaning solvent and a soft cloth.  
Refer to Figure 29.  
5. To reinstall the snap plate, insert the two tabs on the bottom of the snap  
plate into the two slots of the media pathway.  
6. Slide the snap plate toward you.  
7. Press down on the loops to lock the snap plate into place.  
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Loop  
Loop  
Snap  
plate  
Figure 28  
Loop  
Slot  
Tab  
Loop  
Slot  
Tab  
Figure 29  
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Cleaning the Cutter Module  
(For printers equipped with the optional cutter.)  
If labels are not being cut properly or if the cutter jams with labels, turn off  
the printer power and unplug the printer. Then, clean the stationary cutter  
blade with cleaning solvent. This will remove label adhesive and/or paper  
debris. If further cutter cleaning is necessary, or if the cutter continues to  
perform unsatisfactorily, contact an authorized service technician.  
Lubrication  
CAUTION! No lubricating agents of any kind should be used on  
this printer! Some commercially available lubricants  
will damage the finish and the mechanical parts if  
used.  
Fuse Replacement  
The printer uses a metric-style fuse (5 X 20 mm IEC) rated at F5A, 250V.  
The end caps of the fuse must bear the certification mark of a known  
international safety organization (see Figure 37 on page 92). The printer  
comes with two approved fuses: one in the circuit and one in the “spare  
fuse” holder.  
1. Turn off the printer power and unplug the power cord from the back of  
the printer. See Figure 30.  
2. Using a small-blade screwdriver or similar tool, remove the fuse holder  
from the printer.  
3. Remove the faulty fuse and install a new fuse of the correct type. Refer  
to Figure 31. The fuse that goes into the printer first is the one that is  
“in-circuit.” If you use the spare fuse, be sure to order a replacement  
fuse (fuses can be ordered from your Brady distributor).  
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4. Snap the fuse holder back into position.  
5. Reconnect the power cord.  
If the new fuse fails right away, the printer has an internal component  
failure and must be repaired.  
Fuse  
holder  
AC power  
entry  
module  
Small blade  
screwdriver  
Figure 30  
In-circuit  
fuse  
Fuse  
holder  
Spare  
fuse  
Figure 31  
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Adjustments  
Toggle Positioning  
Both toggles should be positioned so that they provide even pressure on the  
media. The toggles are positioned by sliding them to the desired location.  
On media too narrow to accommodate both toggles, position one toggle  
over the center of the media and decrease the pressure on the unused toggle.  
If you are using a 300X-PLUS or 600X-PLUS printer, position the toggle  
over the center of the media.  
NOTE: Make sure that the toggle pressure is even across the width of the  
media. Otherwise, the media and/or ribbon may “drift.”  
Label  
available  
sensors  
Adjusting  
nuts  
Figure 32  
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Printhead Pressure Adjustment  
This adjustment may be necessary if printing is too light on one side or if  
thick media is used. Refer to Figure 32.  
1. Perform the toggle positioning procedure. If the problem is solved, you  
may stop here; otherwise, continue with the rest of this procedure.  
2. Print some labels at 2.4"/61 mm per second (1”/25.4 mm for the  
600 X-PLUS) by running the PAUSE key self test (see page 83).  
3. While printing labels, lower the darkness setting until a gray level of  
printing is seen.  
4. Loosen the knurled (upper) locking nuts at the top of the toggle  
assembly/assemblies.  
5. Increase or decrease spring pressure using the knurled (lower) adjusting  
nuts on the shafts of the toggle(s) until the left and right edges of  
printed area are equally dark.  
NOTE: Printhead life can be maximized by using the lowest pressure that  
produces the desired print quality.  
6. Increase darkness to the optimum level for the media being used.  
7. Retighten locking nuts.  
Media Sensor Position Adjustment  
See “Positioning the Media Sensors” on page 10.  
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Troubleshooting  
LED Error Conditions and Warnings  
Error Condition Ribbon Out  
Problem  
Solution  
In thermal transfer mode, the ribbon is  
not loaded or loaded incorrectly.  
Load the ribbon correctly. See “Ribbon Loading” on  
page 39.  
In thermal transfer mode, the ribbon  
sensor is not sensing correctly loaded  
ribbon.  
