Avery Weigh-Tronix BP-545D Series User manual

BP-545D Series
USER’S
MANUAL
DIRECT THERMAL BAR CODE PRINTER

i
COMPLIANCES ......................................................................................................................... 1
1. Introduction ................................................................................................................. 3
2. Getting Started ............................................................................................................ 3
2.1 Unpacking and Inspection ...................................................................................... 3
2.2 Equipment Checklist............................................................................................... 3
2.3 Printer Parts............................................................................................................ 5
2.3.1 Front View ....................................................................................................... 5
2.3.2 Rear View........................................................................................................ 5
3 Setup ............................................................................................................................. 6
3.1 Setting Up the Printer ............................................................................................. 6
3.2 Loading Label Stock ............................................................................................... 7
3.3 Peel-Off Installation Assembly (Option) ................................................................. 9
3.4 Loading Label for Peel-off Mode (Option) ............................................................ 12
3.5 External Label Roll Mount Installation (Option).................................................... 14
3.6 Cutter Module Installation (Option)....................................................................... 15
3.7 Loading Label in Cutter Mode .............................................................................. 18
3.8 Internal Ethernet Print Server Module Installation (Option).................................. 19
3.9 Diagnostic Tool..................................................................................................... 22
3.9.1 Start the Diagnostic Tool ............................................................................... 22
3.9.2 Printer Function (Calibrate sensor, Ethernet setup, RTC setup………)........ 23
3.10 Setting Ethernet by Diagnostic Utility (Option) ................................................... 24
3.10.1 Using USB interface to setup Ethernet interface ........................................ 24
3.10.2 Using RS-232 interface to setup Ethernet interface ................................... 25
3.10.3 Using Ethernet interface to setup Ethernet interface .................................. 26
3.11. Install Memory Card .......................................................................................... 28
4. Power on Utilities...................................................................................................... 30
4.1 Gap/Black Mark Sensor Calibration ..................................................................... 30
4.2 Gap/Black Mark Calibration, Self-test, Dump Mode............................................. 31
4.3 Printer Initialization ............................................................................................... 34
4.4 Set Black Mark Sensor as Media Sensor and Calibrate the Black Mark Sensor. 35
4.5 Set Gap Sensor as Media Sensor and Calibrate the Gap Sensor....................... 35
4.6 Skip AUTO.BAS ................................................................................................... 35
5. Maintenance .............................................................................................................. 36
5.1 Cleaning................................................................................................................ 36
Contents

ii
6. Troubleshooting........................................................................................................ 38
6.1 LED Status ........................................................................................................... 38
6.2 Print Quality .......................................................................................................... 39
7. LED and Button Operation....................................................................................... 40
7.1 LED....................................................................................................................... 40
7.2 Button Operation .................................................................................................. 40
Revise History ............................................................................................................... 44

2
CAUTION
1. HAZARDOUS MOVING PARTS IN CUTTER MODULE. KEEP FINGER AND OTHER BODY
PARTS AWAY.
2. THE MAIN BOARD INCLUDES REAL TIME CLOCK FEATURE HAS LITHIUM BATTERY
CR2032 INSTALLED. RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN
INCORRECT TYPE.
3. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER INSTRUCTIONS.

3
1. Introduction
Thank you for purchasing the BIRCH BP-545DSeries Direct Thermal Bar Code Printer.
Although it is a compact desktop printer, it is reliable and with superior throughput
performance.
This printer provides both thermal transfer and direct thermal printing at user selectable
speed of: 2.0, 3.0, 4.0 or 5.0 inches per second. It accepts roll feed, die-cut, and fan-fold
labels for both thermal transfer and direct thermal printing. All common bar codes
formats are available. Fonts and bar codes can be printed in 4 directions, 8 different
alphanumeric bitmap fonts and a build-in true type font capability. You will enjoy high
throughput for printing labels with this printer.
2. Getting Started
2.1 Unpacking and Inspection
This printer has been specially packaged to withstand damage during shipping. Please
carefully inspect the packaging and printer upon receiving the bar code printer. Please
retain the packaging materials in cover you need to reship the printer.
2.2 Equipment Checklist
Printer
BarTender UltraLite CD disk
Quick start guide
USB port cable
External universal switching power supply
Power Cord
Label Spindle
Fixing tab x2
1.5” core adapter x2
If any parts are missing, please contact the Customer Service Department of your
purchased reseller or distributor.

