Zebra 110PAX3 Users Guide

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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.

, 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

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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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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.

PAUSE key was pressed.

A pause was requested from the Applicator Port.

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

LIST BAR CODES

LIST IMAGES

LIST FORMATS

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.

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.

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

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

Setting Communication Parameters

Communication parameters must be set correctly for the print engine to communicate with the host. These parameters ensure that the print engine and host are “speaking the same language.” All communication parameters are password protected.

Press LCD Shows Action/Explanation

Setting Serial Communications: Press the RIGHT or LEFT BLACK

SERIAL COMM

RS232

BAUD

- 9600 +

DATA BITS

- 7 BITS +

OVAL key to display other choices.

Default: RS232 Selections: RS232, RS422/485, RS485 multidrop

Select the communications port that matches the one being used by the host computer.

Setting Baud: Press the RIGHT or LE FT BLACK OVAL key to display other choices.

Default: 9600 Selections: 110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200,

28800, 38400, 57600 The baud setting of th e print en gine m ust ma tch the baud se tting of the host for accurate communica tions to take place. Select the value that matches the one being used by the host.

Setting Data Bi ts: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: 7-bits Selections: 7-bits, 8-bits

The data bits of the print engin e must matc h the dat a bits of th e host for accurate communications to take place. Set the data bits to match the setting being used by the host.

NOTE: Must be set to 8 data bits to use Cod e Page 85 0. See the ZPL

Programming Guide for more information.

24 Zebra 116PAX3 User’s Guide

Press LCD Shows Action/Explanation

Setting Parity: Press the RIGHT or LEFT BLACK OV AL key to display

PARITY

EVEN +

STOP BITS

1, STOP BIT +

HOST HANDSHAKE

XON/XOFF

PROTOCOL

NONE

other choices.

Default: Even Selections: Even, odd, none

The parity of the print engine must match the parity of the host for accurate commun icatio ns to t ak e plac e. Select the pa rity that mat ches the one being used by the host.

Setting Stop Bits: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: 1 stop bit Selections: 1 stop bit, 2 stop bits

The stop bits of the print engin e mus t match the stop bit s of t he hos t for accurate communicati ons to t ake place. Se lect the s top bits that match the one being used by the host.

Setting Host Handshake: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: XON/XOFF Selections: XON/XOFF, DTR/DSR

The handshake prot ocol o f the prin t engin e mus t match the han dshak e protocol of the host for communications to take place. Select the handshake protocol that matches the one being used by the host.

Setting Protocol: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: None Selections: None, Zebra, ACK/NACK

Protocol is a type of error checking system. Depending on the selection, an indicator may be sent from the print engine to the host signifying that data has been received. Select the protocol that is requested by the host. Details on protocol can be found in the ZPL II

Programming Guide Volumes I and II.

NOTE: Zebra is the same as ACK/NACK except that Zebra response

messages are sequenced.

NOTE: If Zebra is selected, print engine must use “DTR/DSR” host

handshake protocol.

Zebra 116PAX3 User’s G uide 25

Press LCD Shows Action/Explanation

Setting Network ID: Press the LEFT BLACK OVAL key to move to the

NETWORK ID

00 0 +

COMMUNICATIONS

NORMAL MODE

next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit.

Default: 000 Range: 000–999

Network ID is used t o assi gn a un ique nu mber to a pr int eng ine us ed in an RS-422/RS-485 network . This gi ves the host the means to ad dress a specific print engine. If the print engine is used in a network, you must select a network ID number. This does not affect TCP/IP or IPX networks.

Setting Communications Mode: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Normal mode Selections: Normal mode, diagnostics

The communication diagnostics mode is a troubleshooting tool for checking the interconnection between the print engine and the host. When “diagnostics” is selected, all data sent from the host to the print engine is printed as straight ASCII hex characters. The print engine prints all ch aracters re ceived, includin g control codes, l ike CR ( carriage return). A sample printout is shown in Figure 16 on page 54. NOTES on diagnostic printouts:

• FE indicates a framing error.

• OE indicates an overrun error.

• PE indicates a parity error.

• NE indicates noise.

If there are any errors, check that the communication parameters are correct (see page24). Set the p rint wid th equal to or les s than the label width used for the test.

26 Zebra 116PAX3 User’s Guide

Selecting Prefix and Delimiter Characters Prefix and delimiter chara cters are 2- digit hex values us ed with in the ZP L/ZPL II forma ts sent to th e prin t eng ine. The p rint engine uses the last prefix and delimiter characters sent to it, whether from a ZPL II instruction or from the front panel.

NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The print engine needs to see

different characters to function properly.

Press LCD Shows Action/Explanation

Control Prefix Character: Press the LEFT BLACK OVAL key to move

CONTROL PREFIX

< >7EH +

FORMAT PREFIX

<^>5EH +

DELIMITER CHAR

<,>2CH +

to the next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit.

Default: 7E (tilde—displayed as a black square) Range: 00–FF

The print engine loo ks for th is 2-di gi t hex ch ara cte r to i ndi ca te th e start of a ZPL/ZPL II control instruction.

NOTE: The “H” that is displayed indicates Hexadecimal and is not

entered as part of the value.

Format Prefix Character: Press the LEFT BLACK OV AL key to move to the next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit.

Default: 5E (caret) Range: 00–FF

The print engine loo ks for th is 2-di gi t hex ch ara cte r to i ndi ca te th e start of a ZPL/ZPL II format instruction.

Delimiter Character: Press the LEFT BLACK OVAL key to move to the next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit.

Default: 2C (comma) Range: 00–FF

The delimiter character is a 2-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. Refer to the ZPL II Programming Gu ide Volume I for more information.

Zebra 116PAX3 User’s G uide 27

Selecting ZPL Mode

Press LCD Shows Action/Explanation

Selecting ZPL Mode: Press the RIGHT or LEFT BLACK OVAL key to

ZPL MODE

ZPL II

Power-Up and Head Close Parameters

MEDIA POWER UP

FEED

HEAD CLOSE

FEED

display other choices.

Default: ZPL II Selections: ZPL II, ZPL

The print engine remains in the selected mode until it is changed by this front panel instruction or by using a ZPL/ZPL II command. The print engine accepts label formats written in either ZPL or ZPL II, eliminating the need to rewrite any ZPL formats that already exist. Refer to the ZPL II Programming Guide Volume II for information on th e differences between ZPL and ZPL II.

Media Power-Up: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Feed Selections: Feed, calibration, length, and no motion

This parameter establishes the action of the media when the print engine is turned on.

• Calibration: Recalibrates the media and ribbon sensors.

• Feed: Feeds the label to the first web.

• Length: Determines the length of the label.

• No Motion: Media does not move.

Head Close: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Feed Selections: Feed, calibration, length, no motion

Determines the action of the media after the printhead has been opened and then closed.

• Calibration: Recalibrates the media and ribbon sensors.

• Feed: Feeds the label to the first web.

• Length: Determines the length of the label.

• No Motion: Media does not move.

28 Zebra 116PAX3 User’s Guide

Label Positioning Parameters

Press LCD Shows Action/Explanation

Backfeed Sequence: Press the RIGHT or L EFT BLACK OVAL key to

BACKFEED

AFTER

LABEL TOP +000

- +

LEFT POSITION

0000 +

display other choices.

Default: After Selections: After, Before, Off

This parameter establishes when label backfeed occurs after a label is removed in applicator mode. It has no effect in rewind mode. Th is parameter setting can be superseded by the ~JS instruction when received as part of a label format (refer to ZPL II Programming Guide Vol um e I).

Adjusting Label Top Position: Press the RIGHT BLACK OVAL key to increase the value; press the LEFT BLACK OVAL key to decrease the value. The displayed value represents dots.

Default: +0 Range: –120 to +120 dot rows

The label top position adjusts the print position vertically on the label. Positive numbers adjust the label top position further down the label (away from the prin thead); n egativ e numb ers adjus t the pos ition up the label (toward the printhead).

Adjusting Left Position: Press the LEFT BLACK OVAL key to move to the next position, press the RIGHT BLACK OVAL key to change between + and – and to increase the value of the digit. The displayed value represents dots.

Default: 0000 Range: –9999 to +9999

NOTE: For a negative value, enter the value before changing to the

minus sign. This parameter establishes how far from the left edge of a label the format begins to print by adjusting horizontal positioning on the label. Positive numbers adjust the printing away from the main frame by the number of dots selected; negative numbers shift printing toward the main frame.

Zebra 116PAX3 User’s G uide 29

Press LCD Shows Action/Explanation

Setting the Head Test Count: Press the LEFT BLACK OVAL key to

HEAD TEST COUNT

0000 +

HEAD RESISTOR

0500 OHMS +

APPLICATOR PORT

OFF

move the cursor, press the RIGHT BLACK OVAL key to change the value of the digit.

Default: 0000 (disables the test) Range: 0000–9999

The print engine periodically performs a test of the printhead functionality, called a “printhead test” or “head test.” This param eter establishes how many labels are printed between these internal tests.

Setting the Head Resistor Value: Press the LEFT BLACK OVAL ke y to move to the next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit.

CAUTION: This parameter should be changed only by qualified

personnel!

Initial Value: Factory-set to match the printhead shipped with your print engine.

Default Value: 0500 Range: 488 to 2415

This value has been pre-set at the factory to match the resistance value of the printhead. It does not need to be changed unless the printhead is replaced.

CAUTION: DO NOT set the value higher than that shown on the

printhead. Setting a higher value may damage the

printhead!

A label on the bottom of the printhead element shows the resistance value (ohm value) for the printhead. Take note of the value before installing the replacement printhead.

Setting the Applicator Port: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Off Selections: Off, mode 1, mode 2, mode 3, mode 4

Determines how the print engine interfaces with the applicator.

• Off: The applicator port is off.

• Mode 1: Asserts the ~EN D_PRINT s ignal lo w while the print engine

is moving the label forward.

• Mode 2: Asserts the ~END_PRINT signal high while the print engine is moving the label forward.

• Mode 3: Asserts the ~END_PRINT signal low for 20 milliseconds when a label has been completed and positioned. Not asserted during continuous printing modes.

• Mode 4: Asserts the ~END_PRINT signal high for 20 milliseconds when a label has been completed and positioned. Not asserted during continuous printing modes.

30 Zebra 116PAX3 User’s Guide

Printing Controls

Press LCD Shows Action/Explanation

Start Print Signal: Press the RIGHT or LEFT BLACK OVAL key to

START PRINT SIG

PULSE MODE

RESYNCH MODE

FEED MODE

display other choices.

Default: Pulse Mode Selections: Pulse Mode, Level Mode

This parameter determines how the print engine reacts to the Start Print Signal input on pin 3 of the applicator interface connector at the rear of the print engine.

• In Pulse Mode, labe ls pri nt wh en the s ign al tran si tions from HIGH to LOW.

• In Level Mode, labels print as long as the signal is asserted LOW.

CAUTION: Start Print Sign al is set by the applicato r manufact urer and

should not be changed unless the factory defaults have been reloaded. Please make a note of it! While other choices are valid, the print engine must be returned to its designated setting in order for it to work properly.

