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This manual contains propriet ar y inf or ma ti on of Zebr a Tec hnol ogies Corporation. It is intended sole ly for the
information and use of parties operating and maintaining the equipment described herein. Such proprietary
information may not be used, reproduced, or disclosed to any other parties for any other purpose without the
expressed written permission of Zebra Technologies Corporation.
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Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and
signs are subject to change without notice.
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This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates, uses,
and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may
cause harmful inte rfer ence t o radi o communica tions . Operat ion of this e quipment in a r eside ntial area is likely
to cause harmful interfe r ence in which case the user will be required to correct the inter f erence at his own
expense.
To ensure compliance, this print engine must be used with a Shielded Power Cord and Shielded
Communication Cables.
“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies
Corporation could void the user’s authority to operate the equipment.”
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This digital apparatus does not exceed t he Class A limits for radio nois e emissions from digital appar atus as set
out in the radio interference regulations of the Canadian Department of Communications.
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Zebra Technologies Corporation takes steps to ensure that its published Engineering Specifications and
Manuals are correct; however, errors do occur. Zebra Technologies Corporation reserves the right to correct
any such errors and disc laims liability resulting therefrom.
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In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production, or
delivery of the accompanying product (including hardware and software) be liable for any damages
whatsoever (including, without limitation, damages for loss of business profits, business interruption, loss of
business information, or other pecuniary loss) arising out of the use of or the results of use or inability to use
such product, even if Zebra Technologies Corporation has been advised of the possibility of such damages.
Because some states do not allow the exclusion or limitation of liability for consequential or incidental
damages, the above limitation may not apply to you.
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The copyrights in this manual and the label print engine described therein are owned by Zebra Technologies
Corporation. All rights are reserved. Unauthorized reproduction of this manual or the software in the label
print engine may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506).
Copyright violators may be subject to civil liability.
Zebra 110PAX™, 112PAX ™, 113PAX™, ProPlus™, Platinum™, WebView™, Z-Tools™, and ZebraLink™
are trademarks and ZPL
Technologies Corporation.
®
IBM
is a registered trademark of IBM Corporation.
© 2002 Zebra Technologies Corporation. All rights reserved.
®
, ZPL II®, ZebraNet®, and BAR-ONE® are registered trademarks of Zebra
ii Zebra 116PAX3 User’s Guide
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Zebra 116PAX3 Print Engine..........................................................................................................................1
Getting Started.................................................................................................................................................1
Unpacking..................................................................................................................................................1
Reporting Damage .....................................................................................................................................1
Print Engine Mounting....................................................................................................................................2
Communications..............................................................................................................................................2
ZebraLink™ Real-Time Connectivity and Control Solution..........................................................................3
Print Engine Power..........................................................................................................................................4
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Media Loading ................................................................................................................................................5
Ribbon Loading...............................................................................................................................................7
Removing Used Ribbon ..................................................................................................................................8
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Reflective Media Sensor .................................................................................................................................9
Transmissive Media Sensor.............................................................................................................................9
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Power On/Off Switch....................................................................................................................................11
Front Panel Keys...........................................................................................................................................11
Liquid Crystal Display (LCD).......................................................................................................................12
Control Panel Keys.................................................................................... ....................................................12
Front Panel Indicator Lights (LEDs).............................................................................................................13
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Entering the Setup Mode...............................................................................................................................15
Changing Password-Protected Parameters....................................................................................................15
Leaving the Setup Mode................................................................................................................................16
Configuration and Calibration Sequence ......................................................................................................16
Setting Print Parameters...........................................................................................................................17
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Cleaning.........................................................................................................................................................37
Cleaning the Exterior...............................................................................................................................37
Cleaning the Interior ................................................................................................................................37
Cleaning the Sensors................................................................................................................................37
Cleaning the Printhead and Platen Roller ................................................................................................38
Toggle Positioning ........................................................................................................................................42
Printhead Pressure Adjustment .....................................................................................................................43
Zebra 116PAX3 User’s G uide iii
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Power-On Self Test.......................................................................................................................................45
Power-On Troubleshooting...........................................................................................................................46
Print Engine Troubleshooting .......................................................................................................................46
Print Engine Self Tests..................................................................................................................................50
Introduction..............................................................................................................................................50
CANCEL Key Self Test...........................................................................................................................50
PAUSE Key Self Test..............................................................................................................................51
FEED Key Self Test.................................................................................................................................52
FEED Key and PAUSE Key Self Test.....................................................................................................53
Communications Diagnostics Test...........................................................................................................54
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Single In-line Memory Module (SIMM).......................................................................................................55
Personal Computer Memory Card Interface Association (PCMCIA) Memory Card...................................55
ZebraNet™ PrintServer II.............................................................................................................................55
Remote Front Panel.......................................................................................................................................55
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Standard Features..........................................................................................................................................57
Physical Characteristics.................................................................................................................................57
Environmental Operating Range...................................................................................................................57
Printing Considerations.................................................................................................................................57
Media Specifications.....................................................................................................................................58
Ribbon Specifications....................................................................................................................................58
Zebra Programming Language (ZPL II)........................................................................................................58
Bar Codes......................................................................................................................................................59
Communications Specifications....................................................................................................................59
Memory .........................................................................................................................................................59
Electrical........................................................................................................................................................59
Fuses..............................................................................................................................................................59
AC Power Cord Requirements......................................................................................................................60
AC Power Cord Specifications................................................................................................................60
Power Fuse Replacement ..............................................................................................................................60
Shipping.........................................................................................................................................................61
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Print Engine Communications Interface Technical Information...................................................................69
System Considerations.............................................................................................................................69
Interface Considerations...........................................................................................................................69
RS-232/RS-422/RS-485 Serial Data Port......................................................................................................70
IEEE 1284 Bi-directional Parallel Data Port.................................................................................................73
Cabling Requirements...................................................................................................................................74
Applicator Interface Connector.....................................................................................................................74
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Installation Information .................................................................................................................................79
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Zebra 116PAX3 User’s G uide v
Zebra 116PAX3 User’s G uide vi
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Congratulations! You have just purchased a high-quality thermal demand print engine manufactured by the
industry leader in qual ity, service, and value. For over 30 years , Zebra Technologies Corporation ha s pro vided
customers the highest caliber of products and support.
