System Overview:
This Brady RFID Production System is a flexible and moderate-cost solution for commercial aerospace applications controlled by the ATA Spec 2000: Chapter 9 standard.
This system is constructed around the world's most popular label design software - Bartender - produced by Seagull Scientific. This gives users an editable, 'document-based' tool, with built-in data integration tools to the world's most common database software, and a range of user-interface options (Fully Manual to Fully Automated data entry).
The key feature of the Brady RFID Production System is what it is NOT. This system does not include expensive and inflexible middleware software. There is no proprietary programming code to recompile every time that a customer desires an artwork or data change. Customers can make changes to printed artwork via simple document edits, while the embedded Brady scripting organizes the customer-supplied data so that the RFID chip data always conforms to the ATA Spec2000 standard.
RFID Primer
Hardware Elements:
Find documentation & Specs for the various hardware items under each tab.
Click on Company logo for link to their homepage, or the Product Logo for link to their downloads page.
The Honeywell (formerly Datamax) H4606 is an RFID-capable thermal printer. Brady Corporation provides customized firmware and printhead design changes to allow this printer to support Brady's thick-tag Alloy RFID tag material. The H4606 offers 609 dpi print resolution, allowing unmatched fine detailed print quality.
After installing the Seagull printer driver (see video), download one of the following configuration files to your PC for the tag type and size installed in your printer. Then use the Seagull printer driver to download that configuration file to your printer (see video). Finally, fine-tune the settings for Print positioning as you begin printing your tags from Bartender or Print Station (see video)
| Tag PN | RF Pwr (dB) | Tag Position (inch) | Config File Link |
| THT-HM-LRG-1000-01 | 2 | 1.25 | Printer Configuration File |
| THT-HM-LRG-1000-PF | 4 | 1.25 | Printer Configuration File |
| THT-HM-MED-1000-01 | 5 | 1.25 | Printer Configuration File |
| THT-HM-MED-1000-PF | 8 | 1.25 | Printer Configuration File |
| THT-HM-SML-1000-01 | 6 | 1.25 | Printer Configuration File |
| THT-LM-LRG-1000-01 | 4 | 1.25 | Printer Configuration File |
| THT-LM-MED-1000-01 | 8 | 1.25 | Printer Configuration File |
| THT-LM-SML-1000-01 | 10 | 1.25 | Printer Configuration File |
| Honeywell/Datamax H4606 | |
| Print Width, Resolution | 4.65 inch, (610 dpi) |
| Power Requirement | Auto-sensing 90-132 or 180-264VAC @ 47-63Hz; |
| Size | 13.0 x 12.6 x 18.9 inch (HxWxD); Weight: 18.2 kg (40 lbs) |
| Documentation |
 TTROption Manual Certifications |
| Firmware |  |
| Win10 Printer Driver |  Honeywell Driver |
Click on Company logo for link to their homepage, or the Product Logo for link to their downloads page.
Currently replacing the Datamax H4606 for new orders, the SATO CL4NX Plus thermal printer can support both Brady AIR and ALLOY RFID tags with the same 609 dot/inch resolution.
After installing the Seagull printer driver (see video), download one of the following configuration files to your PC for the tag type and size installed in your printer. Then use the Seagull printer driver to download that configuration file to your printer (see video). Finally, fine-tune the settings for Print positioning as you begin printing your tags from Bartender or Print Station (see video)
| Tag PN | RF Read/Write Pwr (dB) | Tag Position (mm) | Config File Link |
| THT-HM-LRG-1000-01 | 18/24 | 17 | Printer Configuration File |
| THT-HM-LRG-1000-PF | 24/24 | 17 | Printer Configuration File |
| THT-HM-MED-1000-01 | 18/24 | 20 | Printer Configuration File |
| THT-HM-MED-1000-PF | 24/24 | 20 | Printer Configuration File |
| THT-HM-SML-1000-01 | 18/24 | 0 | Printer Configuration File |
| THT-LM-LRG-1000-01 | 24/24 | 17 | Printer Configuration File |
| THT-LM-MED-1000-01 | 24/24 | 20 | Printer Configuration File |
| THT-LM-SML-1000-01 | 24/24 | 10 | Printer Configuration File |
| Sato CL4NX Plus | |
| Print Width, Resolution | 4.09 inch, (609 dpi) |
| Power Requirement | Auto-sensing 100-240VAC @ 50-60Hz; |
| Size | 12.64 x 10.7 x 18 inch (HxWxD); Weight: 15.1 kg (33.28 lbs) |
| Documentation |
Manual |
| Firmware - Additional Brady Firmware ADD-IN MUST be installed after the baseline SATO firmware below. Contact Brady or IDI for Add-In, having printer S/N for verification. |  |
| Win10 Printer Driver | Sato Driver |
Click on Company logo for link to their homepage, or the Product Logo for link to their downloads page.