Resynch Mode: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Feed Mode Selections: Feed Mode, Error Mode

This parameter determines how the print engine reacts if the label synchronization is lost and the label top is not where expected. FEED MODE—If the label top is not where expected, the prin t engi ne feeds a blank label to find the label top position. ERROR MODE—If the label top is not where expected, the print engine stops, enters the PAUSED mode, displays the message “Error Condition Feed Label”, flashes the ERROR LED, and asserts the “Service Required” signal (pin 10 on the Applicator Interface Connector). To resynch the media to the top of the label in this mode, press the P AUSE key to e xit the PAUSED state. The ERROR LE D stops flashing and the “Service Required” signal is deactivated. The action of the print engine is determined by the “Head Close” configuration selection:

•“Calibration”: the print engine feeds labels and recalibrates the media sensors.

•“Feed”: the print engine feeds the labels to the next web.

•“Length”: the print engine feeds labels and calculates the label

length.

•“No Motion”: the media does not move. The user must press the FEED key to cause the print engine to resynch to the start of the next label.

Zebra 116PAX3 User’s G uide 31

Press LCD Shows Action/Explanation

Ribbon Low Mode: Press the RIGHT or LEFT BLACK OVAL key to

RIBBON LOW MODE

25M

REPRINT MODE

DISABLED

display other choices.

Default: 25M Range: Off, 25M, 50M, 75M, 100M

When the Ribbon Low feature is off, the output signal (Pin 9) does not function, the “Low Ribbon” warning is not displayed, and the print engine continues to print until it runs out of ribbon. When the Ribbon Low f eature is set to a ny of the length s, outp ut sign al (Pin 9) on the applicator port is functional. When the amount of ribbon on the supply spindle reaches the specific length, the output signal asserts HIGH to provide a “Ribbon Low” warni ng.

Reprint Mode: Press the RIGHT or LEFT B LACK OVAL key to display other choices.

Default: Disabled Range: Enabled, Disabled

When the Reprint feature is enabled, the “Reprint” input signal (Pin 6) on the applicator port is functional. When the input signal is asserted, the last label printed is printed again. (This includes non-printing labels.) Pressing the PAUSE key also prints the last label printed. When the Reprint feature is disabled, the “Reprint” input signal is ignored.

NOTE: The ^SP command is ignored when the Reprint feature is

enabled. When the Reprint feature is disabled, the ^SP command can be used. In addition, when a received label format is canceled prior to printing, the “reprint” function for the previous label is also canceled. Refer to the ZPL II Programming Guide for additional information.

32 Zebra 116PAX3 User’s Guide

Press LCD Shows Action/Explanation

These parameters are automatically set during the calibration

WEB S. 073

- +

procedure and should be changed only by a qualified service technician. Refer to the ZPL II Programming Guide for information on these parameters. Press the NEXT key repeatedly to skip these parameters.

MEDIA S. 075

- +

RIBBON S. 071

- +

MARK S. 000

- +

MARK MED S. 000

- +

MEDIA LED 082

- +

RIBBON LED 008

- +

MARK LED 005

- +

Zebra 116PAX3 User’s G uide 33

Press LCD Shows Action/Explanation

LCD Adjustment: Press the LEFT BLACK OVAL key to decrease the

LCD ADJUST 000

- +

FORMAT CONVERT

NONE

RTS TAKEUP ARM

XXX

RTS SUPPLY ARM

XXX

IDLE DISPLAY

FW VERSION

RTC DATE

01/31/01 +

RTC TIME

14:55 +

value (reduce brightness); press the RIGHT BLACK OVAL key to increase the value (increase brightness). Range: 00 to 19 This parameter allows you to adjust the brightness of your LCD if it is difficult to read.

Format Convert: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: None Selections: None, 150-300, 150-600, 200-600, 300-600

Selects the bitmap scaling factor. The first number is the original dots-per-inch (dpi) value; the second is the dpi to which you would like to scale.

RTS T ake up Danc er Arm Calibrati on Value: This parameter is used as a diagnostic tool to monitor the voltage supplied to the Ribbon Tensioning System Takeup Dancer Arm. Refer to the Maintenance Manual for information.

RTS Supply Dancer Arm Calibration Value: This parameter is used as a diagnostic tool to monitor the voltage supplied to the Ribbon Tensioning System Supply Dancer Arm. Refer to the Maintenance Manual for information.

Idle Display: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Firmware version Selections: mm/dd/yy (24 hour), mm/dd/yy (12 hour), dd/mm/yy

(24 hour), dd/mm/yy (12 hour), Firmware version

This paramet er selects the LCD options for the real -time clock. NOTE: If the default value is not selected, pressing either BLACK

OVAL key briefly displays the firmware version of the print engine.

RTC Date: Press the LEFT BLACK O VAL key to move to the next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit. This parameter allows you to set the date following the convention selected in “IDLE DISPLAY.”

RTC Time: Press the LEFT BLAC K OVAL key to move to the next digi t position; press the RIGHT BLACK OVAL key to increase the value of the digit. This parameter allows you to set the time following the convention selected in “IDLE DISPLAY.”

34 Zebra 116PAX3 User’s Guide

Press LCD Shows Action/Explanation

IP Resolution*: Press the RIGHT or LEFT BLACK OVAL key to

IP RESOLUTION

DYNAMIC

IP PROTOCOLS

ALL

IP ADDRESS

000.000.000.000 +

SUBNET MASK

000.000.000.000 +

DEFAULT GATEWAY

000.000.000.000 +

display other choices.

Default: Dynamic Selections: Dynamic, permanent

Depending on the selectio n, allows either the user (“permanent”) or the server (“dynamic”) to select the IP address. For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide.

IP Protocols*: Press the RIG HT or LEFT B LAC K OVAL key to display other choices.

Default: All Selections: All, gleaning only, RARP, BOOTP, DHCP, DHCP/BOOTP

If “dynamic” was chosen in the previous parameter, this selection determines the method(s) by which the PrintServer II receives the IP address from the server. For more information, refer to ZebraNet Networking: PrintServer II Installation and User’s Guide.

IP Address*: Press the LEFT BLACK OVAL key to move to the next digit position; pres s the RIGHT BLACK O VAL key to increase the valu e of the digit. This parameter sel ects t he IP add ress if “permanent” was chosen in “IP RESOLUTION.” (If “dynamic” was chosen, the user cannot select the address.) For more information, refer to ZebraNet Networking:

PrintServer II Installation and User’s Guide.

Subnet Mask*: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Permanent (user must set) Selections: Dynamic (user may set but server can assign), permanent

This paramet er selects the part of the IP address that is considered to be part of the local network. It can be reached without going through the default gateway.

Default Gateway*: Press the LEFT BLACK OVAL key to move to the next digit position; press the RIGHT BLACK OVAL key to increase the value of the digit. This parameter selects the IP address that the network traffic is routed through if the destination address is not part of the local network.

* ZebraNet® PrintServer II option required

Zebra 116PAX3 User’s G uide 35

Press LCD Shows Action/Explanation

Selecting the Display Language: Press the RIGHT or LEFT BLACK

LANGUAGE

You have now completed the entire configuration and calibration sequence. You may press either the NEXT key or the SETUP/EXIT key.

DARKNESS

SAVE CHANGES

PERMANENT

PRINTER READY

OVAL key to display other choices.

Default: English Selections: English, Spanish, French, German, Italian, Norwegian,

Portuguese, Swedish, Da nish, S p anish 2, Dutch, Finnish, Japanese, Custom

This parameter allows you to change the language shown on the LCD.

You are now back at the first parameter in the configuration sequence. NOTE: If you pressed the NEXT key b ut are through programmi ng the

print engine confi guration, y ou may press the SETUP/EXIT key and continue with the “SAVE SETTINGS” function.

Save Settings: Press the RIGHT or LEFT BLACK OVAL key to display other choices.

Default: Permanent Selections: Permanent, temporary, cancel, load defaults, load last

save

This display appears when you attempt to exit the setup mode.

• Permanent: Permanently saves the changes, even when print engine power is turned off.

• Temporary: Saves the changes unt il change d again or u ntil power i s turned off.

• Cancel: Cancels all changes since you entere d the setup m ode except for darkness and tear-off position (if they were changed).

• Load defaults: Loads factory defaults.

NOTE: Loading factory defaults requires calibration.

• Load last save: Loads the values from the last permanent save.

Press the NEXT key to activate the displayed choice. You have exited the configuration and calibration sequence and are now ready for normal print engine operation.

36 Zebra 116PAX3 User’s Guide

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CAUTION: Use only the cleaning agents indicated. Zebra Technologies Corporation will not be responsible for damage caused by any other cleaning materials used on the 116PAX3 print engine.

Ta ble 1 provides a recommended cleaning schedule. Cleaning swabs saturated with 90% Isopropyl Alcohol are available from your Zebra distributor as a Preventive Maintenance Kit (part # 47362M).

Table 1. Recommended Cleaning Schedule

AREA METHOD INTERVAL

See Figures 9 and 10 for parts locations. Printhead (1) Alcohol After every 450′ (150 m) of media. Platen Roller (2) Alcohol After every roll of ribbon when printing in the Media Path Alcohol Transmiss iv e Med ia Sens or (3) Air blow/Vacuum Reflective Media Sensor (4) Air blow/Vacuum Ribbon Sensor (Q, Figures 4 and 5 shown on

pages 7 and 8) Ribbon Sensor Reflector (R, Figures 4 and 5

shown on pages 7 and 8) Door-Open Sensor (5) Air blow/Vacuum Peel Bar (6) Alcohol After every roll of media or more often if needed.

Alcohol

thermal transfer mode. After every roll of media when printing in the direct

thermal mode.

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The exterior surfaces of the print engine may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents! If necessary, a mild detergent solution or desktop cleaner may be used sparingly.

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Remove any accumulated dirt and lint from the interior of the print engine using a soft bristle brush and/or vacuum cleaner. This area should be inspected every time a new ribbon is loaded.

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To ensure proper operation of the print engine, all sensors should be cleaned on a regular basis. To locate the position of the media and door-open sensors, refer to Figure 9. Refer to Figure 4 on page 7 and Figure 5 on page 8 for the ribbon sensor and ribbon sensor reflector.

Zebra 116PAX3 User’s G uide 37

Figure 9. Sensor Locations (RH)

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Inconsistent print quality (such as voids in the bar code or graphics) or light print may indicate a dirty printhead. Media movement problems may indicate a dirty platen. For optimum print quality, perform the following cleaning procedure after every roll of media (or 150 meters) or when a “Clean Head Now” warning appears on the LCD.

NOTES: If print quality has deg raded a nd you ha ve n ot chan ged to a dif fe rent t ype of medi a or ri bbon, cleaning the printhea d may solve the pr oblem. It shoul d not be necess ary to change the darkness setting or the toggle pressure.

You do not label formats and images, as well as any temporarily saved parameter settings stored in the print engine’s internal memory, are lost. When power is turned back on, these items must be reloaded.