4
Dealer option
Peel off module assembly.
Guillotine cutter
Full cut: Paper thickness: 0.06~ 0.19mm, 500,000 cuts
Partial cut: Paper thickness: 0.06~0.12mm, 500,000 cuts
Paper thickness: 0.19mm 200,000 cuts
Main board integrated with internal Ethernet
Internal Ethernet print server module
User option
K-012A Smart Keyboard Display Unit (KDU)
External Ethernet print server
 External wireless (802.11b/g) print server
 External roll mount, media OD. 214 mm (8.4”) with 3” core label spindle
 Barcode Scanner

5
2.3 Printer Parts
2.3.1 Front View
Fig.1 Top Front View
2.3.2 Rear View
1 2 345
6
1. USB Interface
2. Cen tronics Interface
3. RS-232C DB-9 Interface
4. Po wer Jack
5. Po wer Switch
6. Rear Label Guide
Top Cover Open Lever
LED Indicator
Feed Button
Top Cover
Clear Window
Backing Paper Opening
Label Opening
Front Panel
Fi
g
.2 Rear View

6
3 Setup
3.1 Setting Up the Printer
1. Place the printer on a flat, secure surface.
2. Make sure the power switch is off.
3. Connect the printer to the computer with the Centronics or USB cable.
4 Plug the DC power cord into the power jack at the rear of the printer, and then
plug the AC power cord into a properly grounded receptacle.
Fig. 5 Attach a power supply to a printer
Power Cord
Power Switch
Power Supply
Plug
USB
RS-232C
Centronics
Power Jack

7
3.2 Loading Label Stock
1. Insert a 1” label spindle into a paper roll (If your paper core is 1 inch, remove the 1.5
inch core adapter from the fixing tab).
Fig 6 Label roll installation (I)
2. Open the printer’s top cover by releasing the green top cover open levers located
on both sides of the printer and lifting the top cover.
3. Place a roll of paper into internal paper roll mount.
4. Feed the paper, printing side face up, through the label guides and place the label
over the platen.
5. Adjust the black center-biased label guides in or out by turning adjustment knob so
they are slightly touch the edges of the label backing.
Fig. 7 Label roll installation (II)
Label Roll
1” Label Spindle
Label Roll Mount
Platen
1.5” Core Adapter
Adjustment Knob
Fixing Tab
Label Guide
Printing Side Face up

8
6. Close the printer top cover slowly and make sure the cover locks levers securely.
Note: Failure to securely close and lock the cover will result in poor print
quality.
Fig. 8 Close the top cover completely

9
3.3 Peel-Off Installation Assembly (Option)
1. Open the top cover.
2. Unscrew the 6 screws in the lower inner cover.
3. Upside down the printer.
4. Unscrew the 2 screws at the lower inner cover
5. Remove the screw at memory card cover.
Remove the
screw
Remove the
screw
Screw
Screws Screws

10
6. Hold the lower cover and lift up the top cover opening levers to separate the lower
inner cover from the lower cover.
7. Thread the harness red connector through the cable hole at the front side of lower
inner cover. Plug the red peel off module harness connector at the location JP17
(%3 ') / JP19 (%P-45') on the main board. Place lower inner cover to the
lower cover. Install the peel-off module to the lower inner cover slot.
8. Gently push peel-off panel to lock to the lower inner cover.
9. Reassemble parts in reverse procedures after installing the module.
Lower inner
cover
Lower cover
Peel-off module
assembly
Install one side first
and install another
side

11

12
3.4 Loading Label for Peel-off Mode (Option)
1. Open the peel-off module by pulling it out.
Fig. 9 Open the peel-off panel
2. Thread the label, printing side facing up, through the label guides and place it on top
of the platen.
3. Thread the label through the liner opening, which is beneath the roller.
4. Adjust the black center-biased label guides by turning adjustment knob to fit the
edge of the label backing.
Fig. 10 Loading label for peel-off mode
5. Push the peel-off panel back to the printer.
6. Close the top cover.
Peel-off Panel
Peel-off Roller
Roller
Adjustment Knob
Peel-off panel

13
Fig. 11 Label loaded completely in peel-off mode

14
3.5 External Label Roll Mount Installation (Option)
1. Attach an external label roll mount on the bottom of the printer.
2. Install a roll of label on the external label roll mount.
Fig. 12 External label roll mount installation (I)
3. Feed the label to the external label feed opening through the rear label guide.
Fig. 13 External label roll mount installation (II)
4. Open the printer top cover by pulling the top cover open levers.
5. Thread the label, printing side face up, through the label guide and place it on top the
platen.
6. Adjust the label guides by turning adjustment knob to fit the edge of the label
backing.
7. Close the printer top cover.
External Label
Roll Mount
Label
External Label
Feed Opening
Rear Label Guide

15
3.6 Cutter Module Installation (Option)
1. Pull the top cover open levers to open the top cover.
2. Remove the front panel from the lower cover.
3. Remove 6 screws on the lower inner cover.
Fig. 14 Remove 6 screws from lower inner cover
4. Upside down the printer.
5. Remove two screws at the hinge
6. Remove the screw that fixes the memory card cover.
Screws Screws
Screw

16
7. Plug in the Cutter Driver IC at U14(%P-45') / U30(%P-45') socket on the
main board.
%P-5' Model %P-45' Model
Note:
For Non-RoHS PCB, use cutter driver IC A3952SB
For RoHS PCB, use cutter driver IC A3953SB
8. Hold the lower cover and lift up the lower inner cover.
9. Arrange the cutter module harness through the bezel.
10.Connect the cutter module harness to the 4-pin socket on printer PCB.
Fig. 16 Cutter module harness arrangement
11.Reassemble lower inner cover back to the lower cover.
12.Install the cutter module into the niche of the printer.
Bezel
Socket
Cutter Driver IC

17
13.Ressemble the parts in the reverse order.
14.Close the top cover.
Niche