To create and print label formats, re fer to the ZPL II Programming Guide (part # 46530L). T his guide is
available by contacting your distributor or Zebra Technologies Corporation. It is also available as a file to
download from Zebra’s Web site: http://support.zebra.com
available. Contact your distributor or Zebra Technologies Corporation for further information.
The Zebra 116PAX3 Maintenance Manual (part # 43490L) contains the information you need to maintain the
print engine properly.
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This user’s guide contains information specific to the 116 PAX3 (600 dot/inch) print engine manufactured by
Zebra Technologies Corporation. The print engine is available in a right-hand configuration (media moves
from left to right) and in a left-hand configuration (media m oves from right to left).
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Save the cartons and all packing materials in case shipping is required. If your print engine is equipped
with the factory-installed remote front panel option, the front panel, mounting bracket, hardware, and
instruction sheet are packaged in bubble wrap securely taped to the print engine. The interconnect cable is
secured to a cardboard panel inside the outer box.
. In addition, label preparation software is
Inspect all components for possible shipping damage:
• Check all e xterior sur faces for da mage.
• Raise the front cover and inspect for damage.
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If you discover shipping damage:
• Immediately notify the shipping company and file a damage report.
• Retain the carton and all packing material for inspection.
• Notify your local Zebra distributor of the damage.
Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the print
engine and will not cover the repair of this damage under its warranty policy. Any damage claim should be
filed with the shipping company.
For shipping information, refer to “Shipping” on page 61.
Zebra 116PAX3 User’s G uide 1
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For specific information on mounting the print engine into an applicator, refer to “Appendix B” on page 79.
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Refer to Figure 1 on page 4. The 116PAX3 print engine comes standard with both an Electronics Industries
Association (EIA) RS-232 serial interface (DB-25 Connector) and an IEEE 1284 bi-directional parallel
interface. The serial interface is also configured for both RS-422/RS-485 single drop and RS-485 multi-drop
serial interfaces. Any of these four interface methods may be used to send commands and label formats from a
host to the print engine.
A DB-15 Applicator Interfa ce Connect or prov ides communi cati on betwee n the pri nt engi ne and the associ ated
applicator hardware. In some applications, control signal timing may be a critical element in the performance
of the print engine. Refer to “Appendix A” beginning on page 69 for control signal descriptions.
2 Zebra 116PAX3 User’s Guide
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ZebraLink is the adva nced print engine manag ement tool t hat enabl es real- time,
remote error notification and systems control for OEMs, distributors, system
integrators, and end-users. ZebraLink’s combined components of WebView,
Alert, and ZBI help address the growing need for networked equipment. Only
ZebraLink gives you the power to control and monitor your print engines
anytime, anywhere. Every ZebraLink print engine (just look for the ZebraLink
logo), when used with ZebraLink-compatible network options, provides three
core features:
®
• WebView (requires ZebraNet
networked users to control multiple functions of the printing process using any standard Web browser,
such as Netscape Navigator or Internet Explorer. Users simply logon to the 116PAX3’s print engine
password-protected Web page via its IP address to view label formats, fonts, and graphics stored in
memory, as well as to adjust common print engine settings such as darkness, media/ribbon sensor values,
and applicator interface modes.
• The Alert feature (requires ZebraNet
back.” With ZebraLink, the print engines provide unsolicited communication to system administrators in
real time. If a 116PAX3 print engine runs out of media or ribbon, it ins ta ntl y not if ies the user by issuing a
detailed error message via e-mail to any text-capable, wired or wireless device, including pagers, cell
phones, PDAs, and PCs. Notification directly from the print engine ensures the proper personnel are
alerted immediately of an error condition so they can respond quickly and return the line to full operation.
• With ZBI, users familiar with ANSI
BASIC programming language can
easily program advance d applications
within the 116PAX3’s print engine,
enabling it to accept and manipulate
information from nearly any data
source (PLCs, weigh scales,
scanners, etc.), as well as to print the
desired information on a labe l. Thus ,
the 116PAX3 pr int engine acts as the
“brain” and creates true stand-alone
applications using a scanner,
keyboard, PLC, or weigh-scale as an
I/O device, replacing the need for a
dedicated computer terminal. ZBI
controls and interprets incoming text
and data streams, which permits the
replacement of any brand of bar code
print engines and printers with the
superior performance and reliability
of Zebra products, without costly
label reformatting.