Perform the media and ribbon sensor calibration (see  
page 17).  
Put the printer in direct thermal mode via the front  
panel and remove ribbon (if loaded).  
In direct thermal mode, when ribbon is  
not used:  
Ensure that the printer driver or software settings are  
correctly set (if applicable).  
Error Condition Paper Out  
Problem  
Solution  
The media is not loaded or loaded  
incorrectly.  
Reload the media. Refer to “Roll Media Loading” on  
page 27.  
Check the position of the upper and lower media  
sensors. See “Positioning the Media Sensors” on  
page 10.  
The media sensor is not adjusted  
properly.  
Either load the correct media or set the printer for the  
correct media type via the front panel.  
The printer is set for non-continuous  
media, but continuous media is loaded.  
Ensure that the printer driver or software settings are  
correctly set (if applicable).  
Calibrate the printer (see page 17).  
Via the front panel, check the sensor type to ensure  
that the correct one is used for the media loaded. See  
page 16. Calibrate the printer (see page 17).  
The incorrect media sensor is being  
used.  
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Error Condition Head Open  
Problem  
Solution  
The printhead is not fully closed.  
Close the printhead.  
Error Condition Head Element Bad  
Problem  
Solution  
If the failed elements impact your printing application,  
One or more of the printhead elements replace the printhead. To override this error, disable  
have failed the printhead element test. the head test count feature on the front panel by  
defaulting the value to “0000.” See page 59.  
Warning Ribbon In  
Problem  
Solution  
Remove the ribbon and set the printer to direct thermal  
mode.  
The ribbon is loaded.  
Ensure that the printer driver and/or software settings  
are correctly set (if applicable).  
Warning Head Too Hot  
Problem  
Solution  
Allow the printer to cool. Printing automatically  
resumes when the printhead elements cool to an  
acceptable operating temperature.  
The printhead is over temperature.  
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Warning Head Cold  
Problem  
Solution  
Continue printing while the printhead reaches the  
correct operating temperature. If the error remains,  
the environment may be too cold for proper printing.  
Relocate the printer to a warmer area.  
The printhead is under temperature.  
Warning Cutter Jammed  
Problem  
Solution  
Turn off the printer power and unplug the printer.  
Inspect the cutter module for debris and clean as  
needed following the cleaning instructions on page 70.  
Cutter blade is in the media path.  
Out of Memory*  
Problem  
Solution  
Insufficient DRAM for the label length, downloaded  
fonts/graphics, and images.  
*There is not enough memory to  
perform the function shown on the  
second line of the error message.  
Ensure that the device, such as FLASH memory or  
PCMCIA card, is installed and not write protected or  
full.  
Ensure that the data is not directed to a device that is  
not installed or available.  
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Print Quality Problems  
General Print Quality Issues  
Problem  
Solution  
Consult your authorized Brady reseller/distributor for  
ribbon combination for your application. information and advice.  
You are using an incorrect media and  
For optimal print quality, set the print speed to the  
lowest possible setting via ZPL II, the driver, or the  
software.  
The printer is set at the incorrect print  
speed.  
For optimal print quality, set the darkness to the lowest  
possible setting via the front panel, the driver, or the  
software.  
The printer is set at the incorrect  
darkness level.  
Clean the printhead according to the instructions on  
page 66.  
The printhead is dirty.  
There is light printing (or no printing) on The toggle pressure needs to be adjusted. Follow the  
printhead pressure adjustment instructions on  
page 73.  
the left or right side of the label or the  
printed image is not sharp.  
Gray lines on blank labels with no consistent pattern  
Problem  
Solution  
Clean the printhead according to the instructions on  
page 66.  
The printhead is dirty.  
Light, consistent vertical lines running through all of the labels  
Problem  
Solution  
Clean the printhead, platen roller, or both according to  
the instructions on page 66.  
The printhead or platen roller is dirty.  
Intermittent creases on the left and right edges of the labels  
Problem  
Solution  
There is too much toggle pressure on  
the printhead.  
Reduce the toggle pressure. Refer to the printhead  
pressure adjustment on page 73.  
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Wrinkled Ribbon  
Problem  
Solution  
Load the ribbon correctly. See “Ribbon Loading” on  
page 39.  
