Lexmark Card Stock Label User Manual

Card Stock & Label Guide

Laser Printers

April 2006

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Edition: April 2006

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Overview ............................................................................................................................... 5

General information ............................................................................................................. 6

Paper and label Industry ..................................................................................................................................6

Print volumes ................................................................................................................................................... 6

Print material testing ........................................................................................................................................ 6

Card stock .......................................................................................................................... 10

Weight ............................................................................................................................................................10

Grain orientation ............................................................................................................................................11

Coatings .........................................................................................................................................................12

Offset powders ...............................................................................................................................................13

Labels .................................................................................................................................. 14

Label characteristics ...................................................................................................................................... 14

Printing on labels ...........................................................................................................................................14

Duplexing paper labels .................................................................................................................................. 15

Label components ......................................................................................................................................... 16

Label design guidelines ................................................................................................................................. 18

Printer specifications ........................................................................................................ 23

Lexmark E238, E240, E240n, E340, E342n .................................................................................................. 25

Lexmark C760, C762 .....................................................................................................................................26

Lexmark X644e, X646e .................................................................................................................................30

Lexmark X850, X852e, X854e .......................................................................................................................34

Lexmark C520, C522, C524 .......................................................................................................................... 36

Lexmark C920 ............................................................................................................................................... 39

Lexmark T640, T642, T644 ........................................................................................................................... 41

Lexmark W840 ............................................................................................................................................... 45

Lexmark C912 ............................................................................................................................................... 46

Lexmark C510 ............................................................................................................................................... 48

Lexmark X422 ................................................................................................................................................50

Lexmark X215 ................................................................................................................................................52

Lexmark C720 ............................................................................................................................................... 54

Lexmark C750 ............................................................................................................................................... 56

Lexmark C752 ............................................................................................................................................... 60

Lexmark C910 ............................................................................................................................................... 64

Lexmark E220 ................................................................................................................................................66

Lexmark E320, E322 .....................................................................................................................................67

Contents

Lexmark E321, E323 .....................................................................................................................................68

Lexmark E230, E232, E234(n), E330, and E332n ......................................................................................... 69

Lexmark E120 ................................................................................................................................................70

Lexmark T430 ................................................................................................................................................ 71

Lexmark T420 ................................................................................................................................................ 73

Lexmark T520, T522 ......................................................................................................................................76

Lexmark T620, T622 ......................................................................................................................................81

Lexmark T630, T632, T634 ........................................................................................................................... 86

Lexmark W812 ............................................................................................................................................... 91

Lexmark W820 ............................................................................................................................................... 92

Optra C .......................................................................................................................................................... 94

Optra C710 .................................................................................................................................................... 95

Optra Color 1200 ........................................................................................................................................... 97

Optra E310, E312 ..........................................................................................................................................98

Optra E, Ep ....................................................................................................................................................99

Optra Es special media printer .................................................................................................................... 100

Optra K 1220 ............................................................................................................................................... 102

Optra M410, M412 ....................................................................................................................................... 103

Optra N ........................................................................................................................................................ 105

Optra plus, 4039, 4029, 4019, WinWriter 600 printers ................................................................................. 106

Optra S ........................................................................................................................................................110

Optra SC 1275 ............................................................................................................................................. 116

Optra T ......................................................................................................................................................... 117

Optra W810 ................................................................................................................................................. 122

Glossary ............................................................................................................................ 123

Index .................................................................................................................................. 127

Contents

Overview

Lexmark has many years of experience in successful card stock and label testing and cross education programs with print material vendors and converters.

This document provides guidelines to help you select appropriate print materials for the following Lexmark laser printers.

Model series Models

4019 models All

4029 models All

4039 10 plus All

4039 12C All

C series C510, C520, C522, C524, C720, C750, C752, C760, C762, C910, C912, C920

E series E220, E230, E232, E234(n), E238, E320, E321, E322, E323, E330, E332n, E340, E342n

Optra™ models All

T series T420, T430, T520, T522, T620, T622, T630, T632, T634, T640, T642, T644

W series W812, W820, W840

WinWriter™ 600 4035 5W

X series X215, X422, X644e, X644e, X646e, X850, X852e, X854e

The information supplied here supersedes other information relating to card stock and labels included with your printer. See other printer documentation for detailed information about the paper, envelopes, and transparencies suitable for your printer.

In addition to printer-specific media recommendations, this document also explains design factors you should consider when purchasing all types of print materials. The glossary on page 123 defines many industry terms. If you have specific stock or design questions, talk with your print materials supplier.

See your printer documentation for general printing information and terms. See the printer registration card, information on the printer CD, or visit our Lexmark Web site at www.lexmark.com/publications for technical assistance contact numbers.

Always test print materials thoroughly before buying large quantities. Doing so will help you avoid unexpected problems when you begin regular printing.

Overview

General information

Paper and label Industry

The paper and label industry includes several different types of businesses: manufacturers, converters, and distributors.

Manufacturers produce the base stock. If the base is for labels, manufacturers may ship it on large rolls or in a cut-sheet form.

Converters take the base stock and convert it into cut-sheet products. Converters may work from rolls with or without the adhesive applied, or they may take a base stock and convert it to meet their customers’ specifications.

The conversion process includes, but is not limited to, cutting the stock to size, perforating the stock, die-cutting, and applying inks and topcoats. Converters work with their customers to convert the base material into a cut-sheet product designed for use in laser printers.

Distributors generally are the direct link to the customer.

Distributors may work with different converters, and converters may work with different manufacturers, as their needs and prices change. Most businesses follow accepted industry conventions, but specifications, standards, formulations, and processes may vary with time or with different companies.

Note: Labels or papers that performed satisfactorily in the past may suddenly create printing problems

because of a change in material or process.

Some large businesses perform all three functions, from manufacturing to distribution. These companies may offer greater expertise and product consistency than companies that concentrate on one facet of the process.

Print volumes

Printing numerous sheets of card stock or labels in a short period of time can create printing problems. Exclusive printing of labels, for example, may result in more frequent service calls. Proper printer maintenance helps alleviate these problems. (Look under “Maintenance procedures” in the index for specific information about maintaining your printer.)

Print material testing

Choosing print materials can seem complex. Unfortunately, it is not possible to write a simple “cookbook” explaining how to select print materials, because there are too many variables you need to address for each specific application.

Be aware that critical factors at the vendor–such as the physical characteristics of the base stock and the manufacturing processes–may change over time.

Print materials can significantly affect printer reliability and downtime. Using materials from converters or vendors who are unfamiliar with laser printing may result in unsatisfactory print quality or other printing problems.

Note: Once you have a successful design, test the print material before placing a large order to avoid costly

mistakes.