PrintServer II) is the configuration component of ZebraLink, and enables
®
PrintServer II) gives 116PAX3 print engines the voice to “talk
ZebraLink Integration
Equipped with 4 MB of RAM and 1.5 MB of non-volatile memory, the 600 dpi 116PAX3 print engine is
capable of handling labels up to 33″ (84 cm) long and can store complex label formats, fonts, and graphics.
Print-and-apply systems with 116PAX3 print engines have the industry’s most advanced monitoring and
management tools av ailable for any a utomated p rint-and -apply appli cation. No other OEM print engines in the
market offer this powerful combination.
Zebra 116PAX3 User’s G uide 3
If your print engine is equipped with the factory-installed remote front panel option, a DB-15 connector is
supplied on the same bracket with the applicator interface for connection to the remote front panel.
NOTE: With the exception of the optional remote front panel, you must supply all in terface cables for
your application. Refer to “Appendix A” beginning on page 69 for specific cable requirements.
CAUTION: Connecting a data communications cable while the power is ON may damage the
116PAX3 print engine.
Refer to Figure 7 on page 12 and ensure that the AC power ON/OFF swit ch is in t he OFF (O) po siti on. Ens ure
that power is off to the host and the applicator. Insert each connector fully and tighten all screws. When
connecting a parallel interface cable, secure the cable to the print engine with the two clips on the connector.
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The power supply in the 116PAX3 print engine automatically detects the applied line voltage and works in the
90 to 264 VAC, 48 to 62 Hz range.
Refer to Figure 1. The AC power cord must have a three-prong female connector on one end that plugs into
the mating connector at the rear of the print engine. If a power cord was not included with your print engine,
refer to “Appendix A” beginning on page 69.
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Refer to Figure 7 on page 12 and ensure that the AC power ON/OFF switch is in the OFF (O) position before
connecting the AC power cord to a nearby electrical outlet.
Figure 1. Power and Cable Connections
4 Zebra 116PAX3 User’s Guide
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If your print engine is a right- hand unit (prin ted labels ar e presen ted on the ri ght-h and side of th e uni t), ref er to
Figure 2 while performing the following procedure. If your print engine is a left-hand configuration (printed
labels are p r esented on the left-han d side of the unit), refer to Figure 3.
1. Load the media on the media supply reel of the applicator (refer to the applicator’s user’s manual).
2. Grasp the outer media edge guide (A) and slide it as far out from the print engine frame as possible.
3. Open the printhead assembly (B ) by unlatching the print head latch (C) from the lo cking pin (D).
4. Press the release but to n (E) on t he segme nted pi nch rol ler as sembly ( F) and al low the as sembly t o pivot up.
5. Thread the media unde r t he u pper guide post (G), b et ween t he rubber pinch rolle r a nd t he associated roller
in the segmented pinch roller assembl y (F) , and unde r the prin thead assembly (B) until approxi mate ly 30 ″
(75 cm) of media extends out of the print engine. Remove the labels from the exposed media.
Figure 2. Media Loading (RH)
Zebra 116PAX3 User’s G uide 5
6. Ensure the media is aligned to the stationary inner media edge guide and the indicator on the peel bar.
7. Close the printhead assembly (B) by rotating the printhead latch (C) until it latches onto the locking
pin (D).
8. Press down on the pivoting segmented pinch roller assembly (F) until it locks closed.
9. Position the outer media edge guide (A) so it just touches the outer edge of the media.
10. Raise the peel roller latch (H) so the peel roller assembly (I) pivots down to a vertical position.
11. Thread the media l i ner ar ound the peel bar ( J), under the lower med ia li ner roller (K), and through the peel
roller assem bly (I). (See Detail.)
NOTE: If the applicator has an air tu be, route the medi a liner bet ween the ai r tube and the pee l bar. Do
not thread the media liner over this tube!
12. Rotate the peel roller assembly (I) up until it locks into the closed position.
13. Thread the media liner under the lower guide post (L) and around the take-up spindle of the applicator
(refer to the applicator’s user’s manual).
Figure 3. Media Loading (LH)
6 Zebra 116PAX3 User’s Guide
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To load ribbon, refer to Figure 4 (for right-hand units) or Figure 5 (for left-hand units).
NOTE: Do not load ribbon if the print engine is to be used in the direct thermal mode.
CAUTION: When installing the ribbon roll on the ribbon supply spindle, ensure that it is fully
seated and that the ribbon is aligned squarely with its core. Do not use ribbon that is narrower
than the media. If the printhead is not protected by the smooth liner of the ribbon, premature
printhead failure may result due to excessive abrasion.
1. Install the ribbon roll onto the supply spindl e (M) an d push it on until it is full y sea te d, so t he ribbon feeds
as shown in Figure 4 for right-hand units or Figure 5 for left-hand units. Ensure that the ribbon core fits
tightly to the spindle. If the core is not tight, proper ribbon tension may not be maintained.