The ribbon is not loaded correctly.  
Set the darkness to the lowest possible setting for  
good print quality. See “Darkness” on page 46.  
The darkness setting is incorrect.  
Set the pressure to the minimum required for good  
Incorrect printhead pressure or balance. print quality. See “Printhead Pressure Adjustment” on  
page 73.  
The media is not feeding correctly. It is Make sure that the media guide and media supply  
“walking” from side to side.  
guide touch the edge of the media.  
Communications  
A label format was sent to the printer but not recognized. The  
DATA light does not flash.  
Problem  
Solution  
Check the printer driver or software communications  
settings (if applicable).  
Check the printer host port setting via the front panel  
(see page 53). Select the port that matches the one  
being used by the host.  
The communication parameters are  
incorrect.  
Are you using the correct communication cable? See  
page 22 for the requirements.  
Via the front panel, check the protocol setting. It  
should be set to “none.” See page 54.  
Ensure that the correct driver is being used, if  
applicable.  
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A label format was sent to the printer. Several labels print, then the  
printer skips, misplaces, misses, or distorts the image on the label.  
Problem  
Solution  
The host is set to EPP parallel  
communications.  
Change the settings on the computer host to standard  
parallel communications.  
Ensure that the flow control settings match.  
Check the communication cable length. See page 22  
for requirements.  
The serial communication settings are  
incorrect.  
Check the printer driver or software communications  
settings (if applicable).  
A label format was sent to the printer but not recognized. The  
DATA light flashes but no printing occurs.  
Problem  
Solution  
The prefix and delimeter characters set  
in the printer do not match the ones in  
the label format.  
Verify the prefix and delimeter characters. See  
page 56.  
Ensure that ZPL is being used.  
Incorrect data is being sent to the  
printer.  
Check the communication settings on the computer.  
Ensure that they match the printer settings.  
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Printer Diagnostics  
Power-On Self Test  
A power-on self test (POST) is performed automatically each time the  
printer is turned on. During this test sequence, the front panel lights and  
liquid crystal display monitor the progress of the POST. If the printer fails  
any of these tests, the word “FAILED” will be added to the display. If this  
occurs, notify an authorized Brady distributor.  
Additional Printer Self Tests  
These self tests produce sample printouts and provide specific information  
that help determine the operating conditions for the printer.  
Each self test is enabled by pressing a specific front panel key or  
combination of keys while turning the POWER switch on. Keep the key(s)  
depressed until the DATA light turns off. When the power-on self test is  
complete, the selected self test starts automatically.  
NOTES: When performing self tests, avoid sending a label format to the  
printer. In the case of a remote host, disconnect all data interface  
cables from the printer.  
When canceling a self test prior to its actual completion, always  
turn the printer power off and then back on to reset the printer.  
When performing these self tests while in the peel-off mode,  
you must remove the labels as they become available.  
If your media is not wide enough or long enough, unexpected  
and/or undesired results may occur. Make sure that your print  
width is set correctly for the media you are using before you  
run any self tests, otherwise the test may print out on the platen  
roller. See page 48 for information on setting the print width.  
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CANCEL Key Self Test  
This self test prints a listing of the  
configuration parameters currently  
stored in the printer’s memory. See  
Figure 33 (depending on the options  
ordered, your label may look  
different).  
1. Turn the printer off.  
2. Press and hold the CANCEL key  
while turning on the power.  
The configuration may be changed  
either temporarily (for specific label  
formats or ribbon and label stock) or  
permanently (by saving the new  
parameters in memory). Saving new  
parameters occurs whenever a  
calibration procedure is performed.  
Refer to page 15 for further  
information about the configuration  
procedure.  
Figure 33  
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PAUSE Key Self Test  
This self test can be used to provide the test labels required when making  
adjustments to the printer’s mechanical assemblies. See the sample printout  
in Figure 34.  