Zebra makes several RFID thermal printer models. However, zebra printers can currently support ONLY Brady's AIR labels, and for that reason we focus the section on the more affordable ZD621R. The thicker Brady ALLOY tags are NOT currently supported for use - even using Zebra's newer On-Metal version of the ZT411R.
Although Zebra does provide a WinOS printer driver, The Bartender template files will only work with the printer drivers from Seagull Scientific.
After installing the Seagull printer driver (see video), download one of the following configuration files to your PC for the tag type and size installed in your printer. Then use the Seagull printer driver to download that configuration file to your printer (see video). Finally, fine-tune the settings for Print positioning as you begin printing your tags from Bartender or Print Station (see video)
| Tag PN | RF Pwr (dB) | Tag Position (inch) | Config File Link |
| TAG-B-1100-LARGE | - | - | Printer Configuration File |
| TAG-B-1100-MEDIUM | - | - | Printer Configuration File |
| TAG-B-1100-SMALL | - | - | Printer Configuration File |
| Zebra ZD621R | |||
| Print Width, Resolution | 4.1 inch, (203, 305, 610 dpi) | 4.1 inch, (305 dpi) | |
| Power Requirement | 100 - 240V AC, 50/60 Hz, PFC; Consumption: 100W typical | 100 - 240V AC, 50/60 Hz, PFC; Consumption: 100W typical | |
| Size | 12.75 x 10.6 x 19.5 inch (HxWxD); Weight: 8 lbm | ||
| Documentation |
User Guide User Guide User Guide |
User Guide User Guide User Guide |
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| Firmware | LinkOS6.2 |
LinkOS6.2 |
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| Win10 Printer Driver | Zebra Driver |
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Click on Company logo for link to their homepage, or the Product Logo for link to their downloads page.
The TSL 1128 handheld reader comes with an optional barcode scanner (recommended) which allows data collection device for both barcodes and UHF tags with a simple 1 or 2-click trigger pull. The reader can be operated either in USB cabled mode (to Win10 PC with installed VCOM driver), or in cordless BlueTooth mode. This reader is used with Brady's Tag Assistant Desktop software. But TSL offers utilities for use with any windows application software.
| Technology Solutions Ltd. | |
| RFID Reader Type | UHF EPC Class 1 Gen 2; Model support for EU, US, and other Frequency Ranges |
| RFID Power | 30 dB Max |
| RFID Antenna | Circular |
| Power Requirement | 4.2 volt Lithium Polymer 2400 mAh battery pack: Removable, Rechargeable, 8.9 watt hrs |
| Size & Weight | 16.0 cm x 7.7 cm x 16.9 cm ; Weight: 13.5 oz |
| Documentation |
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| FTDI Virtual COM Drivers for WindowsOS | |
| BlueTooth Connections to Windows |
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| Firmware |
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| WinOS Support Programs |
|
Click on Company logo for link to their homepage, or the Product Logo for link to their downloads page.
