Datamax A-Class Mark II User manual

Operator’s Manual

Copyright Information:
CG Times (based upon Times New Roman) and CG Triumvirate are trademarks of the AGFA
Monotype Corporation.
Windows and Windows NT are trademarks of the Microsoft Corporation.
NetWare and Novell are registered trademarks of Novell, Inc.
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.
Firmware (Software) Agreement:
The enclosed Firmware (Software) resident in the Printer is owned by Licensor or its suppliers and
is licensed for used only on a single printer in the user’s Trade or Business. The User agrees not
to, and not to authorize or permit any other person or party to duplicate, or copy the
Firmware or the information contained in the non-volatile or programmable memory. The
firmware (Software) is protected by applicable copyright laws and Licensor retains all rights not
expressly granted. In no event will Licensor or its suppliers be liable for any damages or loss,
including direct, incidental, economic, special, or consequential damages arising out of the use or
inability to use the Firmware (Software).
Information in this document is subject to change without notice and does not represent a
commitment on the part of Datamax-O’Neil Corporation. No part of this manual may be reproduced
or transmitted in any form or by any means, for any purpose other than the purchaser's personal
use, without the expressed written permission of Datamax-O’Neil Corporation.
All rights reserved.
© Copyright 2009 by Datamax-O’Neil Corporation
Part Number: 88-2349-01
Revision A

Agency Compliance and Approvals:
C US
Listed
UL60950-1 First Edition, Information Technology Equipment
CSA C22.2 No.60950-1-03, First Edition
IEC 60950-1, 2001, First Edition
The manufacturer declares under sole responsibility that this product
conforms to the following standards or other normative documents:
EMC: EN 55022 (2006,A1:2007) Class B
EN 50024 (1998,A1:2001,A2:2003)
Safety: This product complies with the requirements of
IEC 60950-1, 2001, First Edition
GB4943-2001, GB9254-1998 and GB17635.1-2003
FCC: This device complies with FCC CFR 47 Part 15 Class A.
Note: This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio
frequency energy, and if not installed and used in accordance with the instructions in this
manual, it may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.

Important Safety Instructions:
Throughout the literature accompanying this unit, the exclamation point within
an equilateral triangle is intended to alert the user to the presence of important
operating and maintenance instructions.
This unit has been carefully designed to provide years of safe, reliable performance. However, as
with all electrical equipment, there are some basic precautions that you should follow to avoid
personal injury or damage to the printer:
• Before using the print engine, carefully read all the installation and operating
instructions.
• Moving parts are present during operation – keep body parts, loose clothing, etc. away
from the mechanism.
• Observe all warning instruction labels on the print engine.
• Mount the print engine securely in the applicator system.
• Do not place the print engine on or near a heat source.
• To protect from overheating, make sure no openings on the print engine are blocked.
• Never insert anything into the ventilation slots and openings of the print engine.
• Do not use the print engine near water or spill liquid into it.
• Ensure that the AC power source complies with the ratings listed for the print engine.
• Do not place the AC power cord where it can be stepped on. If the AC power cord
becomes damaged, replace it immediately.
• Consult only qualified, trained personnel to perform service on this print engine. There
are no user-serviceable parts are inside; do not remove the cover.
Special Instructions

The green check box is intended to alert the user to conventions used within this
text or to notable operating details and suggestions.

i
Contents
1 Overview ...................................................................................... 1
1.1 About the Printer ................................................................................................1
1.1.1 Standard Features.....................................................................2
1.1.2 Optional Features......................................................................3
2 Getting Started............................................................................. 5
2.1 Unpacking..........................................................................................................5
2.1.1 Contents..................................................................................6
2.1.2 Additional Requirements ............................................................6
2.2 Mounting Requirements.....................................................................................7
2.3 Host Connections.............................................................................................11
2.3.1 Parallel Port Connections.......................................................... 12
2.3.2 Serial Port Connections ............................................................ 12
2.3.3 RS-422/485 Communications ................................................... 13
2.3.4 USB Port Connections .............................................................. 15
2.3.5 Connecting to the SDIO Slot and USB Host Ports ......................... 15
2.4 Connecting an Applicator.................................................................................16
2.5 Connecting Power............................................................................................17
3 Setting up the Printer................................................................. 18
3.1 Loading Media....................................................................................................18
3.2 Adjusting the Media Sensor .............................................................................22
3.3 Loading Ribbon................................................................................................23
3.3.1 Right Hand Models .................................................................. 23
3.3.2 Left Hand Models .................................................................... 25
3.3.3 Removing Ribbon .................................................................... 26
3.4 Quick Calibration..............................................................................................27
3.5 Print Quality Controls .......................................................................................27