1. Turn off the printer.  
2. Press and hold the PAUSE key while turning on the power.  
n
The initial self test prints 15 labels at 2.4"/61 mm per second  
(1”/25.4 mm for the 600X-PLUS) per second, then automatically pauses  
the printer. Each time the PAUSE key is pressed, an additional 15 labels  
print.  
n
While the printer is paused, pressing the CANCEL key alters the self  
test. Now each time the PAUSE key is pressed the printer prints 15  
labels at 6"/152 mm per second (4”/102 mm for the 600X-PLUS).  
n
While the printer is paused, pressing the CANCEL key again alters the  
self test again. Each time the PAUSE key is pressed the printer prints 50  
labels at 2.4”/61 mm per second (1”/25.4 mm for the 600X-PLUS).  
n
While the printer is paused, pressing the CANCEL key again alters the  
self test a third time. Now each time the PAUSE key is pressed the  
printer prints 50 labels at 6”/152 mm per second (4”/102 mm for the  
600X-PLUS).  
n
While the printer is paused, pressing the CANCEL key again alters the  
self test a fourth time. Each time the PAUSE key is pressed the printer  
prints 15 labels at the printer’s maximum speed.  
n
To exit this self test at any time, press and hold the CANCEL key.  
Figure 34  
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FEED Key Self Test  
See Figure 35.  
1. Turn off the printer.  
2. Press and hold the  
FEED key while  
turning on the power.  
The FEED key self test  
prints out at various  
darkness settings above  
and below that of the  
darkness value shown on  
the configuration label.  
Look at these labels and  
determine which one has  
the best darkness setting  
for your application. This  
value can be entered into  
the printer by setting the  
darkness during the  
Figure 35  
configuration procedure.  
Refer to page 46 for more  
information.  
The value printed on that label is added to (plus) or subtracted from (minus)  
the darkness value specified on the configuration label. The resulting  
numeric value (0 to 30) is the best darkness value for that specific  
media/ribbon combination.  
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FEED Key and PAUSE Key Self Test  
1. Turn off the printer.  
2. Press and hold the FEED and PAUSE keys while turning on the power.  
Performing this self test temporarily resets the printer configuration to the  
factory default values. These values will be active only until power is  
turned off unless you save them permanently in memory.  
Communications Diagnostics Test  
This test is controlled from the front panel display. Refer to page 55. A  
typical printout from this test is shown in Figure 36. Turn off the power to  
exit this self test.  
NOTE: This label will be inverted when printed.  
Figure 36  
Additional Printer Diagnostics  
Additional diagnostic tests are available for this printer, however they are  
beyond the scope of this user’s guide. Refer to the maintenance manual for  
information about these additional tests.  
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Specifications  
NOTE: Printer specifications are subject to change without notice.  
Media Handling  
n
Tear-off mode: Labels are produced in strips.  
n
Peel-off mode: Labels are dispensed and peeled from the liner as  
needed.  
n
n
Cutter mode: Labels are printed and individually cut.  
Rewind mode: Labels are rewound internally.  
Options  
n
n
Cutter  
Rewind  
IBM twinax interface  
IBM coax interface  
n
n
n
n
Cutter-rewind  
Cutter tray  
Media supply spindle  
ZebraNet PrintServer II, including  
Ethernet interface (10Base-T),  
WebView graphical setup and printer  
control, and Alert unsolicited error  
notification  
n
n
(1.6”/40 mm core)  
Media supply spindle  
(3”/76 mm core)  
n
n
n
n
n
n
n
RS-485 interface  
Font cards  
Double-hinged media door with  
clear panel  
DRAM memory expandable to 12 MB  
Memory cards  
Printer drivers for Windows™  
operating systems  
n
n
n
Applicator interface  
Real time clock  
Advance counter  