If power is removed from the pri nt engine when c leaning the printhead , the “Clean Head Now” warning shown on the LCD will not

38 Zebra 116PAX3 User’s Guide

need to turn off the print engine before cleaning the printhead. If power is turned off, all

disappear.

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To clean the printhead and platen roller, refer to Figure 10 and perform the following steps:

1. Open the printhead a ssembly (B) by lifting the printhead latch (C) upwa rd away from the locking pin (D). Remove the media and ribbon.

2. Brush, vacuum, or air blow any accu mulat ed lint and paper dust away fr om the rol le rs. It i s good prac ti ce

to clean the media, ribbon, and door-open sensors at this time. See Figure 9, Figure 4 on page 7, and Figure 5 on page 8.

3. Use a cleaning swab saturated with alcohol to wipe the print elements from end to end. The print elements form the grayish/bl ack stri p (1) j ust behin d the chr ome strip on the un derside o f the pr inthead. Allow a few seconds for the solvent to evaporate.

4. Use a lint-free cloth moistened with alcohol to clean the platen roller (2) and other rollers. Rotate the rollers while cleaning.

5. Reload the ribbon and/or media, latch the printhead, and continue printing.

Figure 10. Printhead and Platen Roller Cleaning (RH)

NOTE: If print quality has not improved, try cleaning the printhead with Save-a-Printhead cleaning

film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra distributor to order the Save-a-Printhead cleaning kit for the 116PAX3 print engine (part # 46902M).

Zebra 116PAX3 User’s G uide 39

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(Recommended for all Zebra print engines—especially 600 dpi print engines).

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The printhead is the most critical component in your print engine, and possibly the most delicate. It is a consumable item just like the brakes on your car, which eventually wear over time. However, with ongoing careful attention and maintenance, you can extend the life of the printhead.

Figure 11 shows photographs of three printheads. The first printhead is brand new. The second has printed over 1 million linear inches of thermal transfer labels and has been properly maintained. The third printhead has printed far fewer labels, but without proper care and maintenance, signs of abrasion and contamination buildup are evident.

Figure 11. Effects of Printhead Maintenance

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For optimum performance, clean the printhead regularly after every roll of media (or 150 meters) or when a “Clean Head Now” warning appears on the LCD. Take care when handling or cleaning the printhead by removing any jewelry that may scratch the printhead and use a grounding strap or anti-static mat to discharge static electricity that could damage the printhead.

To start, use only the pre-soaked (isopropyl alcohol) cleaning swabs provided in the preventive maintenance kit. First, open the media cover to access the printhead, then open the printhead. Lightly blow or brush away any loose dust and li nt parti cles with in the pr int mechanism ( i.e., roll ers, media/r ibbon sens ors, and pr inthead) . NEVER use any hard, metallic, or abrasive objects—such as a screwdriver—to remove adhesives or other contaminants that may have built up on the printhead.

Next, press the swab tip against the printhead and swipe the print elements from end to end. Then, turn the platen rollers while wiping them from side to side. Repeat this step until the swab no longer shows dirt.

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Abrasion: Over time, the movement of media/ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots).

In order to avoid abrasion:

• Clean your printhead frequently and use well-lubricated thermal transfer ribbons with backcoatings optimized to reduce friction.

• Minimize printhead pressure and burn temperature settings by optimizing the balance between the two.

• Ensure that the thermal transfer rib bon is as wide or wider than the label media to prevent exposing the

elements to the more ab rasive label material.

40 Zebra 116PAX3 User’s Guide

Ribbon Backcoating and Buildup: Printhead contamination from direct thermal media or thermal transfer ribbon may occur in ap plica tions requi ring h igh bur n set tings, hi gh head press ure, hi gh speed, or hig h volume. This contamination builds up on the printhead elements, creating a barrier to the heat transformation required to produce high-quality images. Contaminant buildup occurs gradually and results in poor print quality that may look like faded print or failed print element(s). This buildup is very resistant to cleaning with the presoaked swabs and is difficult to remove.

In order to avoid ribbon backcoating and buildup:

• Use thermal transfer ribbons that have been specially cured to provide backcoat protection for high-

demand applications. These ribbons—sometimes referred to as anti-stick ribbons—also dissipate static and provide more lubrication.

• Follow the recommended Printhead Preventive Maintenance procedures.

• Use Zebra’s Save-a-Printhead cleaning film to remove printhead contamination buildup quickly and

easily.

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Save-a-Printhead cleaning film is a specially coated film that removes contamination buildup without damaging the printhead.

Save-a-Printhead c leaning f ilm extends th e l ife of your print head, r educes mainten ance downt ime and the cost of replacing a printhe ad, and is an in expensi ve, easy, and quick way to remove contaminant s withou t having to remove the printhead.

Use Save-a-Printhead cleaning fi lm when you s ee degr ading p rint q ualit y th at loo ks lik e faded print or a fai led print element(s) that cannot be corrected by cleaning with the pre-soaked cleaning swabs.

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NOTE: If power is removed from the p rint eng ine when cleaning the p rinthead , the “Clea n Head Now” warning shown on the LCD will not

disappear.

1. Open the media cover.

2. Open the printhead, remove media and ribbon from the print mechanism.

3. Clean the printhead per the recommended Preventive Maintenance procedures.

4. Position the Save-a-Printhead film in the p rint p ath, pla cing t he glos sy side down away fr om the pr inthe ad

(matte side up).

5. Close and latch the printhead.

6. Slowly pull the full length of the film through the print mechanism.

7. Again, clean the printhead per the recommended Preventive Maintenance procedures.

8. Reload media and ribbon, close and latch the printhead.

9. Close the media cover.

10. Print labels and inspect for improved print quality. If quality has not improved, contact Zebra’s Technical

Support staff at 1.847.913.2259 or visit our Web site: http://www.zebra.com

Zebra 116PAX3 User’s G uide 41

Only one pass of Save-a-Printhead film is required to remove contamination buildup, and each strip of film can be used up to 10 times. Discard the strip when residue buildup or other contamination is apparent.

If a replacement printhead is needed, order one directly from Zebra to ensure that your print engine and parts warranties remain intact and that the product performs optimally.

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The kit contains three 10″ (25 cm) l ong strips of film. Call your authorized Zebr a distributor t o order the Save-a-Printhead cleaning kit for the 116PAX3 print engine (part # 46902M).

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Proper toggle positionin g is impor tant for proper print qual ity. The toggle should be positioned approximately midway across the width of the media.

To position the toggle, loosen the position locking nut (T, Figure 12) by rotating it clockwise. Slide the toggle to the desired position, and tighten the locking nut by rotating it counterclockwise until it is just finger tight to the toggle pivot shaft (X).

NOTE: Perform the Printhead Pressure Adjustment procedure on the next page if there is noticeable bleed or swelling in the printed image (too much pressure) or if there are voids (too little pressure).

Figure 12. Printhead Pressure (Right-Hand Unit Shown)

42 Zebra 116PAX3 User’s Guide

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If the darkness setting (burn duration) is set properly, but printing is too light or if the image shows signs of bleeding or swelling, printhead pressure may need to be adjusted. Refer to Figure 12 to adjust printhead pressure. As a starting point for adjustment, set the position of the adjusting nut (V) so that when the locking nut (U) is tighte ned, it is approximat ely 0.4″ (10 mm) from the yok e (W). Use t he lowe st pressu re possibl e that provides the desired print quality.

1. Refer to “Configuration” beginning on page 15 and set the darkness value (burn duration) ap propriatel y for

your media and ribbon.

2. Refer to the “PAUSE Key Self Test” on page 51 and print test labels.

3. Loosen the pressure adjustment locking nut (U) on the threaded shaft of the toggle assembly by rotating it

counterclockwise.

4. Rotate the adjusting nut (V) clockwise to increase or counterclockwise to decrease the spring pressure.

5. Print test labels and inspect for qu ality.

6. When print quality is acceptable, hold the adjusting nut (V) in position, and tighten the locking nut (U)

against it.

NOTE: Printhead and drive system (belts and bearings) life can be maximized by using the lowest pressure that produces the desired print quality.

Zebra 116PAX3 User’s G uide 43

44 Zebra 116PAX3 User’s Guide

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A Power-On Self Test (POST) is performed each time the print engine is turned ON. During this test, the front panel lights (LEDs) turn ON and OFF to e nsure proper oper ation. At t he end of this self test , only the POWER LED remains lit. Once the POST is complete, the media is advanced to the proper resting position, as determined by the programmed Power-Up setting.

T o initiate the POST, turn the print engine ON using the power switch on the control panel. The POWER LED illuminate s. The other control pan el LEDs and the LCD monitor the progress and indicate the results of th e individual tests. All di splay ed prompt s occu r in En glish; howeve r, when a test fails, the prompt cycl es thr ough the international languages as well.

The normal s elf-test sequence occurs each time the print engine is turned on, as follows:

1. All lights turn on sim ul t aneously and then t urn o f f i n se quence through the following steps.

2. SRAM functionality test performed.

SRAM Test

3. Option ROM functionality test performed. The words “Not Installed”

Option ROM Test

4. Printhead is checked for proper operation.

Printhead Test

are added to the LCD if optional ROM is not used.

5. Proces sor functionality test performed. The word “Failed” is added to

Processor Test

6. E-cubed functionality test performed. The word “Failed” is added to

E-Cubed Test

7. EEPROM/PROM functionality test performed. The word “Failed” is

EEPROM Test

8. Optional PCMCIA Memory Card functionality test performed. The

Memory Card Test

9. Optional Flash Memory Card functionality test performed.

Flash Memory Test

10. Depending on how the ^MF (Media Feed) instruction is set, the print

1 1 . Print engine is ready for op erat ion. Refer to “Configuration” beginning

PRINTER READY

x.x.MB VXX.X.X

the LCD if the test fails.

added to the LCD if the test fails.

words “Not Installed” are added to the LCD if no card is present.

engine feeds to the first web or label length, calibrates ribbon and media sensors, or sets label length and feeds one or more labels.

on page 15 to set specific parameters. Designate prompt language with the ^KL command or from the menu.

Zebra 116PAX3 User’s G uide 45

The following table s pr ovi de s ymptoms, a diagnosis of spe ci fi c ca use s, a nd a r ecommended action that s houl d result in proper print engine operation.

If you need technical assistance, contact your equipment supplier.

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SYMPTOM DIAGNOSIS ACTION

All lights on, but nothing displays on the LCD, and the print engine locks up.

Print engine locks up while runn ing the Power-On Self Test.

EEPROM TEST

Internal electronic or firmware failure. Call a service technician.

Main Logic Board failure. Call a service technician.

EEPROM checksum is incorrect.

Call a service technician.

FAILED

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SYMPTOM DIAGNOSIS ACTION

ERROR CONDITION

RIBBON OUT

Print engine stops; RIBBON light ON, ERROR light flashes.

WARNING

RIBBON IN

RIBBON light ON, ERROR light flashes.

ERROR CONDITION

PAPER OUT

Print engine stops; MEDIA light ON, ERROR light flashes.

ERROR CONDITION

HEAD OPEN

Print engine stops and ERROR light flashes.