ii
4 Using the Control Panel .............................................................. 28
4.1 Layout ..............................................................................................................28
4.1.1 The Display ............................................................................ 28
4.1.2 Keypad Functions.................................................................... 30
4.2 The System Menu............................................................................................31
4.2.1 Media Settings........................................................................ 32
4.2.2 Print Control........................................................................... 35
4.2.3 Printer Options ....................................................................... 37
4.2.4 System Settings ..................................................................... 45
4.2.5 Communications ..................................................................... 55
4.2.6 Diagnostics ............................................................................ 63
4.2.7 MCL Options........................................................................... 66
4.3 The Test Menu.................................................................................................67
4.3.1 Print Quality Label................................................................... 67
4.3.2 Ribbon Test Label ................................................................... 68
4.3.3 Test Label .............................................................................. 68
4.3.4 Validation Label ...................................................................... 68
4.3.5 Print Configuration .................................................................. 69
4.3.6 Print Last Label....................................................................... 69
4.3.7 User-Defined Label.................................................................. 69
5 Operating, Adjusting and Maintaining the Printer....................... 71
5.1 Displayed Messages........................................................................................71
5.1.1 Prompts and Condition Messages .............................................. 71
5.2 Calibration........................................................................................................74
5.2.1 Standard Method .................................................................... 74
5.2.2 Advanced Entry ...................................................................... 76
5.3 Printhead Adjustments.....................................................................................83
5.3.1 Leveling Cam Adjustment......................................................... 83
5.3.2 Burn Line Adjustment .............................................................. 85
5.4 Printhead Replacement....................................................................................86
5.5 Platen Roller Replacement...............................................................................89

iii
5.6 Maintenance Schedule.....................................................................................90
5.6.1 Cleaning the Printhead............................................................. 91
5.6.2 Cleaning the Rollers ................................................................ 93
5.6.3 Cleaning the Peel Assembly ...................................................... 94
5.6.4 Cleaning the Media Sensor, Media Path, and Peel Bar ................... 96
5.6.5 Cleaning Exterior Surfaces ....................................................... 97
5.7 Reset Methods.................................................................................................97
5.7.1 Soft Reset.............................................................................. 97
5.7.2 Level One Reset...................................................................... 97
5.7.3 Level Two Reset...................................................................... 97
5.8 Updating the Firmware.....................................................................................98
5.9 Updating the Boot Loader ..............................................................................100
5.10 Downloading Fonts ........................................................................................101
6 Troubleshooting ....................................................................... 104
6.1 Problem Resolution........................................................................................104
6.1.1 General Resolutions............................................................... 104
6.1.2 Warning and Fault Messages................................................... 108
6.2 Hex Dump Mode............................................................................................115
7 Specifications ........................................................................... 117
7.1 Printer Specifications......................................................................................117
7.2 Approved Media and Ribbon..........................................................................122

iv
Appendix A ................................................................................... 125
Module Assignments..............................................................................................125
File Handling Messages.........................................................................................125
Cut Behind Setup...................................................................................................127
Appendix B ................................................................................... 129
Print Resolutions and Widths.................................................................................129
Speed Ranges .......................................................................................................129
Column & Row Emulation Ranges.........................................................................130
Custom Adjustments:.............................................................................................130
Column, Present, & Row Adjust Ranges................................................................130
Appendix C ................................................................................... 131
PE Peel Bar Location.............................................................................................131
PE to A-Class GPIO Adapter Cable.......................................................................131
Appendix D ................................................................................... 133
Applicator Interface Overview ................................................................................133
Appendix E.................................................................................... 141
Multi-Language Menu.............................................................................................141
Appendix F.................................................................................... 145
Saving a Configuration File....................................................................................145
Appendix G ................................................................................... 147
Ribbon Saver Overview..........................................................................................147
Warranty ...................................................................................... 149
Glossary........................................................................................ 151

A-Class 1
1 Overview
1.1 About the Printer
Congratulations on your purchase of an A-Class Mark II printer. This print engine (hereafter
referred to as “the printer” and, when necessary, by model) is designed for professional integration
into an industrial applicator system.
This manual provides all the information necessary for installation, setup and operation of the
printer. To begin printing, refer to the instructions provided with your label-creation software; or,
to write custom label programs, reference the Class Series 2 Programmer’s Manual on the
Accessories CD-ROM, also available at http://www.datamax-oneil.com
The printer’s model number, located on the Serial Tag affixed to the inside of the front cover,
should be used when referencing specific information within this manual.

2A-Class Mark II
1.1.1 Standard Features
This printer offers the following standard features:
• Right-handed or left-handed configurations
• Electronics card cage
• 8 MB Flash downloadable program memory
• 16 MB DRAM memory
• Host computer accessible memory for object temporary storage
• Two RS-232 serial interfaces (one of which is also RS-422/RS-485 capable)
• One IEEE 1284 compliant parallel interface
• One Ethernet 10/00 interface
• One USB v1.1 interface
• A programmable GPIO Port
• Backlit graphics display
• EFIGS (English, French, Italian, German, and Spanish) display languages
• Industry standard bar code symbologies
• Time stamp at print capability with time and date battery back-up
• Static brushes
• Printhead resistance verification
• Configurable fault-handling capability with reprint and void selections
• Parse error-tolerant command language interpretation
• Internal test labels for verification, validation, and configuration
• Multiple setup restore capability
• Paper retract control after print
• Ribbon low detection and warning
• Power-up, mode, and resident option hardware diagnostics
• Option hardware auto-detection
• Media peel bar
• Media inch counters
• Input line mode (ASCII text input) capability
• Firmware upgrades downloadable
• AGFA Scaleable Font Engine featuring dynamic font attributes

A-Class 3
1.1.2 Optional Features
The following optional features are available:
• DMXrfNetII
A wireless Network Interface Controller with multiple operating system and protocol support,
including trap functions.
• SDIO Interface and USB Host Ports
An interface that accepts external memory storage devices for fonts, graphics, label formats,
and firmware; as well as a port that can accept a USB keyboard for direct data input
applications (e.g., Line Mode).
• International Language Printing Capability (ILPC)
An alternate font set, available for standard or expanded memory:
CG-Times (European) Scaleable font (and Enhanced Language Code Pages)
Kanji Gothic B Scaleable font
Simplified Chinese GB Scaleable font
Korean Hangul Scaleable font
• Linerless Cutter
A mechanism specifically designed to cut linerless media after printing.
• MCL
A software tool suite for information collection applications, allowing input data from peripheral
devices (scanners, weigh scales, keyboards, etc.) without the need of a host computer.
• Remote Display
A factory installed port located on the rear of the printer assembly allowing a remote display to
be attached.
• RFID
A Radio Frequency Identification method that encodes data onto smart labels and tags;
available completely installed and ready for use.
• Thermal Transfer
A printing method that uses ribbon to produce exceptional image clarity (as compared to most
direct thermal media types).
• Rear Pinch Roller
Improves top of form accuracy when using large back feeds.

4A-Class Mark II
Installing Printer Options
The table below lists competency level recommendations for the installation of the various options.
For detailed information regarding an option, contact a dealer or Datamax-O’Neil Technical
Support.
Experience Level
Option Installer
DMXrfNetII DMX Certified Technician
SDIO Interface and USB Host Ports Factory Only
Linerless Cutter DMX Certified Technician
MCL DMX Certified Technician
Remote Display Port Factory Only
RFID Factory Only
Ribbon Saver Factory Only
Thermal Transfer Factory Only
Rear Pinch Roller Factory Only

A-Class 5
2 Getting Started
2.1 Unpacking
The printer is carefully packaged for transit. Upon arrival, inspect the shipping carton(s) for
damage; if evident, immediately report the damage to the freight company.
In order to operate the printer, remove all packaging material:
1. With the Shipping Carton arrows pointing upward, open the Shipping Carton and remove the
Accessories Box and the Top Foams.
2. Carefully lift the wrapped Printer from the carton and place it on a solid level surface.
Accessories Box
Printer
Shipping Carton
Top Foam
Bottom Foam Top Foam
Bottom Foam
3. Remove the Printer from the plastic bag and then remove all remaining packing materials.

Save the carton and packing material for future use.

6A-Class
2.1.1 Contents
Check the contents of the carton for the following items:
• Printer
• Power cord
• Accessories CD-ROM
• Any additionally purchased items or options.
2.1.2 Additional Requirements
Other items can also be needed for operation:
• Media (and ribbon, if necessary); see Section 7.2.
• Interface cables; see Section 2.3 (Host Connections) and
Appendix D (Applicator).
• Software; see the Accessories CD-ROM for Windows
Drivers and basic labeling software.

A-Class 7
2.2 Mounting Requirements
Before installing the printer, ensure that the environmental conditions of the site fall within the
range specified in Section 7, and always avoid the following environments:
• Do not place the printer in direct sunlight or near a heat source; and,
• Do not place the printer where it will be exposed to liquids, or excessive dust or dirt.
Consider the dimensions of the printer before attaching it to the applicator station. The template
below details the opening size and hole locations required for the support structure:
Attach the printer to the support structure using
a #10 screw inserted at each Mounting Hole
position (see note below).
Mounting Holes

The following drawings detail additional mounting considerations:

8A-Class
A-4xxx models
Front View, Peel Assembly lowered:
9.67”
(246mm)
11.81”
(300mm)
2.25”
(57mm)
Side View:
10.45”
(266mm)
7.68”
(195mm)
15.35”
(390mm)
Side View, Cover raised:
7.66”
(195mm)
12.51”
(318mm)
20.17”
(512mm)

A-Class 9
A-6xxx models
Front View, Peel Assembly lowered:
9.67”
(246mm)
11.81”
(300mm)
2.25”
(57mm)
Side View:
9.68”
(246mm)
17.35”
(441mm)
10.45”
(266mm)
Side View, Cover raised:
14.51”
(369mm)
7.66”
(195mm)
22.17”
(563mm)

10 A-Class
Peel Point Dimension

See Appendix C for the PE-Series printer’s dimension.
Peel Bar