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Zebra Programming Language (ZPL II®)  
n
n
Downloadable graphics, scalable and  
bitmap fonts, and label formats  
Object copying between memory areas  
(RAM, memory card, and internal  
FLASH)  
Slew command  
Programmable quantity with print,  
pause, and cut control  
n
n
n
Communicates in printable ASCII  
characters  
n
n
n
n
n
n
Code Page 850 character set  
Adjustable print cache  
Data compression  
Error-checking protocol  
Controlled via mainframe, mini-  
computer, PC, portable data terminal  
Serialized fields  
n
n
n
n
n
Automatic virtual input buffer  
management  
In-spec OCR-A and OCR-B  
UPC/EAN  
n
n
n
n
Automatic memory allocation  
Format inversion  
Mirror image printing  
User-programmable password  
Status message to host upon request  
Four-position field rotation (0º, 90º,  
180º, and 270º)  
Bar Codes  
n
n
n
n
n
n
n
n
n
n
n
n
n
Bar code ratios - 2:1, 7:3, 5:2, & 3:1  
Codabar (supports ratios of 2:1 up to  
ISBT-128  
LOGMARS  
n
3:1)  
CODABLOCK  
MaxiCode  
Micro PDF  
MSI  
n
n
Code 11  
Code 39 (supports ratios of 2:1 up to  
n
PDF-417 (2-dimensional bar code)  
Plessey  
POSTNET  
3:1)  
Code 49 (2-dimensional bar code)  
n
n
Code 93  
Code 128 (with subsets A, B, and C  
QR-Code  
n
Standard 2 of 5  
UPC-A, UPC-E, UPC extensions  
Check digit calculation where  
applicable  
and UCC case C codes)  
Data Matrix  
n
n
EAN-8, EAN-13, EAN extensions  
Industrial 2 of 5  
n
n
Interleaved 2 of 5 (supports ratios of  
2:1 up to 3:1, Modulus 10 Check  
Digit)  
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General Specifications  
General Specifications  
300/600X-PLUS  
203X-PLUS  
360X-PLUS  
Height  
Width  
Depth  
15.5"  
9.15"  
19.5"  
50 lb  
393.7 mm  
232.4 mm  
495.3 mm  
22.7 kg  
15.5"  
393.7 mm  
283.2 mm  
495.3 mm  
25 kg  
15.5"  
393.7 mm  
334.4 mm  
495.3 mm  
30.5 kg  
11.15"  
19.5"  
55 lb  
13.15"  
19.5"  
67 lb  
Weight (without options)  
General (auto adjusting)  
Printing PAUSE test  
90-264 VAC;  
48-62 Hz  
90-264 VAC;  
90-264 VAC;  
48-62 Hz  
180 W  
19 W  
48-62 Hz  
220 W  
19 W  
label at  
slowest speed  
121 W  
20 W  
Power  
consumption  
Electrical  
Printer idle  
Complies with FCC class “B” and Canadian Doc. class “A” rules.  
Carries the CE mark of compliance.  
Compliance  
41º to  
104º F  
5º to  
40º C  
41º to  
104º F  
5º to  
40º C  
41º to  
104º F  
5º to  
40º C  
Thermal transfer  
Direct thermal  
Operating  
environment  
32º to  
104º F  
0º to  
40º C  
32º to  
104º F  
0º to  
40º C  
32º to  
104º F  
0º to  
40º C  
Temperature  
-40º  
to  
140º F  
-40º  
to  
60º C  
-40º  
to  
60º C  
-40º  
to  
60º C  
-40º to  
140º F  
-40º to  
140º F  
Storage  
20 to 85%  
non-condensing  
20 to 85%  
non-condensing  
20 to 85%  
non-condensing  
Operating environment  
Storage  
Relative  
humidity  
5 to 85%  
non-condensing  
5 to 85%  
non-condensing  
5 to 85%  
non-condensing  
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Printing Specifications  
Printing Specifications  
300X-PLUS  
300 dots/inch  
(12 dots/mm)  
600X-PLUS  
600 dots/inch  
(23.5 dots/mm)  
203X-PLUS  
203 dots/inch  
(8 dots/mm)  
360X-PLUS  
300 dots/inch  
(12 dots/mm)  
Resolution  
0.0016” x 0.0016”  
(.042 x .042 mm)  
0.0033” x 0.0039”  
(.084 x .100 mm)  
0.0049” x 0.0049” 0.0033” x 0.0039”  
(.125 x .125 mm) (.084 x .100 mm)  
Dot size (width x length)  
0.12" ± .035"  
(3 mm ±  
.89 mm)  
0.12" ± .035"  
(3 mm ±  
.89 mm)  
0.10" ± .035"  
(2.5 mm ±  
.89 mm)  
0.10" ± .035"  
(2.5 mm ±  
.89 mm)  
First dot location  
from inside media edge  
Maximum print width  
3.4” (86 mm)  
39” (991 mm)  
3.2” (81 mm)  
20” (508 mm)  
5.04” (128 mm)  
39” (991 mm)  
6.6” (168 mm)  
39” (991 mm)  
With standard  
memory  
Non-  
continuous  
printing  
With 12 MB  
memory  
39” (991 mm)  
80” (2032 mm)  
39” (991 mm)  
20” (508 mm)  
39” (991 mm)  
39” (991 mm)  
41” (1041 mm)  
Print  
length  
(max.)  