WARNING

HEAD TOO HOT

Print engine stops and ERROR light flashes.

WARNING

CLEAN HEAD NOW

Front panel LCD text alternates between “Clean Head Now” warning and idle display value.

For Thermal Transfer:

Ribbon not loaded or incorr ectly loaded.

Ribbon sensor not detec ting ri bbon th at is loaded incorrectly.

For Direct Thermal:

Ribbon is loaded.

Media blocking the Ribbon Sensor.

No media loaded or incorrectly loaded. Load media correctly. See “Media

Misadjusted Media Sensor. Check position of the Media Sensor. Print engine set for non-continuous

media, but continuous me dia is loade d.

Printhead is not fully closed. Close printhead completely. Head Open Sensor not working

properly.

Printhead overheated. Allow print engine to cool. Printing

Printhead requires cleaning. See page 38 and clean the printhead.

Load ribbon correctly. See “Ribbon Loading” on page 7.

Perform “Media and Ribbon Sensor Calibration” on page 22.

Remove ribbon. Load me dia co rrec tly. Perform “Media and Ribbon Sensor Calibration” on page 22.

Loading” on page 5.

Install proper media or reset print engine for current media type and perform calibration.

Call a service technician.

resumes when the printhead elements cool to operating temperature.

NOTE: Do not turn off the print engine

while cleaning the printhead. The “Clean Head Now” warning

disappear from the LCD

will not if the print engine is turned off.

46 Zebra 116PAX3 User’s Guide

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SYMPTOM DIAGNOSIS ACTION

Print engine stops and PAUSE light goes ON. The LCD displays:

Not enough memory to perform fun ction shown on the second line.

Explanation of errors:

You may do any of the following:

OUT OF MEMORY

CREATING BITMAP

OUT OF MEMORY

STORING BITMAP

OUT OF MEMORY

1. Creating Bitmap—Bitmap size (label length/width) does not fit in available memory.

2. Storing Bitmap—Not enough memory available to store the bitmap created.

3. Building Format—Label is too complex.

BUILDING FORMAT

OUT OF MEMORY

4. Storing Format—Format i s too large to fit in available memory.

STORING FORMAT

OUT OF MEMORY

5. Storing Graphic—Graphic image is too large to fit in available memory.

STORING GRAPHIC

OUT OF MEMORY

6. Storing Font—Not enough memory available to store the font.

STORING FONT

Long tracks of missing print on several labels.

Fine, angular gray lines on blank labels.

Wrinkled ribbon. Ribbon fed through the machine

Wrinkled ribbon. See “Wrinkled Ribbon” in this table. Print element damaged. Call a service technician. One or more of the printhead elements

has failed the printhead element test.

Wrinkled ribbon. See “Wrinkled Ribbon” in this table.

incorrectly. Incorrect burn temperature. Set the burn temperature to the lowest

Incorrect or uneven pressure. Set the pressure to the minimum

Media not feeding properly; “walking” from side to side.

Strip plate needs adjusting. Call a service technician. Printhead needs vertical adjustment. Call a service technician. Printhead and Platen Roller need to be

realigned.

A. With PAUSE on, send a ~HM

command to the print engine to display the amount o f free m emory. Then either:

Redesign graphic/format to fit available memory or remove items from memory to create more space.

Press PAUSE to skip the formatting step in process and proceed to the next step.

B. With PAUSE on, press CANCEL.

The print engine skips the current label formatting proc ess and goes to the next label.

C. Turn power OFF and then ON to

clear print engine memory and start over.

D. Upgrad e the pri nt e ngi ne to a larger

memory size.

If the failed elements impact your printing application, replace the printhead. To override this error, disable the head test count feature on the front panel by defaulting the value to “0000.” See page 30.

See “Ribbon Loading” on page 7.

possible setting for good print quality.

needed for good print quality. See “Printhead Pressure Adjustment” on page 43.

Make sure that media is snug by adjusting the media guide , or call a service technician.

Call a service technician.

Zebra 116PAX3 User’s G uide 47

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SYMPTOM DIAGNOSIS ACTION

Broken or melted ribbon. Darkness setting too high. Reduce setting for best print quality,

and clean the printhead thoroughly.

Ribbon tension dancer(s) oscillate erratically.

Light printing or no printing on the left or right side of the label.

Printing too light or too dark over the entire label.

Smudge marks on labels. Media or ribbon not designed for high-

Misregistration/skips labels. Media Sensor not positioned correctly. Perform Media Sensor position

Misregistration an d misprint of o ne to three labels.

Vertical drift in top-of-form position. A plus or minus 4-6 dot row

Missing LCD characters or parts of characters.

Changes in parameter settings did not take effect.

Ribbon core is not standard siz e and is slipping on the spindle.

Printhead pressure needs adjustment, printhead out of alignment, or toggle in incorrect position.

Media or ribbon is not designed for high-speed operation.

Incorrect or uneven printhead pressure. Set the pressure to the minimum

speed operation.

Print engine not calibrated. Recalibrate print engine. Improper label format. Use correct label format. Media Sensor is not positioned

correctly. Platen dirty. Clean platen (see page 38). Media does not meet specifications. Use media that meets specifications.

(approximately 0.5 mm) vertical drift is acceptable due to different tolerances of mechanical parts and print engine modes.

Print engine out of calibration. Recalibrate print engine. Platen dirty. Clean platen (page 38). LCD may need replacing. Call a service technician.

Parameters are set incorrectly. Set parameters and save permanently.

A ZPL command has turned off the ability to change parameter.

A ZPL command has changed the parameter back to the previous setting.

If problem continues, there may be a problem with the main logic board.

Replace ribbon with one that has a standard core size.

See “Toggle Positioning” on page 42 and “Printhead Pressure Adjustment” on page 43.

Call a service technician. Replace supplies with those

recommended for high-spee d operation.

needed. See “Printhead Pressure Adjustment” on page 43.

Replace supplies with those recommended for high-spee d operation.

adjustment (see page 9).

Place Media Sensor in proper position (see page 9).

First calibrate prin t engine, th en use the “Label Top Position” setting to correct. See “Configuration and Calibration Sequence” on page16.

Cycle the print engine power OFF and back ON.

Refer to the ZPL Programming Guide or call a service technician.

Call a service technician.

48 Zebra 116PAX3 User’s Guide

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SYMPTOM DIAGNOSIS ACTION

ZPL II was sent to t he print engine, but not recognized.

DATA light always OFF.

DATA light always flashing.

Vertical image or label drift. Print engine using non-continuous

Communications p ara me ters are incorrect.

Incorrect Communications Cable in use.

Prefix and delimiter characters set in print engine do not match the ones used in ZPL II format sent to the print engine.

Incorrect/incomplete ZPL format sent to the print engine.

labels but configured in continuous mode.

Incorrectly positioned media sensor. Ensure the media sensor is properly

Improperly calibrated media sensor. Perform “Media and Ribbon Sensor

Platen dirty. Clean platen (see page 38). Improper printhead pressure set ting s

(toggles). Improperly loaded ribbon or media. Verify that the ribbon and media are

Incompatible media. Ensure the inter-label gaps or notches

Print a Communications Diagnostic Label (see page26). Check for format or overrun errors. Reset communication parame ters (see page 24).

Verify proper cable and replace if necessary.

Set the characters in the print eng ine to match ZPL II format. See “Selecting Prefix and Delimiter Characters” on page 27.

If problem continues, check the ZPL II format for changed ^CC, ^CT, and ^CD.

Configure the print engine for noncontinuous and run calibration routine, if necessary.

positioned to read a single/consistent inter-label gap.

Calibration” on page 22.

Adjust the printhead press ure to ensure proper functionality (see page 43).

properly loaded (see pages 5–7).

are 2 mm–4 mm and consistently placed. Media must not exceed minimum specifications for mode of operation.

Zebra 116PAX3 User’s G uide 49

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These self tests, ill ustrate d on the foll owing pages, produce sampl e labels an d provide sp ecific i nformation that help determine the operating conditions for the print engine.

Each self test is enabled by pressing a specifi c fr ont panel key or combination of keys while turning the power switch ON. Keep the key pressed until the first indicator ligh t turns OFF. The selected self test automatically starts at the end of the PO ST.

NOTES: When performing these self tests, do not send data to the print engine from the host. Full width media should be used when performing Print Engine Self Tests. If your media is not wide

enough, the test labels may print on the label and the platen roller, or in the case of narrow media, not on the label a t al l. To prevent this fr om happe ning, c hec k the confi gurat ion pa rame ter “Setting the Print Width” and ensure it is correct for the media you are using.

If your media is too short, the test label continues on the next label. When canceling a self test prior to its a ctual compl etion, always reset the print engine by turning the

print engine power OFF and then ON. If the print engine is in applicator mode and the liner is being taken up by the applicator, the operator

must manually remove the labels as they become available.

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Press and hold the CANCEL key while turning the print engine power ON. Release the key anytime after the first front panel LED turns OFF.

This self test prints a label that contains a listing of the print engine’s current configur atio n paramet ers sto red in con figur ation (EEPROM) memory (refer to Figure 13). To enable this test, press the CANCEL key while turning the power switch ON.

The configuration may be changed either temporarily (for specific label formats or ribbon and label stock) or permanently (by saving the new parameters in EEPROM memory). Saving new parameters occurs whenever a print engine calibration procedure is performed. Refer to “Confi gur at ion and Calibration Sequence” on page 16 for further details.

Figure 13. CANCEL Key Self Test

50 Zebra 116PAX3 User’s Guide

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Press and hold the PAUSE key while turning the print engine power ON. Release the key anytime after the first front panel LED turns OFF.

This self test comprises four individual test features:

1. The initial self test prints 15 labels at the slowest speed of print engine, then automatically pauses the print engine. When the PAUSE key is pressed, an additional 15 labels print.

2. While the print engine is paused, alter the self test by pressing the CANCEL key once. When the PAUSE key is pressed, the print engine prints 15 labels at 4″ (102 mm) per second.

3. While the print engine is paused, alter the self test a second time by pressing the CANCEL key once. When the PAUSE key is pressed , the print engine prints 50 labels at the slowest s peed.

4. While the print engine is paused, alter the self test a third time by pressing the CANCEL key once. When the PAUSE key is pressed, the print engine prints 50 labels at 4″ (102 mm) per second.

5. While the print engine is paused , alter the self test a fourth t ime by pressi ng the CANCEL key once. When the PAUSE key is pressed, the print engine prints 15 labels at the maximum speed of the print engine.

This self test can be used to provide the test labels required when making adjustments to the print engine’s mechanical assemblies. See Figure 14.

Figure 14. PAUSE Key Self Test Sample Printout

Zebra 116PAX3 User’s G uide 51

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Press and hold the FEED key whi le turn ing the pr int e ngine power ON. Re lease the ke y an y time after t he fir st front panel LED turns OF F.

NOTE: The CANCEL Key Self Test should be performed prior to this self test. Information on the printed configuration label can be used with the results of this self test to determine the best darkness setting for a specific media/ribbon combination.