2. Install an empty ribbon core onto the ribbon take-up spindle (N) and push it on until it is fully seated.
Ensure that the ribbon core fits tightly to the spindle.
3. Open the printhead assembly (B ) by unlatching the print head latch (C) from the lo cking pin (D).
4. Using your thumb and th e side of your index f inger, squeeze the ribbon supply dancer arm ope ning ta b (O)
toward the outer U-shaped channel and pivot open the dancer arm. Carefully thread the ribbon between
the two U-shaped channels, and then slowly release the ribbon supply dancer arm.
5. Thread the ribbon under the printhead assembly (B) and then up toward the ribbon take-up dancer
assembly.
Figure 4. Ribbon Loading (RH)
Zebra 116PAX3 User’s G uide 7
Figure 5. Ribbon Loading (LH)
6. Using your thumb and the side of your index finger, squeeze the dancer arm opening tab (P) toward the
inner U-shaped channel and pivot open the dancer arm. Carefully thread the ribbon between the two
U-shaped channels, and then slowly release the dancer arm.
7. Attach the ribbon to the take-up spindle core (use a label if needed) and wind for several turns in the
direction shown in the illustration. Make sure the ribbon winds evenly on the spindle to prevent the
possibility of the ribbon telescoping.
8. Close the printhead assembly (B) by pivoting the printhead latch (C) onto the locking pin (D).
9. Ensure the ribbon is routed properly in both ribbon dancer assemblies and between the ribbon sensor (Q)
and the ribbon sensor reflector (R) positioned below it.
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To remove used ribbon, refer to Figure 4 (for right-hand units) or Figure 5 (for left-hand units):
1. Open the printhead assembly (B ) by unlatching the print head latch (C) from the lo cking pin (D).
2. If the ribbon is not completely exhausted, wind the remaining ribbon onto the take-up spindle (N), or cut
the ribbon between the take-up spindle and the ribbon take-up dancer assembly.
3. Remove the ribbon, complete with the core, from the ribbon take-up spindle.
4. Remove the supply ribbon core from the ribbon supply spindle (M).
5. Load the new ribbon as explained on page 7.
8 Zebra 116PAX3 User’s Guide
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Some types of media have black marks printed on the underside of the media liner that act as “Start of Label”
indicators. The refle ctive media se nsor se nses these black mar ks. The pos ition of this sensor is n ot adju stabl e.
If you use this type of media, refer to “Media Specifications ” on page 58 for information about black mark
requirements.
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The transmissive media sensor finds “Start of Label” indicators such as a notch or hole in the media or an
interlabel gap between labels. This sensor consists of a light source (positioned below the media) and a light
sensor (positioned above the media). To position this sensor, refer to Figure 6. If the media has a notch or
hole, slide the sensor pos ition i ndicator (Q) alon g the pivo ting segmen ted pinch roller assembly ( F) so the point
of the indicator aligns with the notch or hole in the media. If your media uses an interlabel gap, position the
media sensor approximately at the center of the media width.
Figure 6. Media Sensor Adjustment (RH)
Zebra 116PAX3 User’s G uide 9
10 Zebra 116PAX3 User’s Guide
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The Power On/Off Switch is located on the top of the print engine housing, as shown in Figure 7. When this
switch is placed in the ON ( | ) position, the POWER light turns ON and the print engine automatically
performs a Power-On Self Test (POST). T he Liquid C rystal Display (LCD) validates the steps in the self test.
NOTE: Refer to “Troubleshooting” beginning on page 45 if the print engine stops due to failing a test
in the POST.
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All controls for the print engine are located on the front panel. If your print engine is equipped with the
factory-installed remote front panel option, the front panel is absent from the front of the print engine and all
controls are located on the remote front panel.
Four keys are used to control the various print engine operations:
FEED Key—If you press the FEED key while the print engine is idle or paused, a blank label is fed
immediately. If you press the FEED key while the print engine is printing, one blank label is fed after the
completion of the current batch of labels. Once the blank label has been fed, pressing the FEED key again
feeds a second label.
PAUSE Key—The PAUSE key stops and restarts the printing process. When the print engine is paused, the
PAUSE light is ON. The first time you press the P AUSE key, any partially printed label is completed, then the
printing proces s is sto pped. If the prin t engine is idle when you press t he PAUSE key , no ne w print r equests are
accepted. Press the PAUSE key a second time to resume the printing process.
The PAUSE mode can also be activated/deactivated through pin 5 of the Applicator Port or by sending a
®
ZPL II
CANCEL Key—The CANCEL key functions only when the print engine is paused. When you press the
CANCEL key, the label format that is currently printing is canceled. If no label format is printing, then the
next one to be pri nt ed is canceled. If t her e are no label for m at s s to red in the print e ngi ne waiting to be pr int ed,
the CANCEL key is ignored. To clear the print engine’s entire label format memory, press and hold this key
for several seconds until the DATA light turns OFF. The print engine discards all of the label format data it
has received and returns to the idle state.
.
CALIBRATE Key—The CALIBRATE key functions only in the PAUSE mode. Press once to recalibrate for
proper media length, set media ty pe (continu ous/non -continuo us), and set pri nt method (dir ect thermal/t hermal
transfer).
command to the print engine.