The Alien ALR-H460 handheld reader comes with an integrated barcode scanner, Android OS, and large touchscreen display. When purchased from ID Integration, the ALR-H460 comes with the Brady Tag Commander app pre-installed. Tag Commander allows maintenance and repair organizations to read and update ATA RFID tags with new maintenance records and part status codes.
| Alien Technology | |
| RFID Reader Type | UHF EPC Class 1 Gen 2; Model support for EU, US, and other Frequency Ranges |
| RFID Power/Antenna | 30 dB Max / Circular |
| CPU / Memory / Storage / Expansion | Cortex-A53 1.45GHz quad-core / 2GB RAM / 16GB Flash / 128 GB SDcard |
| Android OS Version / Display Type | Android 6.0 / 5.2-inch 1920 x 1080 display (Corning Gorilla Glass) |
| Power Requirement | 8,000 mAh Li-Po integrated rechargeable battery |
| Size & Weight | 7" (L) x 3.4" (W) x 5.7" (H) ; Weight: 18.5 oz |
| Environment Rating | IP64, Dust & Water resistant |
| Documentation |
|
Software Elements:
Find documentation & Specs for the various hardware items under each tab.
Win10 printer drivers from Seagull Scientific are REQUIRED for full functionality of the ATA template library. DO NOT use drivers from other vendors (even the printer manufacturer) since these will not support the advanced RFID write and locking requirements of the ATA specification. Download links, driver configuration import files, and installation instructions are available in the links provided below:
| Driver & Instruction Links | ||
|---|---|---|
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Import File |
The Bartender Software Suite is a group of Win10 applications which allow users to design label artwork, connect to databases and user prompts, and then print to any print system with a Win10 printer driver. Download links and reference materials are provided here to help get users started with the installation and licensing of the Bartender Suite onto their company network.
- Bartender Edition: Either Enterprise or Automation editions may be used. Please refer to the Features Comparison Chart to determine which Edition best suits your company‘s needs.
- Bartender Version: v2019R6 is the most recent as of March 20, 2020. However, the Brady Template Library is compatible with existing installations of v2016. Download the FREE version of Bartender 2019R6 to evaluate the software. Once you have purchased either the Enterprise or Automation Editions, you will receive an Activation Code that you can use to upgrade from the free version.
- Installation Instruction Video:
Brady‘s ATA Template Library is a collection of ready-made Bartender template with printed artwork and RFID chip encoding per the ATA Spec 2000 Standard. These basic designs meet Boeing and Airbus RFID tag content standards. Production personnel typically initiate a tag print/encode operation from the Bartender Suite utility called "Print Station", or it's web-server based cousin, "Print Portal". 
These utilities autogenerate thumbnail images of any Bartender template file within a specified root network folder. Templates can be organized by department, product, or any other user-defined folder organizational structure. Production users simply click on a tag image to begin the print process with prompted information concerning the printer to use, and any optional data element definitions. View a sample print operation in the video below, or visit the operations tab to see more information as to how these files are used.
Because the template library is editable, users can quickly customize tag designs with printed artwork and data content using the library's "Core Templates" The library also includes pre-built size layouts for all of the Brady tag products, allowing users to quickly replicate designs to other sizes. Each core template contains a predefined ATA variables list, which designers can use to link to external database tables and/or prebuilt template data entry prompt forms.
Brady's ATA Tag Assistant is a Win10 software application to validate that RFID tags conform to the ATA Spec2000 data structure and security rules. It is licensed per PC installation, using the TSL model 1128 RFID reader as the data input device. The program includes a configurable XML file to allow fort he support of all current and future high-memory RFID Gen2 UHF tags.
ATA Tag Assistant stores test results as appended records within a single text log file.
| Brady ATA Tag Assistant | |
| Installation File (Win10 OS) |
v1.0.12
File |
Brady currently provides their Mobile ATA software on the Zebra MC3330R Android terminal. This software allows a user to read any properly formatted ATA RFID tag, and perform the following functions:
- ADD part history records to multi-record, high memory tags.
- UPDATE Life Cyle records to dual-record, low memory tags.
- CLONE ATA tag information to new ATA tag media (printing not supported)
Refer to the User's Manual for detailed process steps.
| Brady Mobile Tag Assistant | |
| Android App (Zebra MC3330R only) |
Assistant
Re/Install Instructions |
System Setup & Operation:
The Brady system is comprised of numerous diverse hardware, software, and consumable elements. In contrast to the previous sections for hardware, software, and materials; we have organized this section by process function. No one process area can successfully be implemented without the other functional steps. We hope that this approach will allow the broader support team to more quickly find answers related to their own individual responsibilities.Admittedly, IT Support is a very broad category. Yet, here we focus on the software & driver installation tasks, network IP address reservation for the RFID printers, along with installation & configuration of the Bartender software suite.
Although the Datamax and Zebra printers can be operated with a local USB cable connection to a single PC, it is far more common (and useful) to install these printers onto your company network - treating them in the same way that you would any other office printer. Please be prepared to reserve static IP addresses for a list of printer Mac Addresses to be supplied either by IDI during on-site installation, or by the local Production support team who will setup the printers.
If Bartender Enterprise Edition is being installed onto a company web server, you will also be installing printer drivers on this same server machine. Doing so will eliminate the need to install printer drivers on the local PCs near the printers. Please click on the appropriate driver download link in the Software/PrinterDrivers section of this website. This download file is a compressed collection of all printer model drivers for the printer company's product family. Review the installation video link, and install drivers either for the Datamax H4606 - 600dpi printer, or any of the supported Zebra RFID printer models.
Also in the Software/PrinterDrivers section, are driver configuration files that can be downloaded and imported into the Seagull Printer Driver to auto configure default settings. Please download the appropriate file and review the linked video to understand the process.
In the Software/BartenderSuite section, there are download links and an excellent installation video from Seagull. If you are installing Bartender Enterprise Edition, you will want to install Bartender + Print Portal (but NOT the Licensing Service) onto the Web Server. The Licensing Service should be installed on a different 24/7 server machine which is accessible by all other network PCs. Without the Licensing Service running, Bartender Suite modules will still operate - but printing will be blocked after a short alert period. Once Bartender Print Portal is installed, you should communicate the URL to the Production Support staff, and assure that this link is accessible by all network customers.
If your company is using the Bartender Automation Edition, all suite components (Except the Licensing Service) will be installed on local PCs. However, the Licensing Service and Admin Console utility will again need to be installed on a dedicated 24/7 server machine which is accessible by all other network PCs.
The use of Print Portal is relatively simple from a management role perspective. It is a simple file/folder repository of user-defined structure. The primary IT support functions are listed below, but please review the detailed Print Portal Overview Video from Seagull by clicking on the image to the right.
- Define root folder location for template files/subfolders.
- Support loading of new template files to secured folder location if needed.
- Set user access defaults.
- Set user GUI file/folder navigation options.
- Define SSL and user security levels.
In this section, we define "Production Support" as hardware setup and maintenance tasks for printers and readers. Also, we include references for local PC driver, and software installation.
The Production support group should locate the Ethernet MAC address information for the printer and exchange this for an assigned static IP address from the IT Network support group. 
Datamax and Zebra printers are generally factory configured to initially support DHCP. Connect the printer via ethernet cable to the local network, power on the printer, and most network environments will auto assign an initial IP address. To see what this assigned IP address is, press and hold the [UP] button on the front panel. After approximately 3 seconds, the display will provide a list of system information. Scroll down to identify the current IP address and Mac Address for the printer network port. Thereafter, you should be able to open a PC browser and enter this IP address into the URL address bar to see the printer's homepage.
From this printer homepage, one can alter settings using the default admin password of "sysadm" . Although it may be more confusing, it's also possible to use the printer's LCD display and keypad to make the same changes. If one uses the printer's LCD display menu, the default admin password is 0000 . The image here shows how to switch the printer from the factory default DHCP network mode to assigning the static IP address provided by the local IT network staff for this printer's MAC address.
Please refer to the Videos link for demonstrations on how to load ribbon and RFID label/tags. Brady's AIR tags are separated by large, full-width gaps. Brady's ALLOY tags are separated by small, short oval notches toward the left side of the media. The notch location is in the tag spacer - not the RFID tag itself. In either case, the printer will be configured for "Transmissive, Gap/Notch" media sensor use.
Please refer to the Videos section of this site to review Datamax printer videos for loading ribbon & media, and setting media edge guide, media sensor position, and printhead pressure adjustments. These are the most common printer setup procedures and also the most common reasons for misprinted tags.