Each label is printed at a different darkness setting, starting at t hre e int ege r (whole number) setting s bel ow the currently configured value and increasing un t il it is three settings darker than the c onfigured value. The relative darkness and speed are printed on each label. The bar codes on these labels can be ANSI-graded to check print quality.

Compare these labels to determine which has the best print quality. Then add or subtract the value printed on that label from the darkness value specified on the configuration label. The resulting numeric value (0.0 to

30.0) is the best darkness value for that specific media/ribbon combination. Use the front panel configuration process to set the Print Darkness parameter to the new value. Refer to Figure 15 for an example of the label.

NOTE: The best print quality for certain media and ribbon combinations may be achieved by using a darkness setting between whole numbers (for example, 7.8).

Figure 15. FEED Key Self Test

52 Zebra 116PAX3 User’s Guide

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Press and hold these two keys while turning the print engine power ON. The print engine configuration is temporarily reset to the factory default values. These values remain active until power is turned OFF. If the

factory default values are permanently saved, a media calibration procedure must be performed. You must also reset the head resistance value and the applicator port settings to their required values (see “Configuration and Calibration Sequence” beginning on page 16).

The following chart indicates which print engine function controls each of the configuration parameters:

Parameter Controlled by

Darkness Configuration, ZPL, and WebView Tear Off Configuration, ZPL, and WebView Print Mode Configuration, ZPL, and WebView Media T ype Calibration, Configur atio n, ZPL, and We bView Sensor Type Configuration, ZPL, and WebView Print Method Calibration, Configur atio n, ZPL, and We bView Print Width Configuration, ZPL, and WebView Label Length Calibration, Configuration, ZPL, and WebV iew Maximum Length Configuration, WebView, and Memory Size Host Port Configuration and WebView Baud Configuration, ZPL, and WebView Data Bits Configur ation, ZPL, and WebView Parity Configuration, ZPL, and WebView Stop Bits Configuration, ZPL, and WebView Host Handshake Configuration, ZPL, and WebView Protocol Configuration, ZPL, and WebView Network ID Configuration, ZPL, and WebView Communications Configuration, ZPL, and WebView Control Prefix Configuration, ZPL, and WebView Format Prefix Configuration, ZP L, and WebView Delimiter Character Configuration, ZPL, and WebView ZPL Mode Configuration, ZPL, and WebView Media Power Up Configuration, ZPL, and WebView Head Close Configuration, ZPL, and WebView Backfeed Configuration, ZPL, an d WebView Label Top Configuration, ZPL, and WebView Left Positio n Configuration, ZPL, and WebView Head Resistance Configuration (must match head resistance label value), ZPL, and WebView Applicator Port Configuration, ZPL, and WebView Start Print Signal Configuration, ZPL, and WebView Resynch Mode Configuration, ZPL, and WebView Ribbon Low Mode Configuration, ZPL, and WebView Reprint Mode Configuration, ZPL, and WebView Web Sensor Configuration, ZPL, and WebView Media Sensor Configuration, ZPL, and WebView Ribbon Sensor Configuration, ZPL, and WebView Mark Sensor Configuration, Z PL, and WebView Mark Media Sensor Configuration, ZPL, and WebView Media LED Configuration, ZPL, and WebView Ribbon LED Configuration, ZPL, and WebView Mark LED Configuration, ZPL, and WebView

Zebra 116PAX3 User’s G uide 53

Parameter Controlled by

LCD Adjust Configuration and WebView Modes Enabled ZPL and WebView Modes Disabled ZPL and WebView Resolution Fixed (head type switch) Socket 1 ID Fixed (option EPROMS) Firmware Fixed (code EPROMS) Configuration Configuration and WebView Memory Fixed (SIMM size and 1 MB standard) B:Memory Fixed (option card) J12 Inter face Fix ed J1 1 Inte rfac e Fixed J10 Inter face Fix ed J9 Interface Fixed J8 Interface Fixed J7 Interface Fixed

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NOTE: The following test cannot be performed until all configura tion and calib ration para meters have been set. For information, refer to “Configuration and Calibration Sequence” beginning on page 16.

This test is performed using the control panel. Refer to “Setting Communications Mode” on page 26. A typical printout from this test is shown in Figure 16.

NOTE: This label is inverted when printed.

Figure 16. Results of Communications Diagnostics Test

54 Zebra 116PAX3 User’s Guide

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Your 116 PA X3 print engine can be equipped with the following options. Contact your equipment supplier for further information and pricing.

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An optional 8 MByte SIMM increases the graphic and font storage capacity of the print engine and/or increases the print length. As this is volatile memory, contents are lost when the print engine is turned off.

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The Type I or Type II PCMCIA memory card is used for graphic, font, and label format storage. This card is an 8 MByte, non-volatile memory device, so the contents are not lost when the print engine is turned off.

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Allows you to connect a Zebra print engine to your Ethernet network. Available for 10Base-T networks.

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Allows you to oper at e fr om t he remote front panel from as far a way as 25′ (7 m). The Remote Front Panel is a factory-installed option. When installed, the front panel is removed from the front of the print engine.

Zebra 116PAX3 User’s G uide 55

56 Zebra 116PAX3 User’s Guide

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• Left-hand and right-hand models • Thermal transfer and direct thermal printing

• 600 dpi (24 dpm m):

Programmable constant printing speeds (per second) of: 1″ (25 mm), 2″ (51 mm), 3″ (76 mm), 4″ (102 mm)

• Full function Front Panel and multi-lingual backlit LCD; 180° rotatable

• Thin glaze printhead with E

Element Energy Contr ol

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Height 11.8″ (300 mm) Width 9.6″ (244 mm) Depth 17.8″ (452 mm) Weight 34.5 lbs. (15.6 kg)

NOTE: For installa tion inform ation, refer to “Appendix B” on page 79.

• Dual media sensors (transmissive is default)

• Real-time clock

• Advanced counter with firmware support for printhead

cleaning

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Operating Temperature

Thermal transfer Direct thermal

Non-condensing relative humidity

Operation Storage

Storage temperature –40° F to 140° F (–40° C to 60° C)

41° F to 104° F (5° C to 40° C) 32° F to 104° F (0° C to 40° C)

20% to 85% 5% to 85%

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Media T ype

(continuous, die-cut, or black mark)

Resolution 600 dots per inch

Dot size 0.0016″ × 0.0016″

First dot location (from inside media edge) 0.093″ ± 0.035″ (2.4 mm ± 0.89 mm) Maximum print width 3.2″ (81.6 mm) Maximum print length

(with full width media)

Non-continuous (4 MB Memory) Non-continuous (12 MB Memory) Continuous (4 MB Memory) Continuous (12 MB Memory)

116PAX3

(24 dots per mm)

(0.035 mm × 0.070 mm)

33″ (838 mm) 33″ (838 mm) 39″ (990 mm)

123″ (3124 mm)

Zebra 116PAX3 User’s G uide 57

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Media width (label and liner) 0.62″ to 4.5″ (13 mm to 114 mm) Minimum label length

Applicator mode Rewind mode Tear-off mode

Registration tolerance (does not include label/liner position tolerances)

Vertical (concurrent labels) Horizontal

Total thickness (including liner) 0.0058″ to 0.010″ (0.148 mm to 0.256 mm) Interlabel Gap (Transmissive Sensor)

Minimum Preferred Maximum

Black Mark (Reflective Sensor)

Length (parallel to inside media edge) Width (perpendicular to inside media edge)

Print Lin e to Peel Ba r Distance 0.464″ (11.8 mm) Media Unwind Force Applicator media supply steady-state tension must be uniform and

Media Rewind Force Applicator media take-up pull tension must be uniform between

0.5″ (12.7 mm); 0.25″ (6 mm) with backfeed off

0.25″ (6 mm)

0.5″ (12.7 mm); 0.25″ (6 mm) with backfeed off

≤±0.020″ (±0.5 mm) (in Applicator mode) ≤±0.020″ (±0.5 mm)

0.015″ (2 mm)

0.118″ (3 mm) Refer to page19 for Maximum Label Length discussion.

0.12″ to 0.43″ (3 mm to 11 mm) ≥0.43″ (≥11 mm)

must not exceed 2 lbs (1 kg). Start/Stop tension transients must not exceed 4 lbs (1.8 kg).

1 and 4 lbs (0.5 and 1.8 kg).

Media registration and minimum label length are affected by media type and width, ribbon type, and print speed. Performance improves as these factors are optimized. Zebra recommends always qualifying any application with thorough testing.

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Width (wound coated side out) 1.0″ to 4.5″ (25.4 mm to 114 mm) Standard length 2,952′ (900 m)

Note: Shorter lengths are accommodated.

Roll size Inner core diameter/Maximum roll size 1.0″ (25.4 mm)/4.2″ (107 mm)

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• Communicates in printable ASCII characters • Format inversion (white on black)

• Controlled via mainframe, mini, or PC • Mirror-image printing

• Downloadable graphics, scalable and bitmap fonts, label

templates, and formats

• Object copying between memory areas (RAM and PC memory card)

• Adjustable print cache • Programmable label qua nti ties with pr int and pa us e

• Data compre ss io n • Automatic serialization of fields

• Automatic memory allocation for “format while printing”•User-programmable password

• Status messages to host upon request

• Four-position field rotation (normal—0°, 90°, 180°, 270°)

• Slew command

control

58 Zebra 116PAX3 User’s Guide

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• Bar code modulus “X” dimensions: — Picket fence (non-rotated) orientation:

0.0049″ mil to 0.049″

— Ladder (rotated) orientation:

0.0049″ mil to 0.049″

• Bar code ratios: 2:1, 7:3, 5:2, and 3:1

• Linear bar codes:

Code 1 1, Code 39, Code 93, Code 128 with subsets A/B C and UCC Case Codes, ISBT -128, UPC-A, UPC-E, EAN-8 , EAN-13, UPC and EAN 2 or 5 digit extensions, Plessey, Postnet, Standard 2 of 5, Industrial 2 of 5, Interleaved 2 of 5, LOGMARS, MSI, and Codabar

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• Bi-Directional Centronics Parallel (36-pin connector) with IEEE 1284-compliant software protocol (standard)

• High-speed serial interfaces: — Serial RS-232C w/DTR hardware handshake via DB-25 connector (standard) — Serial RS-422/485 via 2 or 4-wire w/XON/XOFF handshake on alternate pins of DB-25 connector (standard) — Configurable baud rates between 110 and 57.6K baud with 7 or 8 data bits, standard parity, 1 or 2 stop bits,

DTR/DSR, Xon/Xoff

— Fused +5 @ 500mA supplied at pin 9 of the DB-25 connector

• ZebraNet™ PrintServer II MPS Ethernet network print server—10Base-T (optional)

• Remote Front Panel interface with male DB-15S connector (factory-installed option)

• Applicator interface with female DB-15 connector

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• 4 MByte RAM standard

Optional 8 MByte SIMM Option available for longer labels or additional storage of fonts, graphics, logos, and label formats.

• 4 MByte Resident Flash

• Type II Series C & D PC Card Interface (memory only) standard

Optional 8 MByte PC Memory Card—available for additional storage of fonts, graphics, logos, templates, and label formats. Also available pre-programmed with optional and international scalable fonts.

