Microcom 400 User manual

MICROCOM CORPORATION
MODEL 400
DIRECT THERMAL PRINTER
OPERATOR'S MANUAL
Part Number 880014-0220
March 1999 Software Version 2.2

Operator's Manual
400 Direct Thermal Printer
- Revised March 23, 1999 MSG -
HP and LaserJet II are trademarks of Hewlett-Packard Company.
FastFont is a trademark of Page Technology Marketing, Inc.
Microsoft, Windows, Windows NT are registered trademarks of Microsoft Corporation
Other products, names, and brands are trademarks of their respective holders.
FastFont Typefaces are Copyright ©1993, Page Technology Marketing, Inc.
This manual is subject to change without notice.
Copyright ©1994-1999 Microcom Corporation, Westerville, Ohio - All rights reserved.
Printed in the United States of America

400 Operators Manual
Table of Contents
List of Tables .............................................................vii
List of Figures .............................................................vii
Introduction ................................................................1
CHAPTER 1: FEATURES AND SPECIFICATIONS .................................3
1.1 SPECIAL FEATURES ............................................3
1.2 BAR CODES ...................................................3
1.3 FONTS .......................................................4
1.4 PRINTING .....................................................4
1.5 INTERFACE COMMUNICATIONS ...................................4
1.6 PHYSICAL .....................................................4
1.7 ENVIRONMENT ................................................4
1.8 ELECTRICAL ...................................................5
1.9 OPTIONS ......................................................5
1.10 PRINTER VARIATIONS ...........................................5
1.11 APPROVALS ...................................................5
CHAPTER 2: BASIC OPERATION ..............................................7
2.1 UNPACKING THE 400 PRINTER ...................................7
2.2 INSTALLING LABEL SUPPLY RACKS ...............................7
2.3 INSTALLING OPTIONAL SUPPLY COVER ...........................7
2.4 INITIAL POWER UP .............................................8
2.5 FRONT PANEL SWITCH AND STATUS LIGHTS .......................8
2.5.1 NORMAL MODE ..........................................8
2.5.2 BATCH MODE ............................................8
2.5.3 STATUS LABEL MODE .....................................9
2.5.4 PAPER-OUT MODE ......................................10
2.6 THE STATUS LIGHT ............................................10
2.7 LOADING PAPER ..............................................11
2.7.1 NORMAL AND TAG/TEAR MODES ..........................11
2.7.2 PEEL-AND-DISPENSE MODE ..............................11
2.8 CLEARING LABEL MISFEEDS: DIAPHRAGM REMOVAL ...............12
2.9 CLEANING INSTRUCTIONS ......................................12
CHAPTER 3: COMMUNICATIONS .............................................15
3.1 CABLE PINOUT ...............................................15
3.2 PRINTER CABLES .............................................16
CHAPTER 4: DESIGNING LABELS USING LDS ..................................17
4.1 CONTROL CHARACTERS .......................................17
4.2 GETTING STARTED ............................................17
4.2.1 PC CONNECTION (SERIAL) ................................17
4.2.2 PC CONNECTION (PARALLEL) .............................18
4.2.3 LEARNING LDS .........................................18
4.3 FORMATTING LABELS: AN OVERVIEW ............................19
4.4 LABEL HEADER ...............................................21

Table of Contents
400 Operators Manual
4.4.1 A SAMPLE SESSION (HEADER) ............................25
4.5 LABEL FIELDS ................................................26
4.5.1 BIT MAPPED TEXT AND BAR CODE FIELDS ..................26
4.5.2 DOWNLOADABLE FONT/GRAPHIC IMAGE FIELDS .............31
4.5.3 LINES .................................................33
4.5.4 A SAMPLE SESSION (FIELDS) .............................35
CHAPTER 5: PRINTER COMMANDS ..........................................37
5.1 SPECIAL PRINTER CONTROL CODES .............................37
5.2 PRINTER ENQUIRIES ...........................................38
5.3 SENDING ^D PRINTER COMMANDS ...............................39
5.3.1 SOFTWARE DIP SWITCHES AND EEPROM COMMANDS ........40
5.3.2 PRINTING COMMANDS ...................................45
5.3.3 AUTO-SIZING and VALID GAP COMMANDS ...................46
5.3.4 REAL-TIME CLOCK ......................................48
5.3.5 SERIAL NUMBER COMMANDS .............................50
5.3.6 SAVING FORMAT COMMANDS .............................52
5.3.7 LABEL PRESENCE SENSOR CONTROL .....................55
5.3.8 TEXT STRINGS COMMANDS ...............................57
CHAPTER 6: DOWNLOADABLE GRAPHIC IMAGES ..............................59
6.1 PROCEDURE FOR USING PCX2400 SOFTWARE ....................59
6.2 FORMAT OF GRAPHICS FILES ...................................59
6.2.1 FONT/GRAPHIC STRUCTURE ..............................59
6.3 DOWNLOADABLE GRAPHICS COMMAND SUMMARY ................61
CHAPTER 7: BAR CODES ...................................................63
7.1 TYPES OF BAR CODES .........................................63
7.2 DESIGNING WITH BAR CODES ...................................70
7.2.1 BAR CODE HUMAN READABLES ...........................71
CHAPTER 8: SPECIAL EFFECTS .............................................73
8.1 REVERSED PRINT (WHITE TEXT OVER BLACK) .....................73
CHAPTER 9: DOWNLOADABLE FONTS/GRAPHICS ..............................75
CHAPTER 10: OPTIONS ....................................................77
10.1 MICROCOM GRAPHICS CONVERSION UTILITIES ....................77
10.2 MICROCOM DOWNLOADABLE FONT UTILITY .......................77
10.3 WYSIWYG SOFTWARE PACKAGES ...............................77
10.4 WINDOWS DRIVER ............................................77
10.5 CLEANING KIT ................................................77
APPENDIX A: WARRANTY AND REPAIR PROCEDURES ..........................78
APPENDIX B: LABEL SAMPLES ..............................................79
APPENDIX C: SAMPLE BASIC PROGRAM ......................................80
APPENDIX D: QUICK REFERENCE COMMAND SUMMARY ........................81

Table of Contents
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400 Operators Manual
Index ....................................................................90

400 Operators Manual

400 Operators Manual
List of Tables
Status Light ...............................................................10
Serial Port Configuration .....................................................15
Parallel Port Configuration ...................................................16
Print Speed ...............................................................23
Bitmapped Font Descriptions .................................................28
Bar Code Symbologies ......................................................28
Character Starting Positions ..................................................29
Enquiry Responses .........................................................39
Clock Field Parameters ......................................................48
UPC Zero Reduction Format .................................................64
Code 128 Special Function Access ............................................65
UCC/EAN Application Identifiers ...............................................68
List of Figures
Front View .................................................................6
Rear View .................................................................6
Printer Parts ...............................................................7
Supply Cover ..............................................................7
Status Label ...............................................................9
Printer Feed Mechanism .....................................................11
Microcom Label ............................................................20
Label Header Parameters of a 4" X 3" Label .....................................21
Lines ....................................................................34
Bar code Rotations .........................................................70
UPC-A BAR CODE .........................................................71
Bar code Human Readables ..................................................71
Reverse Imaging ...........................................................73

400 Operators Manual

400 Operators Manual
Introduction
The Microcom 400 is a Direct Thermal label printer with a high resolution (832 dots or 8
dots/mm), 4.09 inch wide print head. The economic size and price have no effect on the
printer's ability to handle a wide variety of labeling tasks - even the most demanding
applications.
The resident Label Design Software (LDS) is a powerful and easy-to-use package that allows
you to create personalized label formats. It can be driven from a PC, mini-computer,
mainframe, and other special purpose devices.
Among many other features, LDS supports downloadable graphics and fonts, multiple serial
numbering, and flexible character spacing. It offers virtually unlimited text font sizes and all
popular bar code symbologies. Graphic images can be printed or optionally stored in the
printer's memory for future use. Bitmapped Fonts, bar codes, and graphic images can be
multiplied in size and printed in 0,90,180,270 degree rotations. Once the labels are designed,
they can be stored in the 400's memory for high speed printer access.
The 400 is capable of printing on most types of label stock or fax paper. It offers operation in a
tag/tear, peel-and-dispense, batch, and user-defined advance mode. It can handle blow-hole,
black-line, label gap, and continuous stock.
Many printer applications use the same label format, but change the data on every label. This
is not a problem for the Microcom 400 printer. Data may be changed without down-loading the
same fixed format, or fixed data fields, time after time. This, along with a greatly increased
through-put, increases data access time and productivity.
Microcom Corporation also offers Windows™ drivers and WYSIWYG (What You See Is What
You Get) software packages which allow quick and easy on-screen label designing, along with
database capabilities.

400 Operators Manual
2

400 Operators Manual 3
CHAPTER 1: FEATURES AND SPECIFICATIONS
The Microcom 400 Direct Thermal printer is designed with many standard features that are
unique when compared to other printers. The 400 is built to meet the demands of complicated
applications and rigorous use. A guarantee of excellence in engineering is provided by fulfilling
the requirements for approval by UL, CSA and the FCC.
1.1 SPECIAL FEATURES
!Direct Thermal tag/ticket feed operation
!Resolution of 8 dots/mm (.0049" per dot) and a print width of 832 dots (4.09")
!WYSIWYG software compatible
!Print speed up to 3.0 inches per second
!Media supply racks for roll sizes up to 5 inches OD (8 inches optional)
!Prints on die-cut, continuous, fax, or preprinted labels up to 6.0 mil thick
!Software-controlled contrast adjustment
!Standard memory of 256Kbytes ROM and 128Kbytes SRAM
!Optional Internal date and time keeping
!Easy to load label path to prevent label jams or misfeeds
!Detects label gap, black line, or blow-hole stock
!Internal statistical counter for inches and labels printed
!Downloadable Fonts and Graphics capability
!Incrementing and decrementing fields
!Machine state enquiries for security and maintenance
1.2 BAR CODES
!Code 39, Interleaved 2 of 5, CODABAR, Code 128, UCC/EAN-128, Code 93, Plessey,
Modified Plessey, UPC-A, UPC-E, EAN-8, EAN-13, Postnet and selectable ratios for
producing HIBC, AIAG, and Logmars
!Bar codes may be printed in 0, 90, 180, and 270 degree rotations

Features and Specifications Chapter 1
400 Operators Manual
4
1.3 FONTS
!Converted HP LaserJet II™ font compatibility and 8 resident bit mapped fonts, including
OCR-A and OCR-B.
!All Bit Mapped fonts expandable in height and width
!Bit Mapped fonts and bar codes in 0, 90, 180, and 270 degree rotations
1.4 PRINTING
!Optional peel function with label taken sensor and release lever
!Tag/tear mode advances label to the tear bar
!Batch mode printing
!User defined label advancement for special stock or application
!Label back-up in tag/tear and peel modes
1.5 INTERFACE COMMUNICATIONS
!Serial: RS-232C, 9-pin female D-Sub connector (DCE) and 2Kbytes buffer
-Flow control: XON/XOFF, CTS/RTS
-Baud rate: 110 to 19200, user-selectable
-Parity: odd, even or none
-Data bits: 7 or 8
!Parallel (optional): 25-pin female
1.6 PHYSICAL
!Rigid painted steel construction
!Height: 5" (127mm)
!Width: 8.5" (216mm)
!Depth: 10.5" (267mm)
!Weight: 12 LBS (5.44 Kg)
1.7 ENVIRONMENT
!Temperature: 0"C to 40"C operating
!Humidity: 10-90% non-condensing

Chapter 1 Features and Specifications
400 Operators Manual 5
1.8 ELECTRICAL
!Voltage: 117 VAC nom.,60Hz
!Current: 3 AMPS maximum
1.9 OPTIONS
!Label supply covers
!Assorted printer cables
!8 inch OD media supply racks
!Real-time clock with battery back-up
!On-screen label design PC software packages
!PCX to printer graphics conversion PC software
!On-demand label support rack
!Windows®95/98 driver
1.10 PRINTER VARIATIONS
!230V European power supply
!Peel and dispense pinch roller with label taken sensor and release lever
!Parallel interface
1.11 APPROVALS
!UL, CSA, CE, Complies with FCC, Class A

Features and Specifications Chapter 1
400 Operators Manual
6
POWER CORD
FRONT PANEL
FRONT PANEL LED
TOP COVER
LABEL SUPPLY SHAFT
PINCH ROLLER RELEASE LEVER (OPTIONAL)
LABEL FEED AND LINE FEED BUTTON
PINCH ROLLER
LABEL SUPPORT RACKS
PUSH TO LIFT HEAD LEVER
PEEL EDGE
DRIVE ROLLER
LINE GUIDE IDLER
LINE GUIDE SHAFT
PAPER LINE GUIDES
REAR PANEL
POWER CORD
POWER SWITCH
LINE GUIDE ADJUSTMENT KNOB
THUMB NUTS
LABEL DIAPHRAGMS
SERIAL PORT
Microcom 400 Printer
Front View
Figure 1
Microcom 400 Printer
Rear View
Figure 2

400 Operators Manual 7
CHAPTER 2: BASIC OPERATION
2.1 UNPACKING THE 400 PRINTER
While unpacking the printer, please check all packing materials closely to avoid misplacing any
necessary parts. After the printer is removed from the box, verify that all parts are present and
in good condition (see Figure 3). All packaging material should be kept and used if the printer
is to be shipped.
Printer Parts
Figure 3
2.2 INSTALLING LABEL SUPPLY RACKS
To install the supply racks, simply place the printer on its face so that the rear panel is facing
up. Locate and remove the lower two screws and mount the lower side of the left and right
racks. Once the lower sides are secured, mount the upper sides in the same manner.
2.3 INSTALLING OPTIONAL SUPPLY COVER
Supply Cover
Figure 4

Basic Operation Chapter 2
400 Operators Manual
8
2.4 INITIAL POWER UP
Before connecting the printer to a power source, verify that the voltage printed on the rear
panel correctly matches the supply.
Plug the printer in and turn the power switch on. The front panel LED should turn green. If this
does not occur, check the power source and if necessary call your service organization.
2.5 FRONT PANEL SWITCH AND STATUS LIGHTS
The front panel switch performs several different functions depending on the printer mode:
2.5.1 NORMAL MODE
The front panel switch (see figure 1) acts as both a paper feed button and a label request
button. If the button is pressed and then released within a half second, the unit will print a label
using the current label format. If the button is held for more than the half second, the unit will
start to feed paper until the button is released.
2.5.2 BATCH MODE
If the printer is in the process of printing a predetermined quantity of labels (see ^D73, section
5.3), pressing the button after the printer has started to print these labels will cause the unit to
pause. Pressing the button again will allow the printer to continue the batch.

Chapter 2 Basic Operation
400 Operators Manual 9
2.5.3 STATUS LABEL MODE
When status label mode is accessed, the printer creates a status label and temporarily
defaults all serial communication settings.
To print a status label, hold the button while turning on the printer until the status light turns
orange. Release the button and a test pattern with statistical information will be printed (see
figure 5). When a status label is created, the communication settings will be temporarily set to
9600 baud rate, no parity, 8 data bits, and 1 stop bit. The printer will return to the old settings,
if different, after power down or a soft reset.
The printed labels and total labels represent the number of labels printed to date. The printed
labels and printed inches fields are user resetable while the total labels and total inches are
not. Printed inches and printed labels are reset using the ^D29 command (see section 5.3).
Other useful information on the power-up label is the unit serial number, the non-resetable
power-on hours, the previous serial parameters (not the default parameters caused by
executing creating a status label), and the revision number of the Label Design Software
(LDS).
The switch bank settings reflect the contents of the four software dip switches that configure
the operation of the printer. See section 5.3, specifically ^D21, ^D22, ^D23 and ^D24, for more
information on software dip switch settings.
PRINTER SERIAL #: 0-123456
PRINTED LABELS: 8432
TOTAL LABELS: 8498
PRINTED INCHES: 25296
TOTAL INCHES: 25494
POWER ON HOURS: 897
SWITCH BANK 1: 10001011
SWITCH BANK 2: 01010001
SWITCH BANK 3: 00000000
SWITCH BANK 4: 00000000
SERIAL PARAMETERS: 9600-N-8-1
EXTRA RAM: YES
400 REV 2.2 070163-0220
Status Label
Figure 5

Basic Operation Chapter 2
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10
2.5.4 PAPER-OUT MODE
After a paper-out condition, the front panel switch serves to load and realign the new label
stock. When a paper out condition occurs, the indicator light will turn red. Pressing the button
and holding it will cause the status light to go from red to yellow and feed paper. The status
light will then flash yellow until the button is pressed for a label request. It will then turn yellow
and the printer will print a duplicate of the last label printed and return to the blinking mode.
This feature was designed to facilitate batches with serial numbers or other variable data. This
process can be repeated as often as necessary to allow the paper to align itself. To return to
the pre-paper out condition, tap the button while the duplicate label is being printed. The status
light will turn green and normal printing may resume.
2.6 THE STATUS LIGHT
The status light has different functions depending upon the mode of the printer. Table 1 shows
the relationship between the status light and the different modes.
Status Light
Color Mode Meaning
Green All On-Line and ready to print
Red All Printer error:
Caused by a paper-out condition or a hardware failure. If
paper is out, follow instructions in section 2.3, otherwise
turn printer off and back on. If condition persists, contact
your service representative.
Flashing
Red All Spike or low voltage on the AC line. The unit will remain in this mode until the condition is removed and the printer is
powered off.
Yellow Tag/tear, Peel Label present. Label is ready to be removed from the
printer mouth
Flashing
Yellow All Printer is paused or in standby mode and is waiting for the front panel button to be pressed. If the paper was just
changed and the reprinted label look good, press the
button during the next print cycle to clear the repeat
function and flashing yellow light.
Flashing
Yellow and
Red
All A serial port buffer over flow has occurred. Check the host
flow control for problems. (Note: the serial buffer will only
accept 9 characters after the printer drops the clear to
send signal or optionally sends the XOFF character.)
Table 1