In addition to the mechanical printer adjustments listed above, there are numerous printer software settings that determine the proper print darkness, speed, encoding position and RF power used. There are also subtle differences in these settings between the various tag types and physical sizes. These setting adjustments can be made from the printer front panel, or its browser homepage, or even by including the settings with a print job. Which method to use is largely personal choice. However, it is important to note that printer settings included with the Bartender print job will override any default settings stored either in the Seagull printer driver, or in the printer's memory.
The Software link on this webpage banner has a tab for Printer Driver download, and a link to an instructional video regarding installation. The Producation Support staff should install the appropriate printer driver(s) on each PC from where local Bartender printing may originate.
The Hardware link on this webpage contains all TSL hardware documentation, drivers, and utilities. BEFORE connecting the TSL reader to a PC for the first time, one must load the FTDI Virtual COM Drivers for WindowsOS. There are detailed instructions on the TSL hardware link, however, the driver install file is provided here as a link
Brady Tag Assistant is PC software, used with the TSL 1128 RFID reader, to validate RFID tag information conforms to the ATA Spec2000 data standard. The Software link on this webpage banner has a tab for Brady Tag Assistant download, and a guide regarding installation and use. This software is licensed per single PC installation. License codes are provided by IDI as document attachements to our invoice. The user will be prompted for this license code during initial program use.
Brady Tag Commander is an Android RFID reader application this is normally pre-installed by IDI on the Alien ALR-H460 before shipment to the end user. The Software link on this webpage has a tab for Brady Tag Commander with links to program installation and user guides. Delivery of the actual .apk file and license code(s) are provided via download link as document attachments to our invoice.
In this section, we provide shop floor users with the key process steps to create and validate ATA-compliant RFID tags.
Bartender software can provide users with a range of data entry options from fully Manual to fully Automated with connections to a corportate database. Which one you will use is determined by the local toolset, Database sophistication, and list of known vs unknown part characteristics at time of tag creation. In all situations, however, the hundreds of ATA Spec 2000 data constraints are embedded into the core Bartender template deisgn. IDI will customize the printed artwork and user data prompts to simplify the tasks required of the shopfloor user. The daily print/encode process will generally involve selecting a tag thumbnail image from a screen, which will present the user with a data entry form where they will enter any variable data such as Serial Number, Weight, or Production/Expiration dates. The tag will then be printed, and can be validated with Brady desktop or mobile software.
If the customer purchases Bartender Enterprise Edition, they will have an 'option' to use a Web Service to allow shopfloor users to select the tag thumbnail images from a browser. This method is highly advantageous to IT departments since it does NOT require the installation of and Bartender softwaere on individual PCs. This does, however, require a much higher level of IT skills and infrastructure to properly use.
A much simpler alternative to the Web Service discussed previously is to use a locally installed Bartender module called 'Print Station'. This program provides users with the same interface simplicity as Web Portal - but without the need for sepearate Web Serviices and IT support.
After a tag has been created, one should 'Validate' that the encoding has been properly performed per the ATA Spec2000 rules. Likewise, and printed barcode should match the encoded data. Brady provides a Desktop software program (Tag Assistant) that uses the TSL 1128 RFID reader/scanner to provide a certification that can be provided to end customers to show that the tag conforms to the spec. Brady also makes an Android mobile app (also called Tag Assistant), which is used to read and update RFID tags. It is important to note, however, that this mobile app and reader CANNOT validate that the tag fully conforms to the ATA spec. The mobile app will do it's best to read data from even malformed tag data. But the mobile app can't certify nor document the validity of the tag data per the ATA spec.
In this section, we provide shop floor users with the key process steps to create and validate ATA-compliant RFID tags.
Although the Datamax and Zebra printers can be operated with a local USB cable connection to a single PC, it is far more common (and useful) to install these printer models onto your company network - treating them in the same way that you would any other office printer.
In this section, we provide Maintenance & Repair teams with the key process steps to read and modify existing ATA-compliant RFID tags, using a mobile Android-OS handheld RFID reader and Brady's Tag Commander Android app.
Although the Datamax and Zebra printers can be operated with a local USB cable connection to a single PC, it is far more common (and useful) to install these printer models onto your company network - treating them in the same way that you would any other office printer.