With standard  
memory  
121” (3073 mm)  
Continuous  
printing  
With 12 MB  
memory  
100” (2540 mm)  
3.9 mil to 39 mil  
52” (1321 mm)  
1.6 mil to 16 mil  
150” (3810 mm)  
4.9 mil to 49 mil  
100” (2540 mm)  
3.9 mil to 39 mil  
Bar code Ladder (rotated) orientation  
modulus  
(“X”)  
Picket fence (non-rotated)  
3.33 mil to 33 mil  
Yes  
1.6 mil to 16 mil  
Yes  
4.9 mil to 49 mil 3.33 mil to 33 mil  
dim.  
Thin-film printhead with Element  
Energy Equalizer (E3)®  
Yes  
Yes  
Ribbon Specification  
Ribbon Specifications  
300/600X-PLUS  
Ribbon must be wound with the coated side out.  
203X-PLUS  
360X-PLUS  
Ribbon width (Brady recom- Minimum  
0.79” (20 mm)  
3.40” (87 mm)  
1.57” (40 mm)  
2.0” (51 mm)  
6.7” (170 mm)  
mends using ribbon at least as  
wide as the media to protect  
the printhead from wear.)  
Maximum  
5.10” (130 mm)  
2:1 media to ribbon roll ratio  
3:1 media to ribbon roll ratio  
984 ft. (300 m)  
1476 ft. (450 m)  
1.0” (25.4 mm)  
3.2” (81.3 mm)  
984 ft. (300 m)  
1476 ft. (450 m)  
1.0” (25.4 mm)  
3.2” (81.3 mm)  
984 ft. (300 m)  
1476 ft. (450 m)  
1.0” (25.4 mm)  
3.2” (81.3 mm)  
Standard  
lengths  
Ribbon core inside diameter  
Maximum ribbon roll outside diameter  
90  
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Media Specifications  
Media Specifications  
Tear-off  
300/600X-PLUS  
0.7" (18 mm)  
203X-PLUS  
0.7" (18 mm)  
360X-PLUS  
0.7" (18 mm)  
Peel-off  
0.5" (13 mm)  
0.5" (13 mm)  
1.5" (38 mm)  
0.5" (13 mm)  
1.5" (38 mm)  
Minimum label length*  
Cutter  
1.5" (38 mm)  
Rewind  
0.25" (6 mm)  
0.25" (6 mm)  
0.25" (6 mm)  
Minimum  
Maximum  
Minimum  
Maximum  
0.79" (20 mm)  
3.54" (90 mm)  
0.003” (0.076 mm)  
0.012” (0.305 mm)  
1.57” (40 mm)  
5.51” (140 mm)  
0.003” (0.076 mm)  
0.012” (0.305 mm)  
2.00” (51 mm)  
7.1” (180 mm)  
0.003” (0.076 mm)  
0.012” (0.305 mm)  
Total media width  
(label + liner, if any)  
Total thickness  
(includes liner, if any)  
Cutter maximum full-width media  
thickness  
.014" (.35 mm)  
.009" (.23 mm)  
.007" (.18 mm)  
Roll media core inside diameter  
Maximum roll diameter  
3” (76 mm)  
8.0” (203 mm)  
0.079” (2 mm)  
0.118” (3 mm)  
3” (76 mm)  
8.0” (203 mm)  
3” (76 mm)  
8.0” (203 mm)  
0.079” (2 mm)  
0.118” (3 mm)  
Minimum  
0.079” (2 mm)  
Preferred  
Maximum  
0.118” (3 mm)  
Inter-label gap  
Maximum inter-label gap =  
2 x (label length for which you have calibrated the printer) + 1”  
Maximum internal fanfold media pack size  
(label + liner) L x W x H  
8.0” x 3.54” x 4.5”  
(203x90x114 mm)  
8.0” x 5.51” x 4.5”  
(203x140x114 mm)  
8.0” x 7.1” x 4.5”  
(203x180x114 mm)  
0.12" x .25"  
(3 mm) x (6 mm)  
0.12" x .25"  
(3 mm) x (6 mm)  
0.12" x .25"  
(3 mm) x (6 mm)  
Ticket/tag sensing notch L x W  
Ticket/tag sensing hole diameter  
0.125" (3 mm)  
±0.060” (±1.5 mm)  
±0.060” (±1.5 mm)  
0.12” (3 mm)  
0.125" (3 mm)  
±0.070” (±1.8 mm)  
±0.070” (±1.8 mm)  
0.12” (3 mm)  
0.125" (3 mm)  
±0.060” (±1.5 mm)  
±0.060” (±1.5 mm)  
0.12” (3 mm)  
Vertical  
Effective leading edge  
registration accuracy*  
Horizontal  
Mark length  
(measuring  
parallel to  
Minimum  
Maximum  
Minimum  
Maximum  
0.43” (11 mm)  
0.43” (11 mm)  
Full media width  
0.43” (11 mm)  
0.43” (11 mm)  
Full media width  
0.43” (11 mm)  
0.43” (11 mm)  
Full media width  
label/tag edge)  
Mark width  
(measuring  
perpendicular to  
label/tag edge  
Additional  
specs. for  
black mark  
sensing  
Mark location  
Mark density  
Marks must be located within .040" (1 mm) of the inside media edge.  
> 1.0 ODU  
(Optical Density Unit)  
> 1.0 ODU  
(Optical Density Unit)  
> 1.0 ODU  
(Optical Density Unit)  
Maximum density of the back of  
the media on which the black  
mark is printed  
0.5 ODU  
0.5 ODU  
0.5 ODU  
* Media registration and minimum label length are affected by media type and width, ribbon type,  
print speed, and printer mode of operation. Performance improves as these factors are optimized.  
Brady recommends always qualifying any application with thorough testing.  
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Power Line Cord Specifications  
n
The overall length must be less than 9.8 feet (3.0 meters).  
n
n
It must be rated for at least 5 A, 250 V.  
The chassis ground (earth) MUST be connected to assure safety and  
reduce electromagnetic interference. The ground connection is handled  
by the third wire (earth) in the power line cord. See Figure 37.  
n
The AC power plug and IEC 320 connector must bear the certification  
mark of at least one of the known international safety organizations  
shown in Figure 38.  
IEC 320  
connector  
Contact  
view  
3 conductor  
<HAR> cable  
Neutral  
Earth  
Live  
AC power  
plug for  
your country  
Figure 37  
+
R
Figure 38  
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Appendix  
Printer Interface Technical Information  
RS-232/RS-422/RS-485 Serial Data Port  
The connections for these standard interfaces are made through the DB25S  
connector on the rear panel. For all RS-232 input and output signals, the  
printer follows both the Electronics Industries Association’s (EIA) RS-232  
specifications and the Consultative Committee for International Telegraph  
and Telephone (CCITT) V.24 standard signal level specifications.  
The following table shows the pin configuration and function of the rear  
panel serial data connector on the printer.  
Pin No.  
Description  
1
FG (frame ground) for cable shield  
2
3
TXD (RS-232 transmit data) output from printer  
RXD (RS-232 receive data) input to printer  
RTS (RS-232 request to send) output from printer  
DSR (data set ready) input to printer  
4
6
7
SG (signal ground) for RS-232  
9
+5 VDC source output (1 Amp maximum)  
SGR (signal ground reference) for RS-422/RS-485  
Data input B(-); RS-422/RS-485  
11  
13  
14  
16  
19  
20  
Data output B(-); RS-422/RS-485  
Data input A(+); RS-422/RS-485  
Data output A(+); RS-422/RS-485  
DTR (RS-232 data terminal ready) output from printer  
NOTE: Pins 5, 8, 10, 12, 15, 17-18, 21-25 are not used and are unterminated.  
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RS-232 connector (DTE)  
rear panel DB-25S  
1
2
3
4
6
7
9
FG (frame ground)  
TXD (transmit data) output  
RXD (receive data) input  
RTS (request to send) output  
DSR (data set ready) input  
SG (signal ground)  
+5 V  
F1  
+5 VDC source  
1 Amp  
20 DTR (data terminal ready) output  
Figure 39  
RS-232 Interconnections  
The printer is configured as Data Terminal Equipment (DTE).  
Figure 39 illustrates the internal connections of the printer’s RS-232  
connector.  
Figure 40 illustrates the connections required to interconnect the printer  
with the standard 9-pin serial port connector on a computer.  
NOTES: If using a 9-pin to 25-pin adapter plug attached to the computer,  
use a null modem cable between the adapter plug and the  
printer.  
To connect the printer to other DTE devices with DB-25  
connectors (such as the serial port of a PC), an RS-232 null  
modem (crossover) cable should be used.  
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DB-9S  
connector  
to computer  
DB-25P  
connector  
to printer  
DCD  
RXD  
TXD  
FG  
TXD  
RXD  
DTR  
SG  
RTS  
DSR  
SG  
DSR  
RTS  
CTS  
RI  
DTR  
Figure 40  
When the printer is connected via its RS-232 interface to Data  
Communication Equipment (DCE) such as a modem, use a standard RS-232  
(straight-through) interface cable. Figure 41 illustrates the connections  
required for this cable.  
DCE  
DTE  
FG (frame ground)  
TXD (transmit data)  
RXD (receive data)  
RTS (request to send)  
CTS (clear to send)  
DSR (data set ready)  
SG (signal ground)  
1
2
3
4
5
6
7
8
20  
1
2
3
4
5
6
7
8
20  
CD (carrier detect)  
DTR (data terminal ready)  
NOTE: Pins 5, 8, 10, 12, 15, 17-18, 21-25 are not used and are unterminated.  
Figure 41  
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Male DB-25  
to printer  
Frame ground  
1
Signal ground ref.  
11  
Data input B(-)  
Data output B(-)  
13  
14  
Data input A(+)  
Data output A(+)  
16  
19  
Figure 42  
RS-422/RS-485 Interconnections  
The printer may be connected to a host by either an RS-422 or an RS-485  
interface. The DB-25 connector on the rear of the printer uses specific pins  
for this purpose. Figure 42 illustrates the required cable wiring for  
interconnecting to the printer’s DB-25 connector. Figure 43 illustrates the  
internal connections of the printer’s RS-422 or RS-485 connector.  
RS-422/RS-485 connector  
rear panel DB-25S  
+5 V  
F1  
9
+5 VDC source  
1 Amp  
14 Data output B(-)  
19 Data output A(+)  
13 Data input B(-)  
+5 V  
10k  
20k  
10k  
16 Data input A(+)  
11 Signal ground reference  
100  
1
Frame ground  
Figure 43  
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Parallel Data Port  
A standard 36-pin parallel connector is available at the rear of the printer for  
connection to the data source. Under normal circumstances, data sent from  
the printer to the host in response to a “Printer Status Request” command is  
sent through the RS-232 serial port. However, if the host has a properly  
configured IEEE-1284 parallel port that is recognized by the printer, status  
information will be returned through the parallel port. Port selection for  
status information is determined each time the printer is turned on.  
Parallel Port Interconnections  
The following table shows the pin configuration and function of a standard  
computer-to-printer parallel cable.  
36-pin  
Description  
Connector  
1
2-9  
10  
nStrobe/HostClk  
Data Bits 1-8  
nACK/PtrClk  
11  
Busy/PtrBusy  
PError/ACKDataReq  
Select/Xflag  
12  
13  
14  
nAutoFd/HostBusy  
Not Used  
15  
16 & 17  
18  
Ground  
+5V @ 1A  
19-30  
31  
Ground  
ninit  
32  
nFault/NDataAvail  
Not Used  
33 & 34  
35  
+5V through a 4.7 KResistor  
NSelectIn/1284 active  
36  
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Index  
A
D
Adjustments  
F
B
C
Calibration  
G
Cleaning  
I
L
Loading the media  
Configuring the printer  
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M
P
Media loading  
Printer configuration  
Media sensors  
Media types  
R
N
Requirements  
O
Operator controls  
S
Self tests  
100  
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