• Additional fonts available on optional EPROMs

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• Dual 32-bit RISC and CISC microprocessors

• Universal Power Supply with power-factor correcting 90–264 VAC, 48–62 Hz

• Power consumption:

Idle = 30 W Printing = 150 W (as measured using the PAUSE Key Self Test label)

• Agency approvals: UL 1950 3rd Edition; CSA 22.2 950-95; EN60950 (IE 950); FCC (Class A); Canadian DOC (Class A); EN55022 (CISPR) (Class A); EN 61000-6-2; EN 61000-3-2; EN 61000-3-3; EN60950 (IE 950); AS/NZS 3548; CNS-13438; VCCI

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• 5 Amp, 250 VAC, 5 × 20 mm IEC style, as supplied with the print engine

Zebra 116PAX3 User’s G uide 59

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Refer to Figure 17. Since many areas of the world have specific power requirements, an AC Power Cord may not be included with your pri nt engine . A power cord must be provi ded by you that meets your loc al elec tric al requiremen ts.

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• The overall length must be less than 9.8′ (3 m).

• It must be rated for at least 5 Amp, 250 VAC.

• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic interference.

This is done by the third wire (earth) in the power cord.

• The AC power plug and IEC 3 20 co nnec tor should bear the ce rt if ic ation mark of at least one of the known international safety organizations shown in Figure 18.

Contact

view

Neutral

Earth

Live

AC power

plug for

your country

3 conductor

<HAR> cable

IEC 320

connector

Figure 17. Power Cord

Figure 18. In ternational Safety Organization C ertifications

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The print engine uses a metric-style fuse (5 × 20 mm IEC) rated for 5 Amps at 250 Volts that bears the certification mark of a known international safety organization (see Figure 18).

The power entry module comes with two approved fuses in the fuse holder; one is “in-circuit” and one is provided as a “spare.”

To replace a fuse, follow this procedure and refer to Figure 19:

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1. Turn off the print engine and unplug the power cord from the back of the print engine.

2. Using a small-blade screwdriver, remove the fuse holder from the power entry module at the rear of the print engine.

60 Zebra 116PAX3 User’s Guide

3. Carefully remove the fuse from the “in circuit” location. To remove the fuse from the “spare” location,

insert the point of a pencil through one of the two holes in the fuse holder; gently push. Repeat this procedure for the other hole.

4. Insert t he spare fuse into the “in circuit” location. (Remember to replace an approved 250 VAC, 5 Amp

fuse in the “spare” location!)

NOTE: The spare fuse should be the exact type and rating as the original “in-circuit” fuse.

5. Reinstall the fuse holder into the power entry module at the rear of the print engine.

6. Reconnect the power cord and turn the print engine on. The print engine should now be ready for operation and the POWER light should be on.

NOTE: If power is not restor ed, an internal comp onen t fai lure may have occurred and the print engine requires servicing. Refer to “Troubleshooting” beginning on page 45.

Figure 19. Installing a Fuse

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CAUTION: Never ship the print engine in any container other than the original packaging. Zebra will not be responsible for any damage that occurs during transit.

To ship the Zebra 116PAX3 print engine, remove all ribbon and media. Carefully pack the print engine in the original packing materials from the factory. A shipping container can be purchased from Zebra Technologies Corporation if the original packaging has been lost or destroyed. Contact your distributor or Zebra Technologies Corporation to order the 116PA X3 Packing Materials Kit (part # 43457M).

Zebra 116PAX3 User’s G uide 61

62 Zebra 116PAX3 User’s Guide

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Effective January 1, 1997

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Zebra Technologies Corporation’s (Zebra®) printers, excluding thermal printh eads which are warranted separately below, are warranted against defects in material or workmanship for twelve (12) months from the date of original shipment by Zebra Technologies Corporation. This warranty does not cover normal wear and tear and shall be null and void i f the equ ipment i s modified, i mprop erly in stal led or us ed, dama ged by acci dent or neglect, or in the event any parts are improperly installed or replaced by the user.

Since printhead wear is part of normal operations, the original printhead and replacement printheads are covered by a limited warranty of six (6) months from the date of original shipment by Zebra Technologies Corporation. To qualify for this warranty, the printhead must be returned to the factory or other authorized service center. Although the user is not required to purchase Zebra brand supplies (media and/or ribbons), to the extent it is det er mi ne d that the use of other supplies (media an d/o r r ibbons) shall have caused any defect in the thermal printhe ad for whi ch a warra nty cla im is made, t he user s hall be respons ible fo r Zeb ra Technologies Corporation’s customary charges for labor and materials to repair such defect. To the extent that it is determined that failure to follow the preventive maintenance schedule and procedures listed in the User’s Guide shall have caused any defect in the thermal printhead fo r which a war ranty claim is made, this limited warranty shall be void.

ZEBRA TECHNOLOGIES CORPORATION’S SOLE OBLIGATION UNDER THIS WARRANTY SHALL BE TO FURNISH PARTS AND LABOR FOR THE REPAIR OR REPLACEMENT OF PRODUCTS FOUND TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP DURING THE WARRANTY PERIOD.

As a condition of this warranty, the user must: (a) obtain a Zebra Return Authorization for the printer, or subassembly(s); (b) ship the printer or subassembly(s), transportation prepaid to the authorized service location; and (c) include with the Product or subassembly(s) a written description of the claimed defect. Unless Zebra Technologies Corporation authorizes return of the entire Product, the user shall return only the subassembly(s). Products returned shall be packaged in the original packing and shipping container or comparable container. In the event equipment is not so packaged or if shipping damage is evident, it will not be accepted for service under warranty. Surface transportation charges for the return of the printer to the customer shall be paid by Zebra Technologies Corporation within the 48 contiguous states and the District of Columbia. Customer shall pay shipping costs, customs clearance, and other related charges outside the designated area. If Zebra Technologies Corporation determines that the Product returned to it for warranty service or replacement is not defective as herein defined, BUYER shall pay all costs of handling and transportation.

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Zebra supplies are warranted to be free from defects in materials or workmanship for a period of either the stated material shelf life or (six) 6 months from date of shipment, whichever occurs first, provided that the BUYER has complied with Zebra Technologies Corporation guidelines on storage, handling, and usage of the labeling supplies in Zebra printers. Zebra Technologies Corporation does not warrant the performance of Zebra labeling supplies on non-Zebra printers.

Any supplies product shown to the satisfaction of Zebra Technologies Corporation, within the time provided, to be so defective shall be replaced without charge, or Zebra Technologies Corporation may issue a credit in such an amount as it deems reasonable.

Zebra 116PAX3 User’s G uide 63

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The above warranties are in lieu of all other warranties, expressed or implied, oral or written, statutory or otherwise, including any implied warranty of merchantability or fitness for a particular purpose.

Zebra Technologies Corporation shall n ot be responsible for t h e spe ci fi c a pplication to which any Products are applied, including but not limited to compatibility with other equipment.

All statements, technical information and recommendations relating to Zebra Products are based upon tests believed to be reliable but do not constitute a guarantee or warranty.

ZEBRA TECHNOLOGIES CORPORATION SHALL NOT, UNDER ANY CIRCUMSTANCES WHATSOEVER, BE LIABLE TO BUYER OR ANY OTHER PARTY FOR LOST PROFITS, DIMINUTION OF GOOD WILL OR ANY OTHER SPECIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER WITH

RESPECT TO ANY CLAIM HEREUNDER. IN ADDITION, ZEBRA TECHNOLOGIES CORPORATION’S LIABILITY FOR WARRANTY CLAIMS SHALL NOT, IN ANY EVENT, EXCEED THE INVOICE PRICE OF THE PRODUCT CLAIMED DEFECTIVE, NOR SHALL ZEBRA TECHNOLOGIES CORPORATION BE LIABLE FOR DELAYS IN REPLACEMENT OR REPAIR OF PRODUCTS.

No salesperson, representative or agent of Zebra Technologies Corporation is authorized to make any guarantee , warranty, or representation in addition to the foregoing warranty.

NO WAIVER, ALTERATION, ADDITION, OR MODIFICATION OF THE FOREGOING WARRANTIES SHALL BE V AL ID UNLESS MADE IN WRI TING AND SIGNED BY AN EXECUTI VE OFFI CER OF ZE BRA TECHNOLOGIES CORPORATION.

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Software and documentation provided by Zebra Technologies Corporation are protected by the United States copyright law and international treaty, and therefore you must treat them like a book, with the exception that you may make copies of the software to protect yourself against loss of the original.

Your right to use the software and documentation as described below is non-exclusive and non-transferable. Zebra retains ownership in the software and documentati on and all othe r ri ght , ti tl e and in terest. The software and documentation may be used by any number of people and the software may be freely moved from one computer to another as long as there is no possibility of it being used by more than one person on more than one computer at the sam e time.

Machine readable fil es rep resent ing gr aphics or fonts which you ha ve crea te d indepe ndentl y may be conve rted to ZPL format files using the software and such files may be used, copied onto diskettes or font cards, given away, or sold without paying license fees to Zebra.

Pictorial or graphic images and machine readable files representing them may be protected by United States copyright law and international treaty provisions which prohibits you from transcribing or scanning such images or using c opying, or con verti ng such f iles wit hout p ermi ssion of th e copyr ight owner. You may not use this software in violation of U.S. copyri ght law or international treaty. By using this software, you agree to be bound by these terms.

Zebra Technologies Corporation warrants the software diskette to be free of defects in material and workmanship for a period of 60 days from the date of purchase. In the event of notification within the warranty period of defects in material and workmanship, Zebra will replace the defective diskette or documentation. Zebra specifically disclaims all other warranties, expressed or implied, including but not limited to implied warranties of merchantability and fitness for a particular purpose. IN NO EVENT WILL ZEBRA TECHNOLOGIES BE LIABLE FOR LOST PROFITS, LOST DATA, OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES CAUSED BY ABUSE OR MISAPPLICATION OF THE SOFTWARE OR BY ITS USE IN VIOLATION OF THE U.S. COPYRIGHT LAW OR INTERNATIONAL TREATY.

64 Zebra 116PAX3 User’s Guide

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YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS OF THIS ZEBRA TECHNOLOGIES CORPORATION PRINTER SOFTWARE AND FIRMWARE LICENSE AGREEMENT (“PSFLA”) BEFORE USING THE PRINTER WHICH IS ENCLOSED OR OTHERWISE ASSOCIATED WITH THIS AGREEMENT. IF YOU DO NOT AGREE WITH THESE TERMS AND CONDITIONS, DO NOT OPERATE THE PRINTER AND PLEASE PROMPTLY RETURN THE PRINTER, ENCLOSURES AND ALL PACKAGING FOR A FULL REFUND.

Zebra Technologies Corporation (“ZEBRA”) hereby grants you a non-exclusive, non-transferable license to use the SOFTWARE and FIRMWARE embedded in the printer and the accompanying documentation according to the followin g terms:

1. The printer enclosed with or otherwise associated with this Agreement has or includes certain

SOFTWARE and FIRMWARE therein which is protected by copyright laws and international copyright treaties, a s well as other intellectual property laws and tre aties. The SOFTWA RE and FIRMWARE is licensed, not sold. Such SOFTWARE and/or FIRMWARE may include, but is not limited to, SOFTWARE and/or FIRMWARE that is licensed under one or more of the following trademarks: ZPL (Zebra Programming Language), ZebraLink, Web View, Web Alert, ZBI (Zebra Basic Interpreter), BarOne, ZTools, Utilities, ZebraNet View for IP, ZebraNet Alert, PC Management Program, ZebraNet View for Networks and ZebraNet Connect.

2. GRANT OF LICENSE. This License grants you the following rights:

• SOFTWARE and FIRMWARE. You may use, access, display, run, or otherwise interact with (“RUN”) the SOFTWARE and FIRMWARE in connection with operating the printer which is enclosed with or otherwise associated with this PSFLA (“PRINTER”). The primary user of the PRINTER may make a second copy for his or her exclusive use on a portable computer/printer.

• Storage/Network Use. You may also store or install a copy of the SOFTWARE and FIRMWARE on a storage device, such as a networ k serve r, used only to RUN the SOFTW ARE and FIRMWARE on your other PRINTERS over an internal network; however, you must acquire and dedicate a license for each separate PRINTER on which the SOFTWARE and FIRMWARE is RUN from the storage device. A license for the SOFTWARE and FIRMWARE may not be shared or used concurrently on different PRINTERS.

• Reservation of Rights. All rights not expressly granted are reserved by ZEBRA.

• Accessing Services Us ing t he SOFTWARE and FIRMWARE. Your use of any se rvi ce ac ces sible using

the SOFTWARE and FIRMWARE is not covered by this PSFLA and may be governed by separate terms of use, conditions or notices.

3. RESTRICTIONS.

• You must maintain all copyright notices on all copies of the SOFTWARE and FIRMWARE.

• Limitations on modifica ti on. You may not modify, adapt, translate, or crea te der iva ti ve wor ks based on

this SOFTWARE OR FIRMWARE or the accompanying documentation.

• Limitations of Reverse Engineering, Decompilation and Disassembly. You may not reverse engineer, decompile, or disassembl e the SOFTWARE or the FIRMWARE, except and only to the exte nt that su ch activity is permitted by applicable law notwithstanding this limitation.

• Rental. You may not rent or lease or lend the SOFTWARE or FIRMWARE.

Zebra 116PAX3 User’s G uide 65

• Support Services. ZEBRA may provide you with support services related to the SOFTWARE and/or FIRMWARE (“SUPPORT SERVICES”), in its discretion. Use of SUPPORT SERVICES, if any, is governed by the ZEBRA policies and programs described in the user manual, in "online" documentation, and/or other ZEBRA provided materials. Any supplemental SOFTWARE or FIRMWARE code provided to you as a part of SUPPORT SERVICES shall be considered part of the SOFTWARE and/or FIRMWARE and is sub ject to the terms of this P SFLA. With respect to technical information you provide to ZEBRA as part of the SUPPORT SERVICES, ZEBRA may use such information for i ts business purposes, i ncluding for product support and development. ZEBRA will not utilize such techn ic al inf ormati on in a fo rm tha t pers onall y iden ti fies you exc ept to the e xte nt nec essar y to provide you with support.

• Replacement, Modificati on and Upgrade of the S OFTWARE and/or FIRMWARE. ZEBRA reserves the right to replace, modif y or up gra de t he SOFTWARE and/or FIRMWARE at any time by of f er ing you a replacement or modified version of the SOFTWARE and/or FIRMWARE or such upgrade and to charge for su ch rep lacement , mo dificat ion or upgra de. Any s uch replace ment or modifi ed SOFTWARE and/or FIRMWARE code or upgrade to the SOFTWARE and/or FIRMWARE offered to you by ZEBRA shall be considered part of the SOFTWARE and/or FIRMWARE and subject to the terms of this PSFLA (unless this PSFLA is superseded by a further PSFLA accompanying such replacement or modified version of or upgrade to the SOFTWARE and/or FIRMWARE). In the event that ZEBRA offers a repl acement or modified ver sion of o r any upgra de to the SOFTWARE and/or FIRMWARE, (a) your continued use of the SOFTWARE and/or FIRMWARE is conditioned on your acceptance of such replacement or modified version of or upgrade to the SOFTWARE and/or FIRMWARE and any accompanying superseding PSFLA and (b) in the case of the replacement or modified SOFTWARE and/or FIRMWARE, your use of all prior versions of the SOFTWARE and/or FIRMWARE is terminated.

4. TERMINA TION. Without prejudice to any other right s, ZEBRA may te rminat e thi s PSFLA i f you fail to

comply with the terms and conditions of this PSFLA. ZEBRA may terminate this PSFLA by offering you a superseding PSFLA f or t he SOFTWARE and/or F IRMWARE or any re placement or modified version of or upgrade to the SOFTWARE and/or FIRMWARE and conditioning your continued use of the SOFTWARE and/or FIRMWARE or such replacement, modified or upgraded version on your acceptance of such superseding PSFLA. In addition, ZEBRA may terminate this PSFLA by notifying you that your continued use of the SOFTWARE and/or FIRMWARE is prohibited. In the event that ZEBRA terminates this PSFLA, you must immediately stop using t he SOFTWARE and/or FIRMWARE and destroy all copies of the SOFTWARE and/or FIRMWARE and all of its component parts.

5. COPYRIGHT. All title and copyrights in and to the SOFTWARE and FIRMWARE, the accompanying

printed materials, and any copies of the SOFTWARE and FIRMWARE, are owned by ZEBRA or its suppliers. All titl e a nd inte llect ual pr opert y right s in an d to the con tent whi ch may be a ccesse d throu gh use of the SOFTWARE and/or FIRMWARE is the property of the respective content owner and may be protected by applicable copyright or other intellectual property laws and treaties. This PSFLA grants you no rights to use such content. If this SOFTWARE and/or FIRMWARE contains documentation which is provided only in electronic form, you may print one copy of such electronic documentation. You may not copy the printed materials accompanying the SOFTWARE and/or FIRMWARE.

6. U.S. GOVERNMENT RESTRICTED RIGHTS. All SOFTWARE and/or FIRMWARE provided to the

U.S. Government pursuant to solicitations issued on or after December 1, 1995 is provided with the commercial rights and restrictions described elsewhere herein. All SOFTWARE and/or FIRMWARE provided to the U.S. Government pursuant to solicitations issued prior to December 1, 1995 is provided with RESTRICTED RIGHTS as provided for in FAR, 48 CFR 52.227-14 (JUNE 1987) or DFAR, 48 CFR

252.227-7013 (OCT 1988), as applicable.

66 Zebra 116PAX3 User’s Guide

7. EXPORT RESTRICTIONS. You agree that you will not export or re-export the SOFTWARE and/or

FIRMWARE, any part thereof, or any process or service that is the direct product of the SOFTWARE and/ or FIRMWARE (the foregoing collectively referred to as the "RESTRICTED COMPONENTS"), to any country, person or entity subject to U.S. export restrictions. You specifically agree not to export or reexport any of the RESTRICTED COMPONENTS (i) to any country to which the U.S. has embargoed or restricted the expor t of goods or se rvi ce s, whi ch cur re nt ly i ncl ude , but ar e not necessarily limited to Cuba, Iran, Iraq, Libya, North Korea, Sudan and Syria, or to any national of any such country, wherever located, who intends to transmit or transport the RESTRICTED COMPONENTS back to such country; (ii) to any person or entity who you know or hav e re ason to know wil l ut il iz e th e REST RICTED COMPONENTS in the design, development or pro duction of nucl ear, chemical or biological weapons; or (iii) to any per son or entity who has been prohibited from participating in U.S. export transactions by any federal agency of the U.S. government. You warrant and represent that neither the U.S. Commerce Department, Bureau of Export Administration nor any other U.S. federal agency has suspended, revoked or denied your export privileges.

8. DISCLAIMER OF WARRANTIES. ZEBRA AND ITS SUPPLIERS PROVIDE THE SOFTWARE

AND/OR FIRMWARE “AS IS” AND WITH ALL FAULTS, AND HEREBY DISCLAIM ALL OTHER WARRANTIES AND CONDITIONS, EITHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING BUT NOT LIMITED TO ANY (IF ANY) IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY, OF FITNESS FOR A PARTICULAR PURPOSE, OF LACK OF VIRUSES, AND OF LACK OF NEGLIGENCE OR LACK OF WORKMANLIKE EFFORT. ALSO, THERE IS NO WARRANTY OR CONDITION OF TITLE, OF QUIET ENJOYMENT, OR OF NONINFRINGEMENT. THE ENTIRE RISK ARISING OUT OF THE USE OR PERFORMANCE OF THE SOFTWARE AND FIRMWARE IS WITH YOU. ZEBRA DOES NOT WARRANT THAT THE OPERATION OF THE SOFTWARE OR FIRMWARE W ILL BE UNINTERRUPTED OR ERROR FREE.

9. EXCLUSION OF ALL DAMAGES. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE

LAW, IN NO EVENT SHALL ZEBRA OR ITS SUPPLIERS BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, DIRECT, INDIRECT, SPECIAL, PUNITIVE, OR OTHER DAMAGES WHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR ANY INJURY TO PERSON OR PROPERTY, DAMAGES FOR LOSS OF PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, FOR LOSS OF PRIVACY FOR FAILURE TO MEET ANY DUTY INCLUDING OF GOOD FAITH OR OF REASONABLE CARE, FOR NEGLIGENCE, AND FOR ANY PECUNIARY OR OTHER LOSS WHATSOEVER) ARISING OUT OF OR IN ANY WAY RELATED TO THE USE OF OR INABILITY TO USE THE SOFTWARE OR FIRMWARE, WHETHER BASED ON CONTRACT, TORT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE, EVEN IF ZEBRA OR ANY SUPPLIER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THIS EXCLUSION OF DAMAGES SHALL BE EFFECTIVE EVEN IF ANY REMEDY FAILS OF ITS ESSENTIAL PURPOSE.

10. LIMITATIONS AND RELEASE OF LIABILITY.

• To the extent that the SOFTWARE and/or FIRMWARE covered by this PSFLA includes emulation libraries, emula tion l ibrar ies a re of f ered “as is”. ZEBRA does not provide a ny warr anty as socia ted wit h the emulation libraries.

• The emulation library does not work 100% correctly or cover 100% of the functionality of the printer language being emulated. Modifications may be required for each target application. If such modification is necessary, prior to making any such modification, you are required to contact ZEBRA to obtain express written consent to make such modification.

Zebra 116PAX3 User’s G uide 67

• If the emulation librar y is sold sepa rat el y by an authorized party other than ZEBRA (“RESELLER” — A party other than ZEBRA which is authorized by ZEBRA to distribute the SOFTWARE and/or FIRMWARE with its application so long as the SOFTWARE and/or FIRMWARE is used with a ZEBRA printer) or is sold bundled with a printer to an end-user by a RESELLER, and if claims are made by the RESELLER that the emulation librar y perf or ms as a 100% emulation solution, ZEBRA is not responsible if the emulation library does not work as advertised by the RESELLER. Furthermore, ZEBRA is not liable for any damages directly or indirectly relating to such emulation library which is sold separately by the RESELLER or which is sold bundled with a printer to an end-user by the RESELLER.

• The SOFTWARE and FIRMWARE was provided to you at no additional charge and ZEBRA has included in this PSFLA terms that disclaim all warranties and liability for the SOFTWARE and FIRMWARE. To the full extent allowed by law, YOU HEREBY RELEASE ZEBRA AND ITS SUPPLIERS FROM ANY AND ALL LIABILITY ARISING FROM OR RELATED TO ALL CLAIMS CONCERNING THE SOFTWARE AND/OR FIRMWARE OR ITS USE. If you do not wish to accept the SOFTWARE OR FIRMWARE under the terms of this PSFLA, do not use the PRINTER enclosed with or otherwise associated with this PSFLA.

11. GOVERNING LAW. If you acquired the SOFTWARE and/or FIRMWARE in the United States of

America, the laws of the State of Illinois, U.S.A. will apply to this contract. If you acquired this SOFTWARE and/or FIRMWARE outside of the United States of America, then local law may apply. If any provision of this PSFLA is held invalid, the remainder of this PSFLA shall continue in full force and effect.

12. QUESTIONS. Should you have any questions, or if you desire to contact ZEBRA for any reason, please

contact the ZEBRA subsidiary serving your country, or write:

Zebra Technologies Corporation

333 Corporate Woods Parkway

Vernon Hills, Illi nois 60061

68 Zebra 116PAX3 User’s Guide

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Communications Code—The print engine sends and receives American Standard Code for Information Interchange (ASCII). This code consists of 128 characters (256 for Code Page 850) including upper- and lower-case letters, numbers, punctuation marks, and various control codes.

Interfaces—The method of interfacing the print engine to a data source depends on the communication options installed in the print engine and the host. The s tandard i nterf aces a re an RS- 232/RS- 422/RS- 485 ser ial data port and an IEEE 1284 bi-directional parallel port. An Ethernet option is available for those applications that require them.

Data Specifications—When communicating via an asynchronous serial data port (RS-232/RS-422/RS-485), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control are user-selectable and should be s et t o ma tc h t hos e of the host compute r. When communicating via t he IEE E 12 84 bi -di re ct ional parallel port, the previously mentioned parameters are not considered. Refer to “Configuration” beginning on page 15 to configure the communication parameters for the print engine.

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RS-232—A serial communication method consisting of data and control signals; available as a standard feature on most PCs and other hosts.

Advantages: Cables and connectors are readily available from computer equipment stores and suppliers; easy to connect; two-way communication between the host and the print engine.

Disadvantages: Slower than the parallel connection; limited to 50′ (15.24 m) of cable. RS-422—A single-user current loop serial communication method. Advantages: Longer cable length, up to 4000′ (1219.2 m); greater immunity to data corruption caused by

industrial motors and fluorescent lights; two-way communication between the host and the print engine. Disadvantages: Not commonly available on standard PCs without additional hardware; slower than the

parallel connection. RS-485—A multiple-user current loop serial communication method that is used to support multiple print

engines connected to a single host. Advantages: Longer cable length, up to 4000′ (1219.2 m); greater immunity to data corruption caused by

parallel connection.

Zebra 116PAX3 User’s G uide 69

IEEE 1284 Bi-directional Parallel—This is a common communication method available on most PCs and other hosts.

Advantages: Fastest of the four communication interfaces; cables and connectors are readily available from computer equipment stor es and supplie rs; two-way communi cation bet ween the host and t he print engi ne; easy to connect.

Disadvantages: Shorter recommended cable length of 6′ (1.83 m); many computers are equipped with only one parallel port, allowing only one IEEE 1284 bi-directional device to be connected at a time.

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The connections for t hes e st an dard interfaces are made t hr ough t he DB- 25 fe male connector on the rear panel. Refer to Table 2. For all RS-232 input and output signals, the print engine follows both the Electronics Industries Association (EIA) RS-232 and the Consultative Committee for International Telegraph and Te lephone (CCITT) V.24 standard signal level specifications.

Table 2. RS-232/RS-422/RS-485 Pinouts

PIN NO. DESCRIPTION

1 Frame ground for cable shield 2 TXD (RS-232 transmit data) output from print engine 3 RXD (RS-232 receive data) input to print engine 4 RTS (RS-232 request to send) output from print engine 6 DSR (data set ready) input to print engine 7 Signal ground for RS-232 9 +5 VDC source output (750 mA maximum)

11 Signal ground r eference for RS-422/RS-485 13 RS-422/RS-485 data input B (–) 14 RS-422/RS-485 data output B (–) 16 RS-422/RS-485 data input A (+) 19 RS-422/RS-485 data output A (+) 20 DTR (RS-232 data terminal ready) output from print engine

NOTE: Pins 5, 8, 10, 12, 15, 17, 18, and 21–25 are unused and unterminated.

70 Zebra 116PAX3 User’s Guide

RS-232 Interconnect io ns—The print engine is configured as Data Terminal Equipment (DTE). Figure 20 illustrates the connections required to interconnect the print engine with the standard 9-pin serial port connector on a PC. Figure 21 illustrates the internal connections of the print engine’s RS-232 connector.

NOTE: If using a 9-pin to 25-pin adapter plug attached to the computer, use a null modem cable between the adapter plug and the print engine. To connect the print engine to other DTE devices with DB-25 connectors (such as an optional serial port of a PC), an RS-232 null modem (crossover) cable should be used.

Figure 20. 9-Pin to 25-Pin Interconnecting Cable

Figure 21. RS-232 Connections

Zebra 116PAX3 User’s G uide 71

RS-422/RS-485 Interconnections—The print engine may be connected to a host by an RS-422/RS-485 interface. The DB-25 Female connector on the rear of the print engine uses specific pins for this purpose. Figure 22 illustrates the required cable wiring for interconnecting to the print engine’s DB-25 connector. Figure 23 illustrates the internal connections of the print engine’s RS-422/RS-485 connector.

Figure 22. RS-422/RS-485 Interconnecting Cable

Figure 23. RS-422/RS-485 Connections

72 Zebra 116PAX3 User’s Guide

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A standard 36-pin IEEE bi-directional parallel connector is available at the rear of the print engine for connection to the data source.

Parallel Port Interconnections—Table 3 shows the pin configuration and f unc ti on of a s ta ndard computer-to - print engine IEEE 1284 bi-directional parallel cable.

Table 3. IEEE 1284 Bi-directional Parallel Connector Pinouts

PIN NO. DESCRIPTION

1STROBE—The high-to-low transition of this input signal latches the data at the eight data inputs into

the print engine.

2–9 DATA BITS 0–7—Parallel data inputs to the print engine. They have TTL input characteristics where

a HIGH (+5 V) level corresponds with a logic 1 and a LOW (0 V) level is a logic 0.

10 ACKNOWLEDGE—This output of the print engine is an active LOW pulse, indicating that the print

engine has received the previous character and is ready to accept another data character. 11 BUSY—This print engine output is active HIGH whenever it cannot accept data. 12 ERROR—This output signal is active HIGH whenever the print engine is out of paper or ribbon. 13 SELECT—The function of this output signal is dete rm ine d by a Pri nt Eng in e Con f igu rati on O pt ion . In

the default condition, SELECT is active HIGH whenever the parallel port is powered up and enabled. 14 AUTOFEED—This input is not used by the prin t engi ne.

15, 33, 34 Not used. 16, 19–30 SIGNAL GROUNDS—The logic GROUNDS and returns for all input and output signals.

17 Chassis ground (for cable shield connections). 18 +5 V fused output, 750 mA maximum 31 INITIALIZE (reset—This input is not used by the print engine). 32 FAULT—This output from the print engine is active LOW whenever any of the following error

conditions are present: Printhead Open, Printhead Over Temperature, Paper Out, Ribbon Out,

Rewind Full (if Rewind is used). 35 +5 V resistive 36 SEL IN—Connected but no t used by the print engine.

Zebra 116PAX3 User’s G uide 73

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Data cables must be fully shielded and fitted with metal or metalized connector shells. Shielded cables and connectors are required to prevent radiation and reception of electrical noise. To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible.

• Do not bundle the data cables tightly with the power cords.

• Do not tie the data cables to power wire conduits.

NOTE: Print engines comply with FCC “Rules and Regulations,” Part 15, Subpart “J,” for Class “A” equipment, using fully shielded 6′ (2 m) data cables. Use of longer cables or unshielded cables may increase radiated emissions above the Class “A” limits.

NOTE: RS-422 and RS-485 applications should use shielded twisted pairs with 120 ohm controlled impedance as recommended in the Appendix of the ITA/EIA-485 specification.

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Refer to Table 4. An external DB-15 connector is present on the rear panel of the print engine for communication with the applicator. An optional DB-15 to DB-9 adapter cable (part # 49609) is available to accommodate existing DB-9 interfaces. Figure 24 illustrates the cabling connection for print engines without the optional remote front panel, and Figure 25 illustrates the cabling connection for print engines with the optional remote front panel. The optional remote front panel comes complete with the cable and connector.

Table 4. DB-15 Connector (Print Engine to Applicator)

PIN # SIGNAL NAME SIGNAL TYPE FUNCTIONAL DESCRIPTION

1 SIGNAL GROUND

(+5V Return)

2+5V

(Fused at 500 mA)

3 START PRINT Input PULSE MODE—The label printing proce ss begins on the HIGH to LO W

4 FEED Input When the print engine is in an idle state or has been PAUSED, assert

Ground JP1 IN—Ground return for Internal +5V power source and is available

here for remote opto-isolators, if required. (JP2 IN) JP1 OUT—Ground return for External +5V power source. (JP2 OUT)

Power JP2 IN—Internal +5V power source supplies power to internal opto-

isolators and is available here for remote opto-isolators, if required. (JP1 IN) JP2 OUT—External +5V power source must be connected here to supply power to internal opto-isolators. (JP1 OUT)

transition of this signal if a format is ready. De-assert this signal HIGH to inhibit printing of a new label. LEVEL MODE—Assert LOW to enable the pr int engine to begi n printing if a format is ready. The print engine prints new labels as long as the signal is asserted. When de-asserted, the label currently printing is completed and the print engine stops and waits for this input to be reasserted LOW.

this input LOW to trigger repeated feeding of blank labels. De-assert HIGH to stop feeding blank labels and register to the top of the next label.

74 Zebra 116PAX3 User’s Guide

Table 4. DB-15 Connector (Print Engine to Applicator)—Continued

PIN # SIGNAL NAME SIGNAL TYPE FUNCTIONAL DESCRIPTION

5 PAUSE Input To toggle the current PA USE state, th is input must be as serted LOW for

200 milliseconds, or until the SERVICE REQUIRED output (pin 10) