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POSMicro I4208 Manual

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  • Page 1 THIS DOWNLOAD APPLIES TO THE FOLLOWING I4208 I4212 I4308 QUESTIONS? BULk DISCOUNTS SE HaBLa Ask the experts at POSMicro.com. ESpañOL FREE SHIPPING* 1.800.241.6264 Live Chat Now support@POSMicro.com Monday - Friday 6 AM to 5 PM Pacific Time *Free ground shipping to the continental USa on orders over $100.
  • Page 2 Operator’s Manual...

  • Page 4: Copyright Information

    Copyright Information CG Triumvirate is a trademark of Agfa Corporation. CG Times based upon Times New Roman under license from the Monotype Corporation. Windows is a registered trademark of the Microsoft Corporation. Ethernet is a registered trademark of Xerox Corporation. All other brand and product names are trademarks, service marks, registered trademarks, or registered service marks of their respective companies.
  • Page 5 Agency Compliance and Approvals UL60950 Information Technology Equipment C22.2 No. 950-M93 Listed EN60950 For 230 Volt Operation (Europe): Use a cord set, marked “HAR,” consisting of a min H05VV-F cord which has a minimum 0.75 square mm diameter conductors, provided with an IEC 320 receptacle and a male plug for the country of installation rated 6A, 250V Für 230 Volt (Europa): Benützen Sie ein Kabel, das mit “HAR”...

  • Page 6: Important Safety Instructions

    Important Safety Instructions The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance instructions in the literature accompanying this unit. This unit has been carefully designed to provide years of safe, reliable performance. As with all electrical equipment, however, there are some basic precautions that you should follow to avoid personal injury or printer damage: Before using the printer, carefully read all the installation and operating instructions.

  • Page 8: Table Of Contents

    Contents 1 Overview....................1 1.1 About the Printer ................1 1.1.1 Standard Features ..............1 1.1.2 Optional Features ..............2 2 Getting Started ..................7 2.1 Unpacking the Printer................. 7 2.1.1 Inspection ................8 2.1.2 Additional Requirements ............8 3 Setting up the Printer................9 3.1 Installation ..................
  • Page 9 4.1.3 Menu Mode: Configuration ............20 4.1.4 Test Mode: Printing Test Labels ..........21 4.2 The System Menu................22 4.2.1 Entrance and Exit Prompts ............22 4.2.2 Media Settings ............... 23 4.2.3 Print Control ................26 4.2.4 Printer Options ............... 28 4.2.5 System Settings ..............
  • Page 10 5.3 Reset Methods ................70 5.3.1 Soft Reset................70 5.3.2 Level One Reset ..............70 5.3.3 Level Two Reset ..............70 5.4 Printhead Assembly Adjustments ............71 5.4.1 Leveling Cam Adjustment ............71 5.4.2 Burn Line Adjustment .............. 72 5.5 Printhead Replacement..............73 5.6 Maintenance ...................
  • Page 11 Approved Media and Ribbon ............100 7.2.1 Controlling Print Quality ............100 7.2.2 Media and Ribbon Requirements ..........101 7.3 Serial Cable Requirements ...............103 Appendix A....................105 Module Assignments ................105 Print Resolutions and Maximum Label Widths ..........105 Available Speeds and Default Settings............106 Appendix B....................107 Custom Adjustment Ranges ..............107 Column &...

  • Page 12: Overview

    Overview 1.1 About the Printer Congratulations on your purchase of an I-Class printer (hereafter referred to as “the printer”). This manual provides information regarding printer setup, operation, and care. To print label formats, refer to the instructions provided with your labeling software; or if you wish to write custom programs, a copy of the Class Series 2 Programmer’s Manual can be found on the Accessories CD and at our web site at http://www.datamax-oneil.com...

  • Page 13: Optional Features

    Standard Features I-Class Model Feature 4206 4208 4212 4308 4406 4604 Direct Thermal Printing Fan-Fold Media Handling Flash Memory Liquid Crystal Display Media Tear Bar Multi-Language Support On-Demand and Batch Printing Resolution (Dots Per Inch) Rotating Media Hub SDRAM 16MB 16MB 16MB 16MB...
  • Page 14 External Keyboard (specify voltage & country requirement when ordering) A portable terminal for stand-alone printing. External Media Rewinder (specify voltage requirement when ordering) label A feature-dependant bidirectional rewinding device: DMXREW1 – rewinds widths up to 4.5 inches (114 mm) into eight-inch (203 mm) •...

  • Page 15: Option Installation

    RFID An integrated Radio Frequency Identification tag encoding and reading device with data capture capabilities, available for immediate or future use: Factory Installed – complete, ready to use. • Ready – factory installed antenna, requiring installation of additional hardware. • RS-422 Serial Interface (unavailable for I-4206 and I-4208 models) Single-drop interface hardware for greater printer to host serial communication distances (at up to 38,400 baud).
  • Page 16 Option Installations (continued) Option Recommended Installer Peel and Present Mechanism Operator Present Sensor Operator RFID-Ready DMX Certified Technician RS-422 Serial Interface DMX Certified Technician Thermal Transfer Operator Twinax/Coax Interface DMX Certified Technician USB Port DMX Certified Technician I-Class...
  • Page 17 I-Class...