Your print materials supplier should be able to help develop your application or solve a problem you have with an existing application. In addition, Lexmark has worked with several suppliers and has business partners in this field. See the printer

General information

registration card, information on the printer CD, or visit our Web site at www.lexmark.com\publications for technical assistance contact numbers.

Design factors

Print materials all have measurable characteristics that you need to consider when selecting or designing forms for your particular application.

Basis weight

Basis weight is a term used to describe the weight in pounds of 500 sheets of paper (one ream). However, the weight is determined based on the standard size of the paper, which may not be the purchased size. For example, the standard size of 20 lb Bond paper is 17 x 22 inches, and a ream of 17 x 22 inch 20 lb Bond paper weighs 20 lbs. If the 17 x 22 inch 20 lb Bond paper was cut, creating four reams of 8.5 x 11 paper, each ream would be labeled 20 lb Bond paper but would only weigh 5 lbs.

If the same paper weighed 24 pounds, it would be called 24 lb Bond. The 24 lb Bond paper is thicker, heavier, and more dense than the 20 lb Bond. Thicker paper means less paper can be placed in a tray, and paper that is heavier and more dense may cause paper jams or feed reliability problems in some printers. Check the printer media weight table located in the printer User’s Guide to verify that the paper basis weight being used is acceptable.

Not all basis weights are related to the same standard sheet size: for example; 70 lb material can be lighter than 40 lb material if it is based on larger base size paper (see the Card stock weights comparison guide on page 11). For a more consistent way to compare weights, see the metric measurement of grams per square meter (g/m2). The metric measurement of grams per square meter has been standardized by the International Organization for Standardization (ISO).

Your printer can accept a wide range of stock weights, but materials either too light or too heavy can cause printing problems. Heavy and/or thicker materials may not heat quickly enough in the fuser, resulting in poor print quality. They may also feed less reliably or skew due to their weight or rigidity. Conversely, lighter materials can wrinkle and jam in the printer due to low beam strength (stiffness).

Depending on the orientation of the stock as it feeds through the printer, you may need to request that heavier materials be cut grain short or grain long to provide flexibility in paper path turns. See the specifications for each printer for more precise recommendations.

Dimensions

All printers have print material dimension limitations. See the printer documentation shipped with your printer for details. You can sometimes redesign forms to overcome these limitations. For example, if you use forms that are shorter than the minimum length supported by your printer, you may be able to link two forms together when printing multiple forms. An optional Universally Adjustable Tray designed for the Optra S, Optra T, and Lexmark T printer families prints on a range of paper sizes including A6 and 3-inch by 5-inch index cards, 3-inch by 7-inch punch cards, and 4-inch by 6-inch postcards.

Environment

Lexmark printers meet or exceed all industry emission regulations and standards. Continuous printing on some papers or other media may create fumes that are not a problem with occasional printing. Make sure your printer is located in a well-ventilated area.

Temperature and humidity can have a major impact on printing. Even small changes (such as from day to night) can greatly affect feed reliability if the print material is just within the range of acceptability.

We recommend that you condition stock while it is still in the original wrapper. To condition stock, store it in the same environment as the printer for 24 to 48 hours before printing to let the stock stabilize at the new conditions. You may need to extend this time several days if the storage or transportation environment is very different from the printer environment. Thick stock may also require a longer conditioning period because of the mass of the material.

Print material testing

General information

If you remove the wrapper from the stock before you’re ready to load it in the printer, the stock may develop uneven moisture content that can cause curl. Prior to loading your stock, we recommend that curl not exceed 3 mm (0.125 in.). Lighter materials, such as paper labels and some integrated forms, are more likely to have printing problems if curl is present.

Most label manufacturers recommend printing in a temperature range of 18 to 24°C (65 to 75°F) with relative humidity of 40 to 60%. Lexmark printers are designed to operate in a temperature range of 15.5 to 32°C (60 to 90°F) with relative humidity of 8 to 80%. Printing in an environment outside these recommendations may cause jams, feeding problems, reduced print quality, and predispensing (peeling) labels.

Inks (preprinted stock)

Preprinted stock introduces semi-liquid and volatile components to the high temperatures and pressure used in the laser printing process. Preprinted inks and colorations must withstand a fuser temperature up to 225°C (437°F) and pressure up to 25 psi without contaminating the printer or creating hazardous fumes.

Thermography inks are not recommended. Thermography inks have a waxy feel and the printed image appears raised above the surface of the print material. These inks can melt and damage the fuser assembly.

Preprinted inks must also be abrasion resistant to reduce ink dust and ink contamination in the printer. If you are printing over a preprinted area, the ink must be receptive to toner to ensure adequate fusing.

All preprinted inks must be thoroughly dry before using printed materials. However, we do not recommend using offset powders or other foreign materials to speed drying. Check with your converter, or the manufacturer or vendor of the ink you plan to use, to determine if the ink is compatible with laser printers that heat the ink to 225°C (437°F).

Perforations and die-cuts

If your form has perforations, the perforation line should stop 1.6 mm (0.06 in.) from each edge of the form to avoid separating the form in the printer path, resulting in a jam. The location of the perforation affects initial pick strength. Perforations closer to the edge may increase the number of jams. For pressure-sensitive materials such as labels, minimize the number of perforations that go through the backing material, or liner, since these can also affect the strength of the form.

Perforations should be ironed so the print material lies flat, reducing nesting of forms. Edges should be smooth and clean with no roll-over. Laser-perfs (also known as micro-perfs or data-perfs) provide greater stability and are preferred. These smaller perforations do not normally nest or create excessive paper dust and debris. Make sure paper chaff and dust created during the conversion process are removed before packaging.

If perforations tent, or crease at the perforation line, the perfs may break, causing a paper jam. Tenting may increase skew, cause double sheet-feeding, or smear the toner on the print material before fusing, resulting in poor print quality. To reduce tenting, use micro-perfs. If the print material is lightly snapped as it moves through the printer, the perforations should hold without breaking.

Die-cutting is used to create shapes in a label or a card stock design. When designing labels, round all corners to prevent delamination of the labels, and avoid cuts through the liner (anvil cuts). Back splits and pop-out windows are also not recommended.

If perforations or die-cuts are part of the design of the print material, ties are recommended. These small uncut areas (approximately 1.6 mm or 0.06 in.) help stabilize the form and prevent tearing at perforations and die-cuts during printing.

For areas with die-cuts or perforations that create a small end product, or where die-cuts or perforations intersect, ties on the corners of the design provide added stability. Ties may be located anywhere along perforations or die-cuts. For pressure-sensitive products, ties help prevent the labels from peeling off the liner while in the printer. Ties cannot, however, be used to compensate for inadequate release strength of the adhesive in label designs.

Note: For specific perforation and die-cut guidelines for your printer, see the appropriate topic under Printer

specifications on page 23.