Zebra 116PAX3 User’s G uide 11
Figure 7. Control Panel
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The control panel shown in Figure 7 contains a backlit LCD. It shows operational status as well as setup
modes and feature parameters.
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Five keys are used to set print and communication parameters:
BLACK OVAL KEYS—These two keys are used to change parameter values depending on the parameter
being displayed. Common uses include increasing or decreasing a value, answering yes or no, indicating ON
or OFF, and scrolling through several choices.
PREVIOUS—Scrolls th e display to th e previous parameter.
NEXT—Scrolls the display to the next parameter.
SETUP/EXIT—Enters and exits the setup mode.
Specific uses of th ese keys a re expl ained with e ach par ameter sett ing des cript ion i n “Configuration” beginning
on page 15.
12 Zebra 116PAX3 User’s Guide
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LEDs on the front panel are a quick indication of the print engine’s status.
LED OFF ON FLASHING
POWER
(Green)
PAUSE
(Yellow)
DATA
(Green)
MEDIA
(Yellow)
RIBBON
(Yellow)
ERROR
(Orange)
Print engine OFF or no
power to print engine.
Normal operation. Print engine is paused (Printhead, ribbon,
No data being received
or processed.
Normal operation.
Media properly loaded.
Normal operation.
Ribbon properly loaded.
No print engine errors. — Print engine error exists. Check LCD for
Power switch is ON and power is being
supplied to print engine.
or paper error detected.
or
PAUSE key was pressed.
or
A pause was requested from the
Applicator Port.
or
A pause was received as part of the label
format).
Data processing or printing taking place. Print engine is receiving data from or
sending status information to the host
computer. Flashing slows when the print
engine cannot accept more data, but
returns to normal once dat a is agai n being
received.
Out of media. (Print engine is paused,
LCD displays error message, and PAUSE
light is ON).
Ribbon in (print engine is in direct ther ma l
mode) or no ribbon loaded (print engine is
in thermal transfer mode). Print engine is
paused, LCD displ ays e rror mes sage, an d
PAUSE lig ht is ON.
status.
—
—
—
—
Zebra 116PAX3 User’s G uide 13
14 Zebra 116PAX3 User’s Guide
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After you have installe d the media and r ibbon and the Power- On Self Test (POST) is complete, the LCD shows
“PRINTER READY.” (If the print engine fails its POST, refer to page 45.) You may now set print engine
parameters for your application using the front panel display and the five keys directly below it.
NOTE: Print engines that are operating on an IP network can be quickly configured using ZebraNet
WebView (optional ZebraNet
Networking: PrintServer II Installation and User’s Guide.
If it becomes necessary to restore the initial print engine defaults, see “FEED Key and PAUSE Key Self Test”
on page 53.
®
PrintServer II required). For information, refer to ZebraNet
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To enter the setup mode, press the SETUP/EXIT key.
Press either the NEXT key or PREVIOUS key to scroll to the parameter you wish to set.
NOTE: You may also press and hold the NEXT and PREVIOUS keys to advance quickly through the
configuration parameters.
Parameters in this section are shown in the order displayed when pressing the NEXT key. Throughout this
process, press the NEXT key to continue to the next parameter, or press the PREVIOUS key to return to the
previous parameter in the cycle.
®
An asterisk (*) in the upper left-han d corner of the LCD indicates that the val ue displayed is different from the
currently stored value.
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Certain parameters, indicated by an illus tr at ion of a key after the titl e, a re pas swor d pr otected by factory
default.
CAUTION: Do not change password-protected parameters unless you have a complete
understanding of what you a re doing! If the paramet er s a re s et incorrectly, they could cause the
print engine to function in an unpredictable way.
The first attempt to change one of these parameters (pressing one of the BLACK OVAL keys) requires you to
enter a four-digit password. This is done via the “ENTER PASSWORD” display.
ENTER PASSWORD
0000 +
The LEFT BLACK OVAL key changes the selected digit positions, and the RIGHT BLACK OVAL key
increases the selected digit value. A fter entering the passwo rd, press the NEXT key. The parameter you wish
to change is displayed. If the password was entered correctly, you can now change the value.
The default password value is 1234. The password can be changed using the ^KP (Define Password) ZPL II
instruction or through ZebraNet
®
WebView (optional ZebraNet® PrintServer II required).
Zebra 116PAX3 User’s G uide 15
NOTE: Once the password has been entered correctly, it does not have to be entered again unless you
leave and re-enter the setup mode using the SETUP/EXIT key.
NOTE: You can disable the password protection feature so that it no longer prompts you for a
password by setting the password to ØØØØ using the ^KPØ ZPL/ZPL II command. To re-enable the
password-protection feature, send the ZPL/ZPL II command ^KPx, where “x” can be any number, one
to four digits in length, except Ø.
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You can leave the setup mode at a ny time by pre ssing th e SETUP/EXI T key. The “SAVE CHANGES” display
appears.
SAVE CHANGES
PERMANENT
There are five choices described below. Pressing the LEFT or RIGHT BLACK OVAL key displays other
choices, and pressing the NEXT key selects the displayed choice.
PERMANENT—Permanently saves the changes. Values are stored in the print engine even when power is
turned off.
TEMPORARY—Saves the new changes until they are changed again or until power is turned off.
CANCEL—Cancels all changes since press ing th e SETUP/EXIT key exc ept t he d arknes s and t ear -o f f set tings
(if they were changed).
LOAD DEFAULTS—Loads factory defaults as the print engine’s operating parameters. The factory defaults
are shown on the following pages.
NOTE: Loading factory defaults requires that a new print engine calibration be performed, which
resets printhead resistance and applicator port values.
LOAD LAST SAVE—Reloads values from th e last perm anent save as the pr int en gine’s operating parameters.
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The configuration paramet er s are shown in t he ord er t hey ar e dis played when the NEXT key is pressed. Press
the NEXT key to move to the n ext parameter or the PREVIOUS key to return to the previous parameter in the
cycle. When a parameter is changed, an asterisk (*) is shown in the upper left c orner of the L CD to indicate
that the value is different from the one currently active in the print engine.
If you want the prompts shown in a languag e other than Englis h, press the PREVIOUS key to s elect t he desire d
language. Exit the setup mode, save permanent, and re-enter the setup mode. The LCD now uses the selected
language.
16 Zebra 116PAX3 User’s Guide
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Press LCD Shows Action/Explanation
— Normal print engine operation.
PRINTER READY
Setting Print Parameters
Adjusting Print Darkness: Press the RIGHT BLACK OVAL key to
DARKNESS 4.0
- +
TEAR OFF +0
- +
PRINT MODE
APPLICATOR
increase darkness. Press the LEFT BLACK OVAL key to decrease
darkness.
Default: 4.0
Range: 0.0 to +30.0
Darkness (burn duration) settings are dependent on a variety of
factors, including ribbon type, media, and the condition of the
printhead. You may adjust the darkness for consistent high-quality
printing.
If printing is too light, or if there are voids in printed areas, you should
increase the darkn es s. If p rin ting is to o d ark, or if there is spreading or
bleeding of printed areas, you should decrease the darkness.
The FEED Key Self Test on page 52 also can be used to det ermine the
best darkness setting. Since the darkness setting takes effect
immediately, you can see the results on labels that are currently
printing.
CAUTION: Set the darkness to the lowest setting that provides good
print quality. Darkness set too high may cause ink
smearing and/or it may burn through the ribbon.
Darkness settings also may be changed by the driver or software
settings.
Adjusting the T e ar-Off Position: Press the RIGHT BLACK OVAL key
to increase the value; pr ess the LEFT BLACK OVAL key to decrease
the value. Each press of the key adjusts the tear-off position by four
dot rows.
Default: +0
Range: –120 to +120
This parameter establishes the position of the media over the tear-off/
peel-off bar aft er printin g so the label an d liner can be torn of f. Positive
numbers move the media out, negative numbers move the media in.
Selecting Print Mode: Press the RIGHT or LEFT BLACK OVAL key
to display other choices.
Default: Applicator
Selections: Tear-off, rewind, applicator
Print mode settings tell the print engine the method of media delivery
that you wish to use.
Zebra 116PAX3 User’s G uide 17
Press LCD Shows Action/Explanation
Setting Media Type: Press the RIGHT or LEFT BLACK OVAL key to
MEDIA TYPE
NON-CONTINUOUS
SENSOR TYPE
WEB
PRINT METHOD
THERMAL-TRANS.
display other choices.
Default: Non-continuous
Selections: Continuous, non-continuous
This parameter tells the print engine the type of media you are using.
Selecting continuous media requires that you include a label length
instruction in your label format (^LLxxxx if you are using ZPL or
ZPL II).
When non-continuous media is selected, the print engine feeds media
to calculate label length (the distance between two detections of the
inter-la bel gap, webbing, or alignment notch or hole).
Setting the Sensor T y pe: Press the RIGHT or LEFT BLACK OVAL
key to display other choices.
Default: Web
Selections: Web, mark
This parameter tells the pri nt en gin e whether you are using media with
a web (gap/space between labels, notch, or hole) to indicate the
separations be tween la bel s or if yo u are us ing me dia with a bla ck ma rk
printed on the back. If your media does not have black marks on the
back, leave your print engine at the defaul t (web ).
Selecting Print Method: Press the RIGHT BLACK OVAL key for the
next value; press the LEFT BLACK OVAL key for the previous value.
Default: Thermal transfer
Selections: Thermal transfer, direct thermal
The print method param eter tell s the pri nt engin e the method o f printing
you wish to use: direct thermal (no ribbon) or thermal transfer (using
thermal transfer media and ribbon).
NOTE: Selecting direct thermal when using thermal transfer media
and ribbon creates a warning con dition, but printing co ntinues.
Verify that the ribbon is correctly inst alled for The rmal T ransfer,
and not installed for Direct Thermal.
18 Zebra 116PAX3 User’s Guide
Press LCD Shows Action/Explanation
Setting Print Width: Press the RIGHT BLACK OVAL key to increase
PRINT WIDTH
1920 dots +
MAXIMUM LENGTH
-33.0 IN 838 MM+
the value; press the LEFT BLACK OVAL key to decrease the value. To
change the unit of measurement, press the LEFT BLACK OVAL key
until the unit of measurement is active, then press the RIGHT BLACK
OVAL key to toggle to a d if f eren t unit of measure (inche s, mm , or dot s ) .
Default: 1920 dots
Print width determines the printable area across the width of the label
given the resolution of the print engine.
NOTE: Setting the width t oo narrow can result in portions of the label
not being printed on the label material. Setting the width too
wide wastes formatting memory and can cause printing off the
label and on the platen. This setting can affect the horizontal
position of the label format if the image was inverted using the
^POI ZPL II command.
Setting Maximum Label Length: Press the LEFT BLACK OVAL key
to decrease the value; press the RIGHT BLACK OVAL key to increase
the value.
Default: 33.0 in. (838 mm)
Range: Values are adjustable in one-inch (25.4 mm) increments.
Maximum length is used in conjunction with the calibration procedure.
The value of this setting determines the maximum label length that is
used during the media portion of the calibration process. Only a few
labels are required to set media sensors. The interlabel gap is
considered part of the label length and must be taken into
consideration. Alway s set the value that is clos est to, but not less than,
the length of the label you are using. For example, if the length of the
label is 5 in. (126 mm) including the interlabel gap, set the parameter
for 6.0 in. (152 mm). If the length of the label is 7.5 in. (190 mm), set
the parameter for 9.0 in. (229 mm).
NOTE: Before beginning the media and ribbon c alibration, be sure that
the Maximum Length is set one increment greater than the
actual media. If the value is set to a smaller value, the print
engine assumes that continuous media is loaded and cannot
calibrate.
Zebra 116PAX3 User’s G uide 19
Listing Print Engine Information
Press LCD Shows Action/Explanation
List Fonts: Press the RIGHT
LIST FONTS
PRINT
LIST BAR CODES
PRINT
LIST IMAGES
PRINT
LIST FORMATS
PRINT
LIST SETUP
LIST ALL
BLACK OVAL key to print a label
listing all available fonts.
This selection is used to print a
label that lists all fonts currently
available in the print engine,
including standard print engine
fonts plus a ny op tional font s. Fo nts
may be stored in RAM, FLASH
memory , font EPROMs, or o ptional
PCMCIA card.
List Bar Codes: Press the RIGHT
BLACK OVAL key to print a label
listing all available bar codes.
This selection is used to print a
label that lists all bar codes
currently available in the print
engine. Bar codes may be stored
in RAM, FLASH memory, or
optional PC MCIA card.
List Images: Press the RIGHT
BLACK OVAL key to print a label
listing all available images.
This selection is used to print a
label that lists all images currently
stored in the print engine’s RAM,
FLASH memory, or optional
PCMCIA card.
List Formats: Press the RIGHT
BLACK OVAL key to print a label
listing all available formats.
This selection is used to print a
label that lists all formats currently
stored in the print engine’s RAM,
FLASH memory, or optional
PCMCIA card.
List Setup: Press the RIGHT
BLACK OVAL key to print a label
listing the current pri nt engine
configuration (as shown in the
sample on the right).
This selection is used to print a
label that lists the current print
engine configuration inform ati on.
(Same as CANCEL Key Self Test.)
List All: Press the RIGHT BLACK
OVAL key to print a label listing all
available font s, b ar cod es, im ages,
formats, and the current print
engine configuration .
This selection is used to print a
label that lists the five previous
selections, as descr ibed.
20 Zebra 116PAX3 User’s Guide
Press LCD Shows Action/Explanation
INITIALIZE CARD
YES
Initialize Memory Card
CAUTION: Perform this operation only when it is necessary to erase
all previously stored info rma t io n from the optional
PCMCIA card. Press the NEXT key to bypass this
function.
1. Press the RIGHT BLACK OVAL key to select “YES.”
If your print engine is set to require a password, yo u are pro mp ted
to enter the password. Enter the password and press the NEXT
key.
2. The LCD shows “INITIALIZE CARD.” Press the RIGHT BLACK
OVAL key to select “YES.”
3. The LCD shows “ARE YOU SURE.”
4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.
or
Press the LEFT BLACK OVAL key “NO” to cancel the request and
return to the “INITIALIZE CARD” prompt.
5. Press the SETUP/EXIT key followed by the NEXT key. If
initialization is still in process, the LCD flashes back and forth
between the two phrases “CHECKING B: MEMORY” and
“PRINTER IDLE.”
When initializatio n is c om ple te, the pr int engi ne au tom ati cally exits
the setup mode and the LCD shows “PRINTER READY.”
NOTE: Depending on the amount of memory in the memory card,
initialization may take up to five minutes to complete.
INITIALIZE FLASH
YES
ARE YOU SURE
NO YES
Initialize Flash Memory
CAUTION: Perform this operation only when it is necessary to erase
all previously store d information f rom the FLASH memo ry .
Press the NEXT key to bypass this function.
1. Press the RIGHT BLACK OVAL key to select “YES.”
If your print engine is set to require a password, you are prompted
to enter the password. Enter the password and press the NEXT
key.
2. The LCD shows “INITIALIZE FLASH.” Press the RIGHT BLACK
OVAL key to select “YES.”
3. The LCD shows “ARE YOU SURE.”
4. Press the RIGHT BLACK OVAL key “YES” to begin initialization.
or
Press the LEFT BLACK OVAL key “NO” to cancel the request and
return to the “INITIALIZE FLASH” prompt.
5. Press the SETUP/EXIT key followed by the NEXT key. If
initialization is still in process, the LCD flashes back and forth
between the two phrases “CHECKING E: MEMORY” and
“PRINTER IDLE.”
When initializatio n is c om ple te, the pr int engi ne au tom ati cally exits
the setup mode and the LCD shows “PRINTER READY.”
NOTE: Depending on the amount of free FLASH memo ry, initialization
may take up to one minute to complete.
Zebra 116PAX3 User’s G uide 21
Media and Ribbon Sensor Calibration
NOTE: Before beginning this procedure, make sure that the media type has been configured, and that the maximum
length is set to a val ue equ al to o r gre ater th an the length of the labels bein g used . If the max imum length is set to
a smaller value, the calibration process assumes that continuous media is in the print engine. See page 23 for
more information.
Perform this procedure when the print engine is first put into service. The calibration allows the print engine to establish
the proper settings for the specific media and ribbon used in your application.
There are two different types of calibration that can be performed by the print engine:
NOTE: The print engine must be paused before pressing the CALIBRATE key.
1) Standard Calibration:Press the CALIBRATE key on the print engine’s front panel. The print engine feeds media and
ribbon, and sets the values it detects for media, media liner (the gaps between labels), media out, and ribbon or no
ribbon (which determines the print mode—thermal transfer or direct thermal). This type of calibration also occurs as
part of the sensor profile and media and ribbon calibration procedures.
2) Media and Ribbon Sensor Sensitivity Calibration:Performing the media and ribbon calibration procedure resets the
sensitivity of the sensors to detect the media and ribbon you are using more easily. With the sensors at their new
sensitivity, the print engine then performs the sta ndard c alibra tion de scribe d abov e. Ch anging the typ e of ribb on and/ or
media may require resetting the sensitiv ity of the medi a and ribbon sen sors. Indica tions that the s ensitivi ty may need to
be reset include a CHECK RIBB ON li ght on with the ribbon properly inst alle d or non-c ontinu ous med ia bein g treated as
continuous media.
Press LCD Shows Action/Explanation
Sensor Profile: Press NEXT to skip this standard calibration
SENSOR PROFILE
PRINT
procedure and continue with the media and ribbon calibration
parameter that follows. Press the RIGHT BLACK OVAL key to initiate
this standard calibration procedure and print a media sensor profile.
See Figure 8. The media sensor profile may be used to troubleshoot
registration problems that may be caused when the media sensor
detects preprinted areas on the media or experiences difficulty in
determining web location. If the sensitivity of the media and/or ribbon
sensors MUST be adjusted, use the media and ribbon sensor
sensitivity procedure described on page 23.
Figure 8. Media Sensor Profile
22 Zebra 116PAX3 User’s Guide
Press LCD Shows Action/Explanation
Media and Ribbon Sensor Sensitivity: Press NEXT to skip the
MEDIA AND RIBBON
CALIBRATE
Media and Ribbon Calibration Procedure
LOAD BACKING
CANCEL CONTINUE
REMOVE RIBBON
CANCEL CONTINUE
CALIBRATING
PLEASE WAIT
— When “RELOAD ALL” is displayed:
RELOAD ALL
CONTINUE
MEDIA AND RIBBON
CALIBRATE
calibration procedure and continue with the host port selection
parameters that follow. Press the RIGHT BLACK OVAL key to start the
calibration procedure.
This procedure i s u sed to adjust the s ens iti vi ty of the m edi a a nd rib bon
sensors. Changing the type of ribbon or media may require that this
calibration be performed. Indications that calibration is necessary are
RIBBON LIGHT on when the ribbon is properly installed and noncontinuous media being treated as continuous media.
NOTE: The procedure must be followed exactly as presented. All
steps must be performed even if only one of the sensors
requires adjustment.
Press the LEFT BLACK OVAL key to cancel the operation, or do the
following:
1. Open the printhead.
2. Remove enough labels from the media roll so that only the media
liner is threaded between the media sensors when the media is
loaded (approximately 8″ or 203 mm).
Press the LEFT BLACK OVAL key to cancel the operation or do the
following:
1. Remove the ribbon.
2. Close the printhead.
3. Press the RIGHT BLACK OVAL key to continue.
The print engine automatically adjusts the scale (gain) of the signals it
receives from the media and ribbon sensors based on the specific
media and ribbon combination being used. On the sensor profile, this
essentially corresponds to moving the graph up or down to optimize the
readings for your application.
1. Open the printhead and pull the media forward until a label is
positioned under the media sensor.
2. Reinstall the ribbon.
3. Close the printhead.
4. Press the RIGHT BLACK OVAL key to continue.
After scale is changed, the print engine performs a calibration
equivalent to pressing the CALIBRATE key. During this process, the
print engine che cks the readings for the me dia and ri bbon based on the
new scale established, determines the label length, and determines
whether you are in direct thermal or thermal transfer print mode. The
process is now complete! To see the new readings on the new scale,
print a sensor profile.
Zebra 116PAX3 User’s G uide 23
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