Chapter 2 Basic Operation
400 Operators Manual 11
2.7 LOADING PAPER
Part of the 400's versatility is in the different ways it processes labels. The following two
sections explain the dispensing modes. Refer to figures 1, 2 and 6 for the printer components.
Printer Feed Mechanism
Figure 6
2.7.1 NORMAL AND TAG/TEAR MODES
Unwind about two feet of stock from the paper supply roll of paper. Set the roll behind the
printer on the table. Remove the label supply shaft. Insert the paper with the thermally
sensitive side up, under the rear threaded paper guide shaft, and into the printer until the
paper stops. Turn the paper guide adjust knob at the rear of the printer until the paper guides
are slightly wider than the label stock. Continue to apply pressure on the paper with your left
hand. Press and hold the front panel button with your pointing finger until the paper has
advanced to a point past the printhead. To align the paper, press down on the head lift lever
and move the paper until the desired alignment is reached. Replace the label supply roll shaft
and stock onto the wire rack. You are ready to print.
2.7.2 PEEL-AND-DISPENSE MODE (optional)
1. Follow the paper loading in the normal and tag mode directions.
2. Remove enough labels to expose about two feet of backing paper.
3. Insert the stock into the printer and allow about three inches to protrude out of
the front.
4. Make sure the leading edge of the backing paper is square and straight. (Tear
at perforation or cut if necessary)

Basic Operation Chapter 2
400 Operators Manual
12
5. Pull and hold the pinch roller release lever and insert the leading edge of the
backing paper between the black drive roller and the white pinch roller, making
sure it is positioned evenly between the rollers.
6. Firmly push the head lift lever and press the feed button until most of the slack
is taken out, then release the lift lever.
7. Continue feeding paper until labels are reached. To avoid a paper jam, remove
the labels as they start to peel.
8. Enable the peel-and-dispense mode using the ^A1^D985command described
in this manual.
*If the label height is over 2", the Microcom Label support rack should be used.
(P/N 040010). This rack will support the peeled label until it is removed.
2.8 CLEARING LABEL MISFEEDS: DIAPHRAGM REMOVAL
The purpose of the label diaphragm is to provide a smooth path for labels through the printer
and provide an easy means of removing label misfeeds. If a label misfeed occurs, remove the
supply roll shaft at rear of printer. Remove the four black thumb nuts which hold the diaphragm
sheets in place. Gently slip the sheets off the threaded studs. Once the sheets are removed
clean all foreign matter and any adhesive gum using the Microcom cleaning solution. To
replace the sheets repeat this process in reverse.
2.9 CLEANING INSTRUCTIONS
The Microcom 400 printer and printhead should be cleaned approximately every 5,000 labels
or every two weeks whichever occurs first. The printer should also be cleaned whenever you
run out of label stock. A Microcom cleaning kit (part #040005) should be used for cleaning and
maintaining a Microcom printer product. It is important to note that the optimum printhead life is
achieved by maintaining a clean printer and printhead.
To clean your Microcom 400 printer:
1) Turn the printer off.
2) Lift the printhead using the "PUSH TO LIFT HEAD" lever and remove any label stock
that remains inside the head mechanism.
3) Using the cleaning brush, sweep away all small label and adhesive particles that may
be in the area of the printhead.
4) Moisten a cleaning swab with the cleaning solution and wipe away any adhesive from
the rollers or the aluminum peel bar.
5) Dampen a swab with cleaning solution and lift the print head by pushing the lever in the
direction of the arrows. Take the moistened swab and gently wipe the underside of the
printhead. Repeat if necessary (if swab is extremely dirty).