Print material testing

General information

Debossing and embossing

Avoid debossing and embossing materials. Embossing leads to nesting and double sheet feeds, and the fusing process significantly reduces the height of the raised image. Printing too close to embossments results in poor print quality and poor fuse grade.

Metallics

We do not recommend using metallics in forms, whether in inks or other materials, due to their conductivity and their ability to bleed charge. This can interfere with toner transfer and cause poor print quality.

Basic form design

When designing forms, include a non-print area of 8.38 mm (0.33 in.) at the top and bottom of the form and 6.35 mm (0.25 in.) on both sides of the form.

In general, portrait orientation is the preferred layout, especially if you are printing bar codes. If your forms require landscape orientation, be aware that variations in paper path speed may produce spacing variations when printing bar codes.

Note: We do not warrant uninterrupted or error-free operation of a product. Warranty service does not

include repair of failures caused by:

• modification or attachments

• accidents or misuse

• unsuitable physical or operating environment

• maintenance by anyone other than Lexmark or a Lexmark authorized servicer

• operation of a product beyond the limit of its duty cycle

• failure to have installed a maintenance kit as specified (if applicable)

• use of printing media outside of Lexmark specifications

• use of other than Lexmark supplies (such as toner cartridges, inkjet cartridges, and ribbons)

• use of other than Lexmark product or component

Print material testing

Card stock

Card stock is a rigid, stiff material that can have a wide variety of constructions. Orientation of paper fibers (grain direction), moisture content, thickness, texture, and other properties can significantly impact printing, as can preprinting, perforation, creasing, and other features common to forms. For example, preprinting introduces semi-liquid, volatile components that must withstand the high temperatures used in laser printing. Perforation and creasing may cause nesting, or interlocking, which can cause paper jams and double sheet feeds.

The following sections describe some of the basic characteristics of card stock. In general, we recommend a single-ply construction of 100% chemically-pulped wood with a vellum finish. Before purchasing large quantities of card stock, make sure you test samples of the print material in your printer.

Weight

The weight of card stock plays a significant role in the print quality and feed reliability of the stock. Confusion often arises when specifying the basis weight of a stock; see Basis weight on page 7 for more information. The basis weight is a term used to describe the weight in pounds of 500 sheets of paper (one ream). Since the sheet size varies from one type of stock to another, the basis weights are not always easily comparable. For example, an office supply store has 8.5 x 11 size cover stock (80 lb Bristol) and 8.5 x 11 size card stock (90 lb Index) side by side on the shelf. Both papers are manufactured by the same company, and a basis weight comparison indicates the card stock (90 lb Index) is heavier than the cover stock (80 lb Bristol). In this example, the cover stock (80 lb Bristol) is actually heavier than the card stock (90 lb Index).

The reason the cover stock is heavier is because before the two types of paper were cut into 8.5 x 11 size pages, the card stock was a larger sheet size than the sheet size of the cover stock. When the papers were cut during the manufacturing process into 8.5 x 11 size pages, more reams (500 sheets) of paper were received from the card stock sheets than from the cover stock sheets. This makes the weight of the cover stock heavier than the weight of the card stock.

It is easier to compare the cover stock metric weight (g/m weights of the two stocks in the previous example, it is immediately evident that 80 lb Bristol cover stock (176 g/m heavier than 90 lb Index card stock (163 g/m2).

Not all printers are able to print on cover stock. This is because cover stock is usually thicker and not able to make the turns in the printer paper path. This causes paper jams and sometimes causes the paper to feed incorrectly. Also, when using a laser printer, toner is pulled onto the paper through an electrical charge. If the paper is too thick, there may not be enough voltage to pull the toner on the paper properly and can cause poor print quality.

To determine if your printer is able to print on cover stock, go to Printer specifications on page 23, locate your printer, and review the supported paper type information. You can also view the supported media in the printer User’s Guide.

) against card stock metric weight (g/m2). If you look at the metric

) is

Card stock

Use the following table to compare the weights of various types of card stock.

Card stock weights comparison guide

Basis weight (lbs/ream)

Printing

Bond

Metric

equivalent

)

(g/m

75 20 50 – – – 50

90 24 60 – – – –

105 28 70 – – – –

108 29 – 40 – – –

118 31 8 0 – – – –

120 32 – – – 67 74

131 35 90 – – – –

135 36 – 50 – – –

431.8 x

558.8 mm

(17 x 22 in.)

Offset

635 x

965.2 mm

(25 x 38 in.)

Cover

508 x

660.4 mm

(20 x 26 in.)

Bristol

571.5 x

889 mm

(22.5 x 35 in.)

Index

Bristol

647.7 x

774.7 mm

(25.5 x 30.5 in.)

Tag

609.6 x

914.4 mm

(24 x 36 in.)

148 39 100 – – – –

163 43 – 60 – 90 100

176 47 120 65 – – –

199 53 – – 110 110 –

203 54 – – – – 125

Card stock weights may vary ± 5%.

Depending on the printer, material thicker than 0.30 mm (0.012 in.) may present feed reliability problems, and material thicker than 0.17 mm (0.007 in.) may reduce print quality. Contact your supplier to determine the weight of any card stock you currently use.

See the individual printer specifications in this document for more information about the card stock weights your printer supports.

Grain orientation

Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain short, running the width of the paper, or grain long, running the length of the paper.

The orientation of the grain contributes to the rigidity of card stock and affects feed reliability. The recommended grain orientation depends on the weight of the stock and whether the printer feeds the stock short-edge first or long-edge first. For lighter card stocks, grain long is recommended to reduce potential curl problems. Curl may decrease the ability of the form to move reliably through the printer.

Most printers feed paper short-edge first. If your printer supports larger paper sizes, such as 11x17 in. or A3, it may feed some paper sizes long-edge first. See your printer documentation for more information.

Grain orientation

For materials fed short edge first:

Card stock

Grain short is recommended for stock heavier than 135 g/m2

Feed direction

Grain direction

For materials fed long edge first:

Grain long is recommended for stock heavier than 135 g/m2

Feed direction

Grain long is recommended for stock lighter than 135 g/m2

Feed direction

Grain direction

Grain short is recommended for stock lighter than 135 g/m2

Feed direction

Grain direction

See the individual printer specifications in this document for more information about the recommended grain direction for card stock you use with your printer.

Grain direction

Coatings

Surface texture and coatings on card stock significantly affect toner adhesion (fuse grade), print quality, and feed reliability. We recommend a vellum finish for the best printing performance. We do not recommend glossy coatings and slick surfaces or surfaces that mimic laid finishes (glossy paper, not glossy card stock, is acceptable for some printers). Paper smoothness also affects print quality. If the paper is too rough, the toner does not fuse to the paper properly; if the paper is too smooth, it can affect feed reliability. We recommend smoothness to be between 100 and 400 Sheffield points (150 to 250 is optimal). Using media higher than 300 Sheffield could result in printing degradation.