  • Page 18: Getting Started

    Getting Started 2.1 Unpacking the Printer The printer has been carefully packaged to prevent transit damage. (Inspect the container for damage; if evident, notify the shipping company before acceptance.) Complete the steps below to ready the printer for use: A. With the arrow pointing upward, open the box. B.

  • Page 19: Inspection

    2.1.1 Inspection After removing the packaging, check the contents of the shipment. The following items should be included: Printer • Power Cord • Accessories CD • Any special or additionally purchased items. • 2.1.2 Additional Requirements Other items can also be needed for operation: An interface cable;...

  • Page 20: Setting Up The Printer

    Setting up the Printer 3.1 Installation Interface and connect power to the printer: A. Place the printer on a firm, level surface. B. Turn OFF the Host Computer then, depending upon your system, connect an appropriate interface cable from the host to the printer; see Section 3.1.1. C.

  • Page 21: Communications

    3.1.1 Communications Following power-up (or after a period of inactivity), interface port selection occurs automatically upon detection of valid data. If the incoming (received) data flow stops and the Host Timeout Value (see Section 4.2.6) is exceeded, partially received formats will be ignored and the port detection process repeated.

  • Page 22: Media Loading

    3.2 Media Loading Load media according to its type: A. Raise the cover. B. Rotate the Printhead Latch then raise the Printhead Assembly. C. Slide the Media Guide outward and then rotate it downward. D. If using roll media on a 1.5-inch (38mm) core, grasp then pull firmly outward to remove the 3-Inch Media Hub;...

  • Page 23: Loading Roll Media

    3.2.1 Loading Roll Media A. Slide the Roll Media onto the Media Hub until it reaches the Backstop. Backstop Roll Media Media Hub Media Guide B. Route the Media under the Media Idler, through the Media Sensor, and then straight out the front of printer.

  • Page 24: Loading Fan-Fold Media

    E. If using thermal transfer media, load ribbon (see Section 3.4); otherwise, go to Step F. F. Lower the Printhead Assembly and rotate the Printhead Latch into the locked position. Close the cover then turn ON the printer. After READY is displayed, press and hold the FEED Key until at least one label gap (or mark) is advanced;...
  • Page 25 B. Route the Media under the Media Idler (also, if equipped over the Internal Rewinder; and, if through the Rear Media Slot, over the Media Hub). Media Idler Media Media Sensor Media Internal Rewinder Media (Optional Equipment) Guide C. Pass the media through the Media Sensor then straight out the front of the printer. D.

  • Page 26: Media Sensor Adjustment

    3.3 Media Sensor Adjustment The Media Sensor detects media presence, and top-of-form (except when using continuous stock). Adjust the Media Sensor as follows: A. With media loaded and the Printhead Assembly raised for visual access, grasp the Slide Tab of the Media Sensor. B.

  • Page 27: Ribbon Loading

    3.4 Ribbon Loading The Thermal Transfer Option type determines the applicable ribbon type [Coating Side In (CSI) or Coating Side Out (CSO)]. Depending upon the option type, load ribbon as follows: A. Unlock the Printhead Latch and raise the Printhead Assembly. Following the Directional Arrows on the Thermal Transfer Option, orient the Ribbon Roll accordingly and then slide it completely onto the Ribbon Supply Hub.

  • Page 28: Quick Calibration

    Removing Used Ribbon When the Ribbon Roll is depleted, pull the empty core from the Ribbon Supply Hub. Grasp the used roll on Ribbon Take-Up Hub then pull and squeeze to remove the spent ribbon. (To remove partially depleted rolls, cut the ribbon then remove the roll and discard any used ribbon as described above.) 3.5 Quick Calibration The printer is calibrated to sense a wide range of media.
  • Page 29 I-Class...

  • Page 30: Using The Control Panel

    Using the Control Panel 4.1 Operation The Control Panel is composed of a display, indicators, and mode-dependant keys for easy access to printer functions. 4.1.1 Display and Indicator Lights  Liquid Crystal Display (LCD) The LCD provides textual information: STOP ERROR READY Following initialization, the READY message;...

  • Page 31: Ready Mode: Normal Operation

    4.1.2 Ready Mode: Normal Operation (Ready Light ON)  The PAUSE Key temporarily suspends printing, and pressing it again returns normal operation.  The FEED Key advances labels, and clears any corrected faults. Pressing and holding it initiates calibration; see Section 3.5.

  • Page 32: Test Mode: Printing Test Labels

     The ESCAPE Key moves through previous menu levels to Ready Mode.  The TEST Key terminates printing then restores Menu Mode. 4.1.4 Test Mode: Printing Test Labels  The DOWN ARROW Key scrolls to the previous test function.  The UP ARROW Key scrolls to the next test function.

  • Page 33: The System Menu

    4.2 The System Menu The MENU Key accesses seven system branches: MEDIA SETTINGS • PRINT CONTROL • PRINTER OPTIONS • SYSTEM SETTINGS • COMMUNICATIONS • DIAGNOSTICS • MCL OPTIONS • Notes: (1) Entering the menu takes the printer offline and halts the processing of new ...

  • Page 34: Media Settings

    Displayed Message Details MENU MODE The Menu Key has been pressed, where: ENTER PASSWORD Requires entry of the correct security password for menu access. 0 0 0 0 KEEP HOST CHANGES? Requires a decision regarding existing host commands that have affected the configuration of the printer, ENTER=YES where pressing ENTER will save these changes or pressing ESC will discard them.
  • Page 35 Media Settings (continued) Menu Item Details SENSOR TYPE Selects the Top Of Form (TOF) sensing method used to determine the leading edge of the label, where: Senses the gaps or notches in the media. GAP CONTINUOUS TOF sensing is not used; see LABEL LENGTH. REFLECTIVE Senses the reflective (black) marks on the underside of the media.
  • Page 36 Media Settings (continued) Menu Item Details PAUSE ON RIBBON LOW Sets the printer to pause when the RIBBON LOW DIAMETER setting is met, where: ENABLED Forces the user to press the PAUSE Key to proceed with the print job. Allows printing to continue until ribbon empty is DISABLED declared.

  • Page 37: Print Control

    4.2.3 Print Control The Print Control menu contains print quality, throughput, formatting, and custom setup functions: Menu Item Details HEAT Controls the burn-time of the printhead (selectable as “Heat” in most labeling programs), where: (0 - 30) Is the number based on duration, corresponding to 10 print darkness.
  • Page 38 Print Control (continued) Menu Item Details PRESENT DISTANCE Sets the label stop position, where: (0 - 4.00) Is the label travel distance at output. 0.00in MOTOR THROTTLING Controls the current to the stepper motor, where: Counts labels versus time and, if needed, pauses ENABLED printing to maintain a cooler motor temperature.

  • Page 39: Printer Options

    4.2.4 Printer Options The Printer Options menu contains module, file-handling, and option functions: Menu Item Details MODULES Controls memory handling functions, where: PRINT DIRECTORY Prints a listing of available space, files, and types; see Appendix A. PRINT FILE Prints from a list of available files. FORMAT MODULE Formats the selected module, erasing all data.
  • Page 40 Printer Options (continued) Menu Item Details CUT BEHIND Allows a number of small labels to queue before a cut is performed, increasing throughput, where: Note: This mode can be used without a cutter to  allow the presentation of an extra label, with retraction occurring upon the next job or feed operation.
  • Page 41 Printer Options (continued) Menu Item Details BARCODE COUNT Specifies a number of bar codes per label and generates a fault when the number present is incorrect, where: (0 - 99) Sets the number of bar codes to count, where 00 (Auto 00 Mode) allows a variable number.
  • Page 42 Printer Options (continued) Menu Item Details RFID Controls the RFID operation, where: RFID MODULE Sets the mode of RFID operation, where: Disables RFID. DISABLED Selects the Securakey option. UHF CLASS 1 Selects the Alien option. UHF MULTI-PROTOCOL Selects the UHF cross-platform option. RFID POSITION Sets the RFID encoding position, where: (110 - 4.00)
  • Page 43 Printer Options (continued) Menu Item Details DSFID LOCK Locks the DSFID value, where: Is not protected. DISABLED ENABLED Is write-protected. EAS VALUE Selects the Electronic Article Surveillance value, where: (HEX) Is the value (00 - FF). 00 AUDIO INDICATOR ERASE ON FAULT Allows tag data erasure when errors are detected, where: Keeps data.
  • Page 44 Printer Options (continued) Menu Item Details KILL CODE Code to permanently deactivate the tag, where: 00 00 00 00 Is the code, in the form B3, B2, B1, B0. ACCESS CODE Code to protect tag memory contents, where: 00 00 00 00 Is the code, in the form B3, B2, B1, B0.
  • Page 45 Printer Options (continued) Menu Item Details RETRY ATTEMPTS Sets the number of retry attempts, where: (0 - 9) Is the retry count before a fault is declared. 3 AUTO DETECT TAG Allows the printer to establish the tag to transducer distance setting.
  • Page 46 Printer Options (continued) Menu Item Details START OF PRINT Selects the type of input signal required to initiate printing, where: ACTIVE HIGH Triggers printing with a high signal. EDGE Triggers printing with a signal edge transition. LOW PULSE Triggers printing with a low pulse. HIGH PULSE Triggers printing with a high pulse.

  • Page 47: System Settings

    Printer Options (continued) Menu Item Details BACKUP LABEL Positions a presented label for printing (provided the PRESENT DISTANCE setting is greater than zero), where: Disables backup positioning. DISABLED ACTIVE LOW Positions the label when a logic low is received. ACTIVE HIGH Positions the label when a logic high is received.
  • Page 48 System Settings (continued) Menu Item Details INTERNAL MODULE D Allocates a number of 1KB memory blocks for internal Memory Module D; where: 1024 K (XXX - XXXX) Is the memory allocation; see Appendix A for the memory ranges, types, and availability. DEFAULT MODULE Designates the memory module for storage when no other location is specified;...
  • Page 49 System Settings (continued) Menu Item Details MEDIA COUNTERS Provides a recorded count of inches printed and time; where: ABSOLUTE COUNTER Shows the total number of inches printed and the set date. (Non-resettable) RESETTABLE COUNTER Shows the number of inches printed and the last reset date.
  • Page 50 System Settings (continued) Menu Item Details UNLOCK FEATURE Unlocks a corresponding feature with the entry of the correct code. 0 0 0 0 0 0 SET FACTORY DEFAULTS Returns the printer settings to the factory-programmed values or the Factory Setting File values, where: SET FACTORY DEFAULT? Overwrites the current configuration and restores the default configuration (), or if selected the Factory...
  • Page 51 System Settings (continued) Menu Item Details PEEL MODE Allows the SOP signal to initiate (via GPIO option) the feeding of the labels, where: Feeds regardless of SOP. DISABLED ENABLED Feeds only when SOP is received. Allows menu password protection, where: SECURITY SELECT SECURITY Enables or disables the security feature, where:...
  • Page 52 System Settings (continued) Menu Item Details AUTO Identifies then activates the appropriate emulation parser for the data. Note: Correct identification can be dependant upon  the HOST SETTINGS / HOST TIMEOUT (see Section 4.2.6). Also, extraneous characters may, in some cases, render the data unrecognizable, thus requiring manual selection of the mode.
  • Page 53 System Settings (continued) Menu Item Details MODE Repositions media, where: Moves media only when the next label is ready to print, DISABLED minimizing edge curling. ENABLED Moves media according to BACKUP DELAY timing after a cut, cleared sensor, or SOP signal to allow fastest throughput.
  • Page 54 System Settings (continued) Menu Item Details FAULT HANDLING Determines the label disposition and user action if a fault occurs, where: LEVEL Sets the printer response upon declaration of a fault, where: Stops printing and declares a fault. Then, following STANDARD correction of the problem, the FEED Key must be pressed to clear the fault and reprint the label in process.

  • Page 55: Communications

    System Settings (continued) Menu Item Details VOID DISTANCE Sets the distance to print VOID on a faulted label, where: (10 – 2.00) Is the distance, measured from the trailing edge, which 0.50in establishes the text size. Note: VOID will not be printed if insufficient text ...
  • Page 56 Communications (continued) Menu Item Details 9600 BPS 19200 BPS 28800 BPS 38400 BPS Is the speed in Bits Per Second. 57600 BPS 115000 BPS 1200 BPS 2400 BPS 4800 BPS PROTOCOL Sets the data flow control (handshaking) method. Uses XON/XOFF and CTS/DTR flow control. BOTH SOFTWARE XON/XOFF...
  • Page 57 Communications (continued) Menu Item Details SERIAL PORT D Controls the RS-232 communications settings for optional Serial Port D; see SERIAL PORT A. Note: The maximum baud is 38.4K BPS.  PARALLEL PORT A Controls the communications settings for Parallel Port A, where: PORT DIRECTION Allows data return from the printer, where:...
  • Page 58 Communications (continued) Menu Item Details WLAN ADHOC? Restores the WiFi defaults and initiates infrastructure mode with an SSID of “Any.” All existing access point CANCEL KEY = YES associations will be deleted then established with the closest available. (Useful when moving the printer to a geographically distant location.) Note: Press the ESC Key to exit the menu item ...
  • Page 59 Communications (continued) Menu Item Details SNMPTRAP DESTINATION Specifies the SNMP Trap Address, where: 000.000.000.000 Is the address in standard octet format where SNMP traps will be sent when SNMP service is installed on your receiver. Note: When zeroed, no traps are sent. ...
  • Page 60 Communications (continued) Menu Item Details Sets the Maximum Transmission Unit packet size, where: Is the packet size, in bytes. 01500 (512 - 65515) GRATUITOUS ARP Sets the Address Resolution Protocol notification rate, where: Is the time, in minutes. 0000 (0 - 2048) PORT NUMBER Sets the network communications port, where: 09100 (1 - 65535)
  • Page 61 Communications (continued) Menu Item Details SET FACTORY DEFAULTS Returns the NIC to factory-programmed values, where: SET FACTORY DEFAULTS? Restores the default settings. CANCEL KEY = YES Note: Press the ESC Key to exit the menu item  without changing the current settings. HOST SETTINGS Sets host communication parameters;...
  • Page 62 Communications (continued) Menu Item Details HEAT COMMAND Determines how a host software Heat command is handled, where: Processes commands normally. ENABLED DISABLED Ignores commands; instead, Heat is controlled via the menu setting; see Section 4.2.3. SPEED COMMANDS Determines how host software Print, Feed, Reverse, and Slew commands are handled, where: Processes commands normally.
  • Page 63 Communications (continued) Menu Item Details MAX LENGTH COMMAND Determines how a host software Maximum Label Length (<STX>M) command is handled, where: Processes commands normally. ENABLED DISABLED Controls the setting via the menu; see Section 4.2.2. OPTION FEEDBACK Allows feedback characters from an optional device to be returned to the host device, in the format of <A;B;C;D;E;F>[CR], where: A - Is the device type: R = RFID;...

  • Page 64: Diagnostics

    4.2.7 Diagnostics The Diagnostics menu contains testing functions: Menu Item Details HEX DUMP MODE Allows raw code received from the host to print, where: Executes commands and prints label formats normally. DISABLED ENABLED Prints received data without processing; see Section 6.2.
  • Page 65 Diagnostics (continued) Menu Item Details LOOPBACK Not Supported PRINT SIGNAL INFO Prints signal names, pin assignments, settings, and current states for reference. GPIO SIGNAL INFO WED 11:04AM 24MAR2003 CARD ID#1 OUTPUT SIGNALS INPUT SIGNALS END OF PRINT START OF PRINT PIN# 8 PIN# 6 ACTIVE HIGH...

  • Page 66: Mcl Options

    Diagnostics (continued) Menu Item Details SENSOR READINGS Displays A-D sensor values (0 – 255), where: THR TRAN RIBM 24V  Are the sensor readings, where: THR = Printhead thermistor sensor; • TRAN = Media sensor when set to Gap or Continuous, or •...

  • Page 67: The Test Menu

    4.3 The Test Menu The TEST Key accesses six resident format selections that are printed at selected heat and speed settings (see Section 4.1.4 for printing details). Notes: (1) With the exception of the Configuration Label, all test labels require full ...

  • Page 68: Ribbon Test Label

    4.3.3 Ribbon Test Label The Quick Ribbon Test Label can be used to verify thermal transfer functions. 4.3.4 Validation Label The Validation Label can be used to verify print quality. 4.3.5 Print Last Label The Print Last Label function reprints the most recent test label, format received from the host, or format recalled from a memory module.
  • Page 69 I-Class...

  • Page 70: Operating, Adjusting And Maintaining The Printer

    Operating, Adjusting and Maintaining the Printer 5.1 Displayed Messages During operation the printer (when not in Menu or Test Mode) displays several types of information: Prompts and Condition Messages (see Section 5.1.1); and, • Fault and Warning Messages (see Section 6.1.2). •...
  • Page 71 Prompts and Condition Messages (continued) Displayed Message Description Action The MENU Key is being pressed Release the MENU Key DISPLAY CONTRAST and held, and now the LCD when the desired contrast is being adjusted. contrast is achieved. No action is required. The network card is initializing, a Depending upon the DMXNET INITIALIZING...

  • Page 72: Calibration

    Prompts and Condition Messages (continued) Displayed Message Description Action No action is required. The power switch has been turned SYSTEM INITIALIZING Wait briefly while the ON or a reset has occurred. process completes. No action is required. SYSTEM RESET A reset has occurred. Wait briefly while the IN PROGRESS...
  • Page 73 Three samples are required: Empty: Nothing in the sensor. • Gap (or Mark): The media liner, notch, or reflective mark in the sensor. • Paper: The label (and liner, if any) in the sensor. • With the correct SENSOR TYPE selected (see Section 4.2.2), perform a Standard Calibration as follows: Step Action...
  • Page 74 Standard Calibration (continued) Step Action Displayed Message Comment Proceed according to your media: Die-cut – remove a label See Section 3.3 for from the backing sensor positioning material then place the details. backing in the sensor. Adjust the Sensor Eye Mark over the center of the backing.
  • Page 75 Standard Calibration (continued) Step Action Displayed Message Comment GAP MODE CALIBRATION COMPLETE  The calibration was Or, for reflective media: successful if  CALIBRATION COMPLETE REFLECTIVE MODE appears. Observe the LCD. CALIBRATION COMPLETE  (If, however, another Or, for continuous media: message was displayed ...

  • Page 76: Advanced Entry Calibration

    5.2.2 Advanced Entry Calibration Advanced Entry is the alternate calibration method for special-case media types. In the procedure, sensor readings for the label and TOF values are taken using different sampling algorithms. From this compiled list of values the best algorithm is selected and then used to generate new readings for manual entry into memory.
  • Page 77 Advanced Entry Calibration (continued) Step Action Displayed Message Comment See Section 3.3 for GAIN TRAN <yyy> sensor positioning Press the Key. <0 - 31> details.  Place the label under the  If using preprinted Or, for reflective media: Sensor Eye Mark, and then media, ensure the label ...
  • Page 78 Advanced Entry Calibration (continued) Step Action Displayed Message Comment Proceed according to your media type: Die-cut – remove a label from the backing material then place the backing into the sensor. Adjust the Sensor Eye Mark over GAIN TRAN <yyy> the center of the backing.
  • Page 79 Advanced Entry Calibration (continued) Step Action Displayed Message Comment Press the Key to GAIN TRAN <yyy> increment the Gain Number <0 - 31> then press the  and record the resulting  TOF Value. Or, for reflective media: Repeat this step for each of GAIN REFL <yyy>...
  • Page 80 Advanced Entry Calibration (continued) Step Action Displayed Message Comment a) Place the media in the sensor. Record the reading and label it “P” GAIN TRAN <yyy> (paper). <0 - 31> b) Place the backing, notch,  The samplings using the or mark in the sensor.

  • Page 81: Reset Methods

    Advanced Entry Calibration (continued) Step Action Displayed Message Comment After all entries have been made, press the From READY, press the SAVE CHANGES? to back out of the menu and FEED Key to advance to ENTER KEY = YES then press the the next label TOF.

  • Page 82: Printhead Assembly Adjustments

    5.4 Printhead Assembly Adjustments Mechanical adjustments ensure consistent print quality across a wide range of media types and sizes. 5.4.1 Leveling Cam Adjustment Adjust the Leveling Cam for even pressure distribution when using less than full width media [4 inches (102mm)]; in addition, perform the adjustment when changing to a different width of media: A.

  • Page 83: Burn Line Adjustment

    Example 2 – Correct adjustment produces a complete image, with even print contrast across the label. Note: Under-adjustment can cause ribbon wrinkling,  lateral label movement, and excessive wear on printer components. 5.4.2 Burn Line Adjustment Adjust the Burn Line only after trying the print quality improvement suggestions in Section 5.4.1 and 7.2.1.

  • Page 84: Printhead Replacement

    Equally turn each Adjustment Screw counter-clockwise until the burn line is positioned past the platen roller apex. Print a Validation Label; see Section 4.3.4. (The print on the label should have a light, uneven appearance.) D. Tighten the Locking Screws just enough to remove any play in the printhead assembly, while leaving them loose enough to allow for adjustment.
  • Page 85 C. With the printhead locked in the down position, loosen the Printhead Mounting Screw (it will remain in the assembly). D. Rotate the printhead latch forward and, while supporting the Printhead, raise the Printhead Assembly. Disconnect the Cables and then remove the Printhead. E.

  • Page 86: Maintenance

    5.6 Maintenance The following list and table detail the recommended items, techniques, and schedules to help you safely and effectively maintain the printer: Isopropyl alcohol • Cotton swabs • A clean, lint-free cloth • Soft-bristle brush • Soapy water/mild detergent •...

  • Page 87: Cleaning The Printhead

    5.6.1 Cleaning the Printhead NEVER use a sharp, hard or abrasive object on the printhead. CAUTION If print quality declines the typical cause can be traced to debris buildup on the printhead; left unattended, the printhead service life can be reduced. The printer can be programmed to remind you to perform cleaning (see Section 4.2.2.) Depending upon the media and printing parameters used, different cleaning methods are recommended.
  • Page 88 B. Move media (and ribbon, if present) away from the printhead, as necessary. Using a cotton swab moistened (not soaked) with isopropyl alcohol, gently wipe away buildup on the Printhead while paying special attention to cleaning the Burn Line. Allow the printhead to dry.

  • Page 89: Cleaning The Platen Roller

    5.6.2 Cleaning the Platen Roller NEVER use a sharp object to clean the Platen. CAUTION Grit, adhesive, and ink buildup can cause a decline in print quality and, in extreme cases, cause labels to stick and wrap around the roller. Clean the platen roller as follows: A.

  • Page 90: Cleaning Interior And Exterior Surfaces

    5.6.3 Cleaning Interior and Exterior Surfaces Interior Surfaces – Turn OFF and unplug the printer. Remove all media. Then, using a soft bristle brush or compressed air, remove all dust particle buildup inside the printer. Exterior Surfaces – Turn OFF and unplug the printer. Remove all media. Then, using a soft cloth or sponge dampened with general-purpose cleanser (never abrasive cleansers or solvents) wipe the exterior surfaces until clean.
  • Page 91 5.7.1 Updating from Ready Mode Application Version 2.091 (or greater) Update Procedure Step Displayed Message Action Comment(s) As an example, this would Using the DOS copy be entered as: command (where “filename” is the program copy i4212_1105.zg lpt1 to be loaded and “lpt1” is the selected interface READY (Where “lpt1”...

  • Page 92: Updating From Download Mode

    5.7.2 Updating from Download Mode Application Version 2.08 (or less) Update Procedure* Step Displayed Message Action Comment(s) The Boot Loader version is Turn OFF the printer. displayed. BOOT–PA10 Press and hold the PAUSE Note: This information will 02.08 2/11/00  Key and TEST Key while vary with the printer model and turning ON the printer.

  • Page 93: Possible Problems

    5.7.3 Possible Problems The following is list of possible error messages when downloading updates: Application Update Error Messages Displayed Message Descriptions / Causes / Solutions The printer detected an error during the decompression and transfer of file data from cache storage into the Flash DECOMPRESSION ERROR memory.

  • Page 94: Boot Loader Updates

    5.8 Boot Loader Updates The printer stores its Boot Loader program in Flash memory on the main logic card. As available, updates can be found on our web site at ftp://ftp.datamax-oneil.com and then installed in the printer. If power is lost while UPGRADING SOFTWARE is displayed, the printer will become non-functional and will require factory programming or a main logic card.
  • Page 95 I-Class...

  • Page 96: Troubleshooting

    Troubleshooting 6.1 Problem Resolution When a problem is encountered, the information in this section will help resolve it. Locate the description of the problem to find an appropriate solution. For problems that are accompanied by a displayed message, see Section 6.1.2. Note: If you have questions, or if problems persist, contact a qualified technician or ...
  • Page 97 General Resolutions (continued) If experiencing this Try this solution… problem… Erratic media The printer may require a calibration – See Section 3.5. movement: The printer may be in Hex Dump Mode – See Section 6.2. • Erratic printing (instead of the label format, If using the serial communication the port settings may be •...
  • Page 98 General Resolutions (continued) If experiencing this Try this solution… problem… The LCD is off, but The Display Contrast may set too low – Press and hold the indicator lights are MENU Key; see Section 4.1.1. illuminated: Verify that the AC power cord is connected to the outlet and •...
  • Page 99 General Resolutions (continued) If experiencing this Try this solution… problem… Ensure that the printer is at READY. • Send the job again while observing the Ready Indicator • Nothing happens when (see Section 4.1.1.) – If the indicator does not flash, check printing from your the printer and host for protocol and port settings.

  • Page 100: Warning And Fault Messages

    6.1.2 Warning and Fault Messages The printer displays messages when the possibility of a problem or an actual fault occurs. Depending upon the displayed message, find the possible action or solution in the tables below. Note: Warning and Fault Messages do not appear in Menu or Test Mode. ...
  • Page 101 Warning Messages (continued) Warning Messages Displayed Message Description Action(s) Possible low or fluctuating line • voltage level – Try moving the printer to another AC outlet; if the condition persists, call for service. The printer has detected LOW VOLTAGE a low operating voltage. If printing black over more •...
  • Page 102 Fault Messages (continued) Fault Messages Displayed Message Description Action(s) WARNING! Use extreme care. Turn OFF and unplug the printer before proceeding. The printer has detected Examine the cutter for CUTTER FAULT a cutter mechanism obstructions and ensure its cable fault. is properly connected.
  • Page 103 Fault Messages (continued) Fault Messages Displayed Message Description Action(s) Try the following procedures: Load media. Ensure that the • labels are passing through the Media Sensor and, if necessary, readjust the Media The printer cannot detect Sensor over the TOF mark; OUT OF STOCK media.
  • Page 104 Fault Messages (continued) Fault Messages Displayed Message Description Action(s) Press any key to continue. Ensure that the reflective mark is inserted facedown in the media sensor during calibration; also, REFLECTIVE MODE Consistently low sensor ensure that the reflective mark is CANNOT CALIBRATE...
  • Page 105 Fault Messages (continued) Fault Messages Displayed Message Description Action(s) Press the FEED Key to clear. If the bar code is free from anomalies (e.g., voids, insufficient quiet zones, etc.) yet the fault continues, try the following: 1) Ensure that the bar code is capable of being read by the scanner;...
  • Page 106 Fault Messages (continued) Fault Messages Displayed Message Description Action(s) If media is moving: 1) Press the FEED Key. It may be necessary to re-calibrate the printer; see Section 5.2. 2) The Media Sensor may be out of position. Readjust it; see Section 3.3.

  • Page 107: Hex Dump Mode

    6.2 Hex Dump Mode Hex Dump Mode is a useful tool for diagnosing problems, including communication and syntax errors, allowing a comparison of input strings (sent by host) to output data (received by printer). To decode this information, the Class Series 2 Programmer’s Manual is an essential reference.

  • Page 108: Specifications

    Specifications 7.1 General Bar Codes Code 39, Interleaved 2 of 5, Code 128 (subsets A, B and C), Codabar, LOGMARS, UPC-A, UPC-E, UPC 2 & 5 digit addendums, EAN-8, EAN-13, EAN 2 & 5 digit addendums, UPC Random Weight, Code 93, Plessey, Universal Shipping Container Symbology, Code 128 MOD 43, Postnet, USS/EAN-128 Random Weight, Telepen, USD-8 (Code 11), UPS MaxiCode (modes 2 &...
  • Page 109 Environmental Operating Temperature: 32 F – 100 F (0 C to 38 C) Storage Temperature: 0° F – 140° F (-17° C to 60° C) Humidity: 10% – 95% non-condensing Dust: Non-conducting, non-corrosive Electromagnetic Radiation: Moderate RF fields can be tolerated Mechanical Height: 12.70 inches (322.6 mm)
  • Page 110 Printing (continued) Maximum Print Width: 4.10” (104.0 mm): I-4206, I-4208, I-4212 4.16” (105.7 mm): I-4308 4.10” (104.0 mm): I-4406 4.16” (105.7 mm): I-4604 Print Length Range: .25”- 99” (6.4 - 2514.6 mm): I-4206, I-4208, I-4212, I-4308 .25”- 84” (6.4 - 2133.6 mm): I-4406 .25”- 55”...

  • Page 111: Approved Media And Ribbon

    7.2 Approved Media and Ribbon To achieve optimum print quality and maximum printhead life, DATAMAX-O’NEIL brand media and ribbons must be used. These supplies are specially formulated for use in this printer. The use of non-Datamax-O’Neil supplies may affect the print quality, performance, and life of the printer or its components (see the Warranty Statement).

  • Page 112: Media And Ribbon Requirements

    7.2.2 Media and Ribbon Requirements Suggested applications are listed in the following table (and for specific information consult a Datamax-O’Neil Media Representative or other qualified specialist): Media and Ribbon Overview Ribbon Print Print Image Thermal Transfer Type Speed* Energy Durability Great Label TTL GPR Plus 10 –...
  • Page 113 Dimensional Requirements are listed in the following table: Side View Top View Media Dimensional Requirements Designator Description Minimum Maximum Label width 1.00 4.65 Liner width 1.00 4.65 Gap (or notch) between labels – Label length – Media thickness .0025 .010 Notch opening width .500 Media edge to sensor aperture distance...

  • Page 114: Serial Cable Requirements

    7.3 Serial Cable Requirements Wiring diagrams, suggested applications, and part numbers for serial interface cables are given in the table below. (Contact a reseller for ordering information.) Applicable Serial Interface Cables Null Modem (MXM) “PC” (DB9P) to Printer Part Number 556000 Part Number 556001 For connection to a PC compatible with For connection to other DCE equipment.
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  • Page 116: Appendix A

    Appendix A Module Assignments Memory Module Designator Module Size Volatile* Location / Use 1024 KB Main logic card SDRAM – for graphics, fonts, and (default size) formats Optional GPI/O Multi-Expansion Card – for 4 MB graphics, fonts, and formats Main logic card Flash – for graphics, fonts, and 256 KB formats (all models except I-4206 and I-4208).

  • Page 117: Available Speeds And Default Settings

    Available Speeds and Default Settings Printer Speed Ranges and Defaults* Speed Range Default Setting Model Function MMPS MMPS Print 2 – 6 51 – 152 Feed 2 – 8 51 – 203 I-4206 Reverse 2 – 4 51 – 102 Slew 2 –...

  • Page 118: Appendix B

    Appendix B Custom Adjustment Ranges Row, Column, and Present Adjust Ranges (in dots) Column Adjust, Default Model Row Adjust and Present Adjust Setting I-4206, I-4208, & I-4212 -100 – 2030 -100 – 100 I-4308 -150 – 3000 -150 – 150 I-4406 -200 –...
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  • Page 120: Appendix C

    Appendix C Menu Multi-Language Support The printer allows new menu languages and / or replacement of the Datamax-O’Neil provided translations. A Microsoft Excel Spreadsheet defines the menu dictionary and a new language column is added or an existing column modified. Then, by clicking on the “Generate DPL file(s)”...
  • Page 121 Creating a Menu Language:  Invoke Excel and open the gemmsglst.xls file. Excel opens the file and the following screen appears.  Click the “Enable Macro” box and the following appears: Click On Column J and enter your new language, or modify an existing one. Tips: A) Message Size –...
  • Page 122 C) Comments – This field can be modified with no effect.  When editing has been completed, highlight all of the columns you desire to create (more than one language may be selected) by pressing the letter above the column. ...

  • Page 123: Advanced File Handling Information

    Contact Datamax-O’Neil Technical Support if problems continue (be prepared to provide the Gemmsglst.xls and the DPL download file that you have created). Other possible error messages are as follows: Menu Language Error Message Description Please select the entire column(s) or the After pressing the Generate DPL File(s) desired language(s), by clicking on the radio button, the languages to convert...

  • Page 124: Appendix D

    Appendix D Configuration Files With application version 5.01 and above, the printer can save and restore complete printer settings, including media calibration parameters, in internal Configuration Files. Here are the highlights and restrictions of the feature: Eliminates the need to repeat the manual steps of a special printer setup, making •...
  • Page 125 Follow the steps below to save a manually entered setup as a configuration file: Step Displayed Message Action Comment You are entering MENU READY Press the Key. MODE. Use the Key to Key can also MENU MODE scroll to SYSTEM be used.

  • Page 126: Appendix E

    Appendix E Printer Driver and Port Setup Install the Printer Driver and Port software according to the host’s operating system. The example below highlights the driver Windows XP; other installations will be similar. installation for Windows XP Driver and Port Installation Start the Windows Ensure that Local “Add Printer...
  • Page 127 Windows XP Driver and Port Installation (continued) In the Printer Name Ensure Standard is or IP Address field selected and then enter the IP click Next. address of your printer. The Port Name field does not need to be changed. When finished click “Next”.
  • Page 128 Windows XP Driver and Port Installation (continued) Click OK. Select your printer from the list and then click Next. Name your printer Select whether or in the Printer not to share this name: field. Next printer on your select whether or network.
  • Page 129 Windows XP Driver and Port Installation (continued) If prompted with Your computer will the "Digital now copy the Signature Not necessary files from Found" window, the CD-ROM. click “Continue The driver and port Anyway” to installation is now continue complete. The installation.

  • Page 130: Glossary

    Glossary alphanumeric Consisting of alphabetic, numeric, punctuation and other symbols. backing material The silicon-coated paper carrier material to which labels with adhesive backing are affixed (also referred to as “liner”). bar code A representation of alphanumeric information in a pattern of machine-readable marks.
  • Page 131 DPI (dots per inch) A measurement of print resolution, rated in the number of thermal elements contained in one inch of the printhead (also referred to as “resolution”). DPL (Datamax-O’Neil Programming Language) programming commands used specifically for control of and label production in Datamax-O’Neil printers. A complete listing of commands can be found in the Class Series 2 Programmer’s Manual.
  • Page 132 on demand An output regulator (i.e., the Present Sensor) that inhibits printing when a label is already present. preprinted media Label stock that contains borders, text, or graphics, floodcoating, etc. perforation Small cuts extending through the backing and/or label material to facilitate their separation (also referred to as “perf”).

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