Coatings

Card stock

Offset powders

We do not recommend using offset powders or other foreign materials to speed drying. Offset powders are used by print shops to prevent printed pages from sticking together. Powder is usually sprayed on the printed page right before it reaches the stacker on the offset printing press. This powder provides an intermediate layer between two sheets of paper, preventing ink transferring from one sheet to another.

Offset powders

Labels

Labels (also called pressure-sensitive materials) are multi-ply materials consisting of a “sandwich” of various combinations of face sheets (printable stock), adhesives, and removable protective backings (liners). The multiple layers can result in thick, difficult-to-handle materials.

Labels are among the most difficult print materials for any printer to reliably feed and print. The heat, pressure, and paper paths required by laser printers create a particularly difficult environment for printing labels. Temperatures near 225°C (437°F) [temperatures vary between printers; check the section for your specific printer] and pressures to 25 psi can be necessary for the fusing process. Heavy label stock can absorb heat, which in turn affects toner adhesion and print quality and causes problems such as delamination.

Note: To prevent labels peeling off or delaminating, make sure the release strength of the labels you use is

sufficient to withstand the temperature and pressure extremes generated during printing.

Label characteristics

The materials used to construct labels have a wide range of properties that can affect printing. In addition to volatile components in adhesive, volatiles are also in some label materials. We recommend that volatile emissions from the label, up to 160°C (320°F), should be a minimal amount. These low boiling point volatiles can produce emissions when they are heated in the fuse,r and they can potentially produce vapors which can cause damage to the printer. Preprinted inks can also cause printer contamination, and may be present on one or both sides of the label sheet.

Observing recommended label design guidelines can minimize contamination as well as prevent other critical problems, such as labels peeling off and causing jams in the printer, or the label or adhesive melting if the sheet stops in the fuser during a paper jam.

Review label designs with a converter or vendor who is knowledgeable about labels and laser printer characteristics to ensure you use labels suitable for your application.

Note: Before purchasing large quantities of labels, make sure you extensively test the labels with your

printer.

Printing on labels

Use full label sheets only. Partial sheets (with areas exposed by missing labels) can cause labels to peel off during printing, resulting in a paper jam. Partial sheets can also contaminate your printer and cartridge with adhesive and can void the printer and cartridge service warranties.

Do not feed labels through the printer more than once. Doing so may result in adhesive contamination to the cartridge and other components.

Depending on your printer model and the number of labels you print, printing labels may require special printer maintenance. (Look under “printer maintenance” in the index of your User’s Guide, publications CD, or Software and Documentation CD for specific information about maintaining your printer.)

If you print large quantities of labels or other glossy print media on a Lexmark™ C750 or C752, replace the fuser housing with a web oiler field upgrade kit (P/N 12G6307 for a 115 V printer, P/N 12G6308 for a 220 V printer).

Labels

Duplexing paper labels

Due to the special construction of labels, they are not typically duplexed. However, if certain design, construction, and usage guidelines are followed, you can print on both sides of the label sheet successfully.

When developing a paper label for duplexing, the converter should ensure the label design protects against contamination or buildup. Contamination adversely affects paper feeding and causes paper jams in the printer.

We recommend labels used for duplexing have a non-adhesive border around the label area. In addition, make sure the release strength is sufficient to withstand temperatures of 225°C (437°F) and pressures to 25 psi. This is particularly important with a duplex application since the label is subjected to these extremes twice. Use label ties whenever possible. These small uncut areas (approximately 1.6 mm or 0.06 in.) help stabilize the label sheet and prevent tearing at perforations and die-cuts during printing. In addition, using ties helps prevent the labels from predispensing in the printer.

The slits and cuts in the labels expose the adhesives to the printer. For best results when duplexing labels, position the label sheet so the slits and cuts are not aligned with the ribs in the duplex or redrive areas of the printer. (Figure 1 and Figure 2 on page 16 illustrate the rib locations for the Optra S and the Optra T, respectively.) This eliminates any contact points between the label adhesive and the printer, thereby preventing any adhesive contamination in the printer.

Other steps to ensure optimal printing include orienting the label in the tray so the label end is fed into the printer first and using long grain paper. Long grain paper tends to feed more reliably than short grain paper, which tends to curl more easily. As with any industry, product changes and improvements are constantly being developed. Therefore, if a converter develops a short grain sheet for use with duplexed labels, test the sheet to make sure it performs satisfactorily. We recommend testing any material with your application and printer before purchasing large quantities.

To use the duplex label application, you must install a special fuser wiper.

Printer Fuser wiper part number

S1855, T612, T614, T520, and T522 99A1082

T620 and T622 18A1467

T630, T632 and T634 56P2109

T64x, X644e, and X646e 40X2666

The wiper makes it possible to print on both sides of paper labels specifically designed for duplexing. In addition, you can use the wiper to simplex paper labels and duplex paper in the same printer. When ordering a new cartridge, be sure to order the cartridge that includes the correct fuser wiper.

20 mm

21 mm

27 mm

22 mm

15.5 mm

21.5 mm

28 mm

26 mm

17 mm

15 mm

Reference

plate

Figure 1. Optra S rib locations (rib width = 2mm)

Duplexing paper labels

Labels

16 mm

11 mm

15 mm

13 mm

16 mm

17 mm

Figure 2. Optra T and Lexmark T rib locations (rib width = 2mm)

26 mm

18 mm

12 mm

20 mm

15 mm

12 mm

4.02 mm

Reference

Plate

Label components

Labels are composed of three basic parts: the liner, the adhesive, and the face sheet. Labels may also have topcoats that affect printing. Choosing appropriate materials for each of these label components will help ensure reliable printing.

Liners

The liner, also known as the carrier or backing, is the material onto which the label is attached. The liner carries the label through the printer and directly affects feed reliability. Liner weights and construction vary based on the printable face stock used. (See Face sheet (printable stock) on page 17.) Tissue-backed, plain bond, or bond-like, porous, lay-flat liners are preferred. Liners constructed for use in high speed laser printers (50 or more pages per minute) may not produce acceptable results.

A liner should bend easily and snap back to its original flat state when released. If the form remains bent, it may cause paper jams or damage to the edge of the sheet, particularly in earlier printer models using a corner buckler rather than an auto compensator to separate the sheets. The following table shows which printers use a corner buckler and which use an auto compensator.

Note: If your printer is not listed here, contact your Lexmark representative to verify which method your

printer uses to separate sheets of labels.

Printers using a corner buckler Printers using an auto compensator

• 4019, 4029, 4039, 4049

• Lexmark E220, E320, E321, E322, E323, T420, W820, X422

• Optra 12L, 12R, Lxi, Lx, Rx

• Optra R+, Rt+, Lx+, Lxi+

• Optra C, Optra Color 1200, Optra N

• Optra M410, M412, W810

• C910, C912, C920

Some liner materials used in pressure-sensitive constructions are called label papers. Label papers are either M.F. (machine finish) or E.F. (English finish) papers that are calendered, supercalendered, or coated on one side. Machine

• Lexmark E230, E232, E234(n), E330, E332n, C510, C750, C752, T520, T522, T620, T622, T630, T632, T634, T640, T642, T644, X215

• Optra S 1250, S 1650, S 2450

• Optra S 1255, S 1625, S 1855, S 2455

• Optra Se 3455

• Optra T610(n), T612(n), T614(n), T616(n)

Label components

Labels

finishes have varying degrees of surface smoothness. The smoothness is determined by the number of times the paper passes through the rollers (wet or dry) during manufacturing. An English finish is uncoated and low gloss in appearance. Label papers may also be used as the face sheet for pressure-sensitive paper products, such as the materials used in dual web forms construction.

Supercalendering produces high gloss surfaces that may be slick. Some supercalendered liners are difficult for printers to pick and feed reliably. We do not recommend using supercalendered liners designed for high-speed laser printers (50 or more pages per minute).

Some pressure-sensitive constructions use Kraft liners or bleached Kraft liners. Kraft liners are made from sulfate pulp and are M.F. or M.G. (machine glazed). Most machine glazed papers have a high gloss appearance. High gloss, glazed surfaces may increase skew and are more difficult for the printer feed mechanism to handle reliably. Some Kraft liners may produce acceptable results; however, we strongly recommend extensive testing of pressure-sensitive constructions using Kraft liners.

Tissue-backed or plain bond liners reduce toner contamination inside the printer and improve feed performance. Slick, nonporous liners are harder to feed and increase toner buildup in the fuser and on the backup roll. Rough backings, on the other hand, can increase paper path friction, which can cause skew and paper jams. The face material of the liner needs to have a melt temperature that can also withstand the fuser temperatures of nearly 225°C (437°F). Since there is a stripped area of a maximum of 3 mm, this can expose the face material to these temperatures and could cause melting or contamination in the fuser.

Excessive paper dust or chaff associated with the liner may affect print quality. If a liner material produces excessive paper dust or chaff during the conversion process, some of this debris may be packaged with the material and end up in the printer. Liner materials that produce excessive paper dust or chaff as they feed through the printer may also affect print quality.

Your forms supplier can provide additional information on liners.

Adhesives

There are three basic types of label adhesives: removable, permanent, and semi-permanent (cold temp). All types, with proper design, can be used with your printer. Acrylic-based adhesives are generally preferred for cut sheet label printers.

The major adhesive-related printing problem is printer and cartridge contamination. The adhesives are semi-liquid and may contain volatile components. If the sheet jams in the fuser, the adhesive can melt, thereby contaminating parts of the printer or releasing fumes. To avoid exposing adhesive to the paper path guides, drive rollers, charge roller, photoconductor drum, transfer roller, and detack fingers, use full label sheets.

Zone coating means placing the adhesive only where needed. Paper labels and integrated forms typically use zone coating. In addition, a non-adhesive border of 1 mm (0.04 in.) around the outside edge of the label sheet generates good results. Check with your adhesive manufacturer or forms supplier for more information about designing labels for your printer.

A stripped edge matrix along the outer border of the stock, combined with adhesive that does not ooze, helps prevent adhesive contamination. This design requires a stiffer backing material to prevent damage when the sheet is aligned on the reference edge. Generally, vinyl and polyester labels are well-suited for this design. Paper and dual web designs may require testing to determine which backing produces good results. (See Label design guidelines on page 18 for more information on matrices.)

Make sure the release strength is adequate so labels stay attached to the liner and do not peel off in the printer. Adhesives must be able to withstand pressures to 25 psi and fuser temperatures of 225°C (437°F) without delaminating, creating hazardous fumes, or oozing around edges of labels, perforations, or die-cuts. Shear strength should be strong enough to prevent adhesive stringers. Contact your forms supplier for additional information.

Face sheet (printable stock)

Paper, vinyl, and polyester are the most common materials used for printable stock. Your forms supplier can provide information on whether the printable stock you want to use can withstand temperatures of 225°C (437°F) [temperatures

Label components

Labels

vary between printers; check the section for your specific printer] and pressures to 25 psi. Carefully test the stock to ensure it functions satisfactorily with your printer.

Topcoats

Topcoats for non-paper labels may be either water based or solvent based. Avoid topcoats containing chemicals that emit hazardous fumes when heated or exposed to pressure. Topcoats affect the print quality, feed reliability, and adhesion of toner to the face sheet. Topcoats must be able to withstand temperatures up to 225°C (437°F) [temperatures vary between printers; check the section for your specific printer] and pressures up to 25 psi for 100 milliseconds to prevent fuser damage.

Water-based topcoats tend to be more conductive than solvent-based topcoats and are more difficult to fuse. With some water-based topcoats and heavy liners, the fuse grade may fall below acceptable levels. Solvent-based topcoats tend to be lower in conductivity than water-based topcoats. With some solvent-based topcoats, fuse grade is within acceptable levels when heavier liners are used.

Print quality may degrade when using topcoats on labels with heavier liners. Using a lighter liner may reduce the appearance of splatter. Test forms carefully with your printer to be sure the topcoat used performs acceptably for your application.

Label design guidelines

Labels with a stripped edge matrix have the area around the outer edge of the cut sheet removed. Labels with a total strip matrix have the unneeded portion of the die-cut stock around the labels (including a portion between the labels) removed to

make it easier to peel the labels from the backing.

Butt cut labels are cut flush to one another, with no extra area between them. Avoid using butt cut labels without a stripped edge matrix.

Die-cut labels are cut with a non-print area between each label. For best results, do not print within 2.3 mm (0.090 in.) of the edge of the label, of the perforations, or of the die-cuts of the label.

If you are using a butt cut or die-cut label, make sure adhesive contamination does not occur. Labels use varying levels and types of adhesive, as well as a variety of liner materials and face stocks. Adhesive can ooze with all label stocks. Make sure die-cuts are free of adhesive stringers. Zone coating or pattern adhesive with a 1 mm (0.04 in.) or larger non-adhesive border provides the greatest protection from adhesive contamination.

If zone coating is not used, we recommend a stripped edge matrix. The stripped edge matrix varies with the type of face stock, liner, and adhesive materials. See the following table for stripped edge matrix guidelines. Measurements may vary ±0.5 mm.

Stripped edge matrix guidelines

Total weight

Face type

Paper (Cut Sheet or Dual Web)

Vinyl 265—300 g/m

Polyester and other face materials

Use a non-oozing adhesive.

Must be 1.6 mm (0.0625 in.) in some circumstances. See Vinyl and polyester labels on page 22.

of label

140—180 g/m

Varies 3.0 mm (0.125 in.)

Edge matrix

removal

1.6 mm (0.0625 in.)

3.0 mm (0.125 in.)

2.4 mm (0.094 in.)

Location of strip

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

215.9 mm (8.5 in.) at leading edge

279.4 mm (11.0 in.) at driver edge

Label design guidelines

Labels

Using cut sheet labels with adhesive applied to the edge of the sheet will contaminate your printer and your cartridge and could void your printer and cartridge warranties.

When using pressure-sensitive materials without zone coating, choose butt cut labels without any stringers and with a stripped edge matrix. If a total strip matrix is in the design for the final product, print before removing the matrix. If the matrix must be removed before printing, round all corners and make sure adhesive is not exposed.

Figure 3 on page 19 illustrates a recommended label design for Optra plus printers as well as the 4039, 4029, and 4019 laser printers. The Non-print area may vary, depending on the printer model.

Figure 4 on page 20 illustrates a recommended label design for Optra S, Optra T, and Lexmark T laser printers, which use a different paper picking mechanism.

Leading edge

8.5 in.

215.9 mm

0.094 in.

2.4 mm

Liner edge

Stripped edge

0.125 in. 3 mm

Driver edge

11 i n .

279.4 mm

0.06 in.

1.6 mm

Perforation end

Liner edge

waste strip 6.35 mm (0.25 in.)

waste strip

0.25 in.

6.35 mm

0.5 in.

12.7 mm

0.25 in.

6.35 mm

Non-print area

0.33 in.

8.38 mm

Top perforation

0.33 in.

8.38 mm

Non-print area

Non-print area Non-print area

(Not drawn to scale)

Figure 3. Design guidelines, vinyl label for Optra plus, 4039, 4029, and 4019 printers

Label design guidelines

0.094 in.

2.4 mm

Labels

Leading edge

8.5 in.

215.9 mm

Liner edge

Stripped edge

0.125 in. 3 mm

Driver Edge

11 i n .

279.4 mm

0.06 in.

1.6 mm

Perforation end

Liner edge

0.25 in.

6.35 mm

0.79 in.

20 mm

0.25 in.

6.35 mm

Non-print area

0.33 in.

8.38 mm

Top perforation

0.33 in.

8.38 mm

Non-print area

Non-print area Non-print area

(Not drawn to scale)

Figure 4. Design guidelines, vinyl label for Optra S, Optra T, and Lexmark T printers

Cut sheet paper labels

Generally, cut sheet paper labels work well with your printer. Coating or sizing to make the paper liquid-resistant decreases toner adhesion and increases the risk of toner contaminating the fuser. At a minimum, paper labels should be equivalent in weight and rigidity to a 20 lb xerographic, bond paper.

Label design guidelines

Labels

Dual web forms

Constructing dual web forms involves joining together rolls of two different materials (usually pressure-sensitive paper and bond paper) and then converting to a cut sheet product. This construction requires a stripped edge matrix. The liner must be rigid enough to withstand the pick force of the printer.

The two materials must be thin enough for the sheet to lie flat in the paper tray. Orient the form in the tray so that the pressure-sensitive area feeds into the printer first. The form should have no adhesive exposed in the overlay area or anywhere along the front or back of the form. We recommend designing a non-adhesive strip with a minimum width of 1 mm (0.04 in.) along the edges of the overlay.

To help prevent material from slipping in the fuser, we recommend knurling, which roughens up the exposed silicon area at the glue joint.

See Figure 5 on page 21 for an illustration of the recommended dual web form design. The Non-print area may vary, depending on the printer model.

The face sheet of a dual web form is usually a paper pressure-sensitive product; therefore, the guidelines for paper labels are applicable to dual web forms.

Leading edge

(8.5 in.)

Liner edge

Stripped edge

0.0625 in.

1.6 mm

Reference edge

(11 in.)

0.0625 in.

1.6 mm

0.25 in.

6.35 mm

Non-print area

Pressure-sensitive

Paper

(Not drawn to scale)

Non-print area

0.33 in.

8.38 mm

Overlay

Figure 5. Design guidelines, dual web form

Label design guidelines

Labels

Vinyl and polyester labels

Vinyl labels work well within specified design parameters. Vinyls are heat-sensitive, so the liners need to be thick enough to absorb excess heat and prevent melting. A total strip matrix may cause adhesive contamination. Thin liners or weak pull strength may lead to labels peeling off the form inside the printer, which will require printer servicing. See Figure 3 on page 19 for an illustration of a vinyl label design for Optra plus printers and Figure 4 on page 20 for Optra S, Optra T, and Lexmark T printers.

As illustrated on page 20, a leading and trailing edge stripped area is recommended to be a maximum of 3 mm. This area is recommended to prevent adhesive being close to the edge, which can contaminate your printer. Certain materials used in label construction, which have liner face melt temperatures lower than the fuser temperature, may require the leading and trailing edge stripped areas to be 1.6 mm maximum due to feeding problems. It is preferred that the liner face be constructed with material that can withstand our fuser temperatures, which eliminates the need for changing the stripped areas from 3 mm to 1.6 mm. If a 1.6 mm stripped area is used, it is very important that the 1.6 mm tolerance be held tightly. With a stripped area of less than 1.6 mm, it is highly possible that adhesive contamination will occur.

Vinyls are non-absorbing, which leads to toner build-up in the fuser that requires special maintenance. See “maintenance procedures” in the index for specific information about maintaining your printer. Vinyls may require a topcoat to ensure good toner adhesion.

Polyester labels are less heat-sensitive but are also non-absorbing. Backings for polyester labels can be thinner, but requirements for coatings and cleaning are similar to vinyl labels.

It is recommended that when you run vinyl labels, you install a special oil fuser cleaner, P/N 99A0725 or 40X2665. When you order a new cartridge, be sure to order the cartridge that will include the correct fuser cleaner.

Integrated forms

To create integrated forms, the converter uses hot melt adhesives to apply the label adhesive and liner to a base material (generally paper). Oil bleed, recognizable by a discolored face sheet, can be a problem with these forms. Oil may also migrate from the top of the liner to the back surface of the liner while it is on the roll, before the conversion process takes place. The forms created from this material may then be slick, and the pick mechanism of your printer may be unable to successfully move all the sheets from the tray into the printer. Jamming and misfeeds increase when oil is present on the back of the liner.

The adhesive on these forms is commonly patterned on two or four sides (that is, the forms have a non-adhesive border on either two or four edges). We recommend designing a 1 mm (0.04 in.) non-adhesive border (zone coated) on all four sides.

When printing on integrated forms with a long grain base material, orient the form in the tray so the paper portion of the form feeds into the printer first. Orient the pressure-sensitive portion of the form toward the portrait left edge. For integrated forms with a short grain base material, orient the form in the tray so the pressure-sensitive portion feeds into the printer first.

Due to the unique construction of integrated forms, you may experience stacking problems in the output bin. Test some forms before purchasing large quantities. Contact your Lexmark marketing representative if you experience stacking problems with these forms.

Label design guidelines

Printer specifications

To locate your printer, select one of the links in the Models column or go to the page number.

Model series Models

C series Lexmark C510 on page 48

E series Lexmark E120 on page 70

Optra series Optra C on page 94

Lexmark C520, C522, C524 on page 36 Lexmark C720 on page 54 Lexmark C750 on page 56 Lexmark C752 on page 60 Lexmark C760, C762 on page 26 Lexmark C910 on page 64 Lexmark C912 on page 46 Lexmark C920 on page 39 Optra C on page 94 Optra C710 on page 95

Lexmark E220 on page 66 Lexmark E230, E232, E234(n), E330, and E332n on page 69 Lexmark E238, E240, E240n, E340, E342n on page 25 Lexmark E320, E322 on page 67 Lexmark E321, E323 on page 68 Optra E310, E312 on page 98 Optra E, Ep on page 99 Optra Es special media printer on page 100

Optra C710 on page 95 Optra Color 1200 on page 97 Optra E310, E312 on page 98 Optra E, Ep on page 99 Optra Es special media printer on page 100 Optra K 1220 on page 102 Optra M410, M412 on page 103 Optra N on page 105 Optra plus, 4039, 4029, 4019, WinWriter 600 printers on page 106 Optra S on page 110 Optra SC 1275 on page 116 Optra T on page 117 Optra W810 on page 122

T series Lexmark T430 on page 71

Lexmark T420 on page 73 Lexmark T520, T522 on page 76 Lexmark T620, T622, Lexmark T630, T632, T634 on page 86 Lexmark T640, T642, T644 on page 41 Optra T on page 117

W series Optra W810 on page 122

Lexmark W812 on page 91 Lexmark W820 on page 92 Lexmark W840 on page 45

Printer specifications

Model series Models

WinWriter™ 600 Optra plus, 4039, 4029, 4019, WinWriter 600 printers on page 106

X series Lexmark X215 on page 52

Lexmark X422 on page 50 Lexmark X644e, X646e on page 30 Lexmark X850, X852e, X854e on page 34

Printer specifications

Lexmark E238, E240, E240n, E340, E342n

Limit label printing to occasional use of paper office labels designed for laser printers. We do not recommend using vinyl or polyester labels.

The printer supports paper and label stock from 60—90 g/m and index card stock up to 43 lb (163 g/m2). You can load up to

E238, E240, E240n

The following table lists the maximum basis weights supported by Tray 1, Tray 2, and the manual sheet feeder.

E340, E342n

Lexmark E238, E240, E240n, E340, E342n: Overview of card stock and label support

Paper source

Tray 1 – – – 163 g/m

Tray 2 – – – 163 g/m

Manual Feed 163 g/m

Note: The E238 printer does not support a second drawer option.

Index Bristol Tag Cover Paper Vinyl

50 label sheets in tray 1. Card stock must be sent through the manual feeder one sheet at a time.

Card Stock Labels

–

163 g/m

– 163 g/m2 –

For paper and transparency specifications, refer to the printer publications CD.

Media specifications

Labels Width: 89 to 216 mm (3.5 to 8.5)

Length: 210 to 356 mm (8.27 to 14 in.)

Weight: Up to 163 g/m2 (43 lb)

Thickness: Up to 0.25 mm (0.01 in.)

Smoothness: 100 to 400* Sheffield

* 150—250 Sheffield is optimal. Using media higher than 300 Sheffield could result in printing degradation.

Card stock Weight: From 120 to 163 g/m

From 75 to 163 g/m

Note: To minimize curl, use the rear exit when printing on card stock and labels.

Index Bristol (16—90 lb)

Tag (50—100 lb)

Maintenance procedures

If the print quality begins to degrade when printing sheets of labels, we suggest you:

Print 5 sheets of paper, wait approximately 5 seconds, then print 5 more sheets of paper.

To maintain printer feeding reliability, repeat this cleaning process every time you replace the print cartridge, or more often with some media. Failure to follow maintenance procedures could cause jamming, poor print quality, feeding problems, and fuser problems.

Lexmark E238, E240, E240n, E340, E342n

Printer specifications

Lexmark C760, C762

The Lexmark C760 and C762 prints on many labels designed for use with laser printers.

The following table lists the maximum basis weights supported by the trays and the multipurpose feeder. More detailed specifications appear on the following pages.

Note: The optional 2000-sheet drawer supports paper only.

Lexmark C760 and C762: Overview of card stock and label support

Card stock Labels

Paper source

Tray 1 163 g/m

500-sheet drawer 163 g/m

Multipurpose feeder 163 g/m

Vinyl labels are supported only when printing environment and media are 20—32.2°C (68—90°F).

The skew performance of heavy vinyl labels may be enhanced by feeding from an optional 500 sheet drawer if

placement of the image is critical.

Index Bristol Tag Cover Paper Vinyl

163 g/m

176 g/m

180 g/m

199 g/m2 260 g/m

300 g/m2

1, 2

For paper and transparency specifications, refer to the printer publications CD.

The following table indicates the paper sizes each tray supports

Media specifications

Labels Thickness: 0.102 to 0.305 mm (0.004 to 0.012 in.)

Smoothness: 100 to 400* Sheffield

* 150—250 Sheffield is optimal. Using media higher than 300 Sheffield could result in printing degradation.

Standard trays

The Lexmark C760 and C762 paper feeding mechanism uses advanced technology that enhances feeding reliability. The Lexmark C760 and C762 trays, which hold approximately 500 sheets of 20 lb (75 g/m supported media.

) bond paper, reliably feed all

Pick roller technology

The Lexmark C760 and C762 uses an auto compensator to pick the media rather than the corner buckler system used by earlier printer models.

The Lexmark C760 and C762 trays have two rollers that touch the media in two places (see Figure 11 on page 61). Avoid placing deep perforations in these areas since the media may nest, causing multiple sheet feeds. Perforations that could cause nesting and tenting should fall outside the 0.31—1.05 in. area on the leading edge of the media. (This is different from the 0.50 in. we recommend leaving at the top of the form for printers with a corner buckler system.) You may want to use micro-perfs to avoid nesting problems. See Perforations and die-cuts on page 8 for more information.

Lexmark C760, C762

1.05 in.

Printer specifications

Pick roller location

0.31 in.

1.34 in.

1.93 in.

4.84 in.

5.43 in.

Direction of feed

Figure 6. Location of pick rollers

Lexmark C760, C762

Printer specifications

Labels are one of the most difficult print materials for laser printers. A fuser equipped with a web oiler may be required for label applications to optimize feed reliability. Contact your local service representative for ordering information.

When printing on labels:

• Using the printer operator panel, set the Paper Type to Labels in the Paper Menu. For vinyl and other heavy

labels, set the Labels Weight (under the Paper Weight menu) to Heavy, and set the Labels Texture (under the Paper Texture menu) to Smooth.

• Do not load labels together with paper or transparencies in the same paper tray. Combining print materials can

cause feeding problems.

• Use full label sheets. Partial sheets may cause labels to peel off during printing, resulting in a paper jam. Adhesive

material may contaminate your printer. It could also void your printer and cartridge warranties.

When feeding labels, the number of labels per sheet can affect registration more than basis weight. Typically, the more labels per sheet, the better the registration.

When printing on card stock:

• Set the Paper Type to Card Stock in the Paper Menu.

• Do not use card stock that is creased. It may cause paper jams.

Print material specifications

Range or maximum weight supported

500-sheet tray and

Print material

Paper (grain direction1)

Card stock (grain Long

)

Xerographic or business paper

Index Bristol 163 g/m2 (90 lb) 163 g/m2 (90 lb)

Tag 163 g/m

Cover 176 g/m

Card stock (grain Short

)

Index Bristol 199 g/m2 (110 lb) 199 g/m2 (110 lb)

Tag 203 g/m

Cover 216 g/m

Labels Paper 180 g/m

Dual-web paper 180 g/m

Vinyl

Polyester 220 g/m

Integrated forms Pressure-sensitive area

Paper base (grain long) 75 to 135 g/m

optional 500-sheet drawer

60 to 176 g/m

(16 to 47 lb bond)

(100 lb) 163 g/m2 (100 lb)

(65 lb) 176 g/m2 (65 lb)

(125 lb) 203 g/m2 (125 lb)

(80 lb) 216 g/m2 (80 lb)

(48 lb bond) 199 g/m2 (53 lb bond)

300 g/m2 (92 lb liner) 260 g/m2 (78 lb liner)

(59 lb bond) 220 g/m2 (59 lb bond)

140 to 175 g/m

(20 to 36 lb bond)

See Grain direction on page 63 for specific recommendations.

Pressure-sensitive area must enter the printer first.

Paper less than 75 g/m2 is supported only when the relative humidity is less than 60% and is not supported in duplex.

Vinyl labels are supported only when printing environment and media are 20—32°C (68—90°F).

Multipurpose feeder

60 to 176 g/m

(16 to 47 lb bond)

140 to 175 g/m

75 to 135 g/m

(20 to 36 lb bond)

Lexmark C760, C762

Printer specifications

Grain direction

Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain long, running the length of the paper, or grain short, running the width of the paper.

For 60 to 135 g/m2 (16 to 36 lb bond) paper, we recommend grain long stock. For papers heavier than 135 g/m2, grain short is preferred.

Maintenance procedures

If the print quality begins to degrade when printing sheets of vinyl labels, we suggest you follow the three cleaning steps below:

1 Print 5 sheets of paper.

2 Wait approximately 5 seconds.

3 Print 5 more sheets of paper.

To maintain printer feeding reliability, repeat this cleaning process every time you replace the black print cartridge, more often with some media. Failure to follow maintenance procedures could cause jamming, poor print quality, feeding problems, and fuser problems.

Troubleshooting

The following table provides solutions for some common card stock and label problems. See your printer documentation for more troubleshooting information.

Solutions to printing problems

Problem Solution

Print on heavy stock is blurred or out of focus.

Toner rubs off the page. Make sure the Paper Type setting is appropriate for your print material.

Printing shows voids. Change the Paper Type to Plain Paper.

If you print large quantities of labels or other glossy print media, replace the fuser housing with a web oiler (P/N 56P1555 for a 115 V printer or P/N 56P1556 for a 220 V printer).

Make sure the Paper Type setting is appropriate for your print material. (Card stock in excess of 203 g/m [54 lb bond] may not produce acceptable print results.)

Print 5 sheets of paper, wait approximately 5 seconds, and then print 5 more sheets of paper to remove any toner that may have accumulated.

Use a lighter weight stock. (The material being used exceeds 300 g/m

Print 5 sheets of paper, wait approximately 5 seconds, and then print 5 more sheets of paper to remove any toner that may have accumulated.

Lexmark C760, C762

Printer specifications

Lexmark X644e, X646e

The Lexmark X644e and X646e print on many labels designed for use with laser printers.

The following table lists the maximum basis weights supported by the trays and the multipurpose feeder. More detailed specifications appear on the following pages.

Note: Scanning large quantities of labels is not recommended.

Lexmark X644e and X646e: Overview of card stock and label support

Card stock Labels

Grain

Paper source

direction

Integrated tray (grain long)

(grain short)

Optional 250sheet drawer

Optional 500sheet drawer

Multipurpose

feeder

Printing labels on the X644e and X646e, require a special label fuser cleaner that prevents duplexing.

(grain long) (grain short)

Index

Bristol

163 g/m 199 g/m

120 g/m 163 g/m

163 g/m 199 g/m

120 g/m 163 g/m

Tag Cover Paper

163 g/m 203 g/m

120 g/m 163 g/m

163 g/m 203 g/m

120 g/m 163 g/m

176 g/m 216 g/m

135 g/m 176 g/m

176 g/m 216 g/m

135 g/m 176 g/m

Dual-web

paper

180 g/m2180 g/m2220 g/m2300 g/m2

163 g/m2 163 g/m2220 g/m2260 g/m

180 g/m2180 g/m2220 g/m2300 g/m2

163 g/m2 163 g/m2220 g/m2260 g/m

Polyester Vinyl

It is recommended that when you run vinyl labels, you install a special oil fuser cleaner, P/N 40X2665. When you order a new label cartridge, order the X644H01A high yield return print cartridge or X644X01A extra high yield print cartridge.

It is possible to duplex certain labels that have been specifically designed for this application. To duplex labels, consult the Lexmark “Converter Lists” to see which converters have successfully developed this type of label, and you must install a special fuser wiper. The wax wiper that is used with the X644e and X646e is P/N 40X2666 (Cartridges designed for duplex label printing contain two wax wipers. Change the wax wiper at the halfway point of your normal cartridge usage to provide additional cleaning and optimize performance.)

Due to label design characteristics, unacceptable feeding may be experienced from the multipurpose feeder.

Media specifications

Labels Thickness: 0.102 to 0.305 mm (0.004 to 0.012 in.)

Smoothness: 100 to 400* Sheffield

* 150—250 Sheffield is optimal. Using media higher than 300 Sheffield could result in printing degradation.

Card stock Weight: Up to 199 g/m

Up to 203 g/m

Index Bristol (90 lb)

Tag (100 lb)

Lexmark X644e, X646e

+ 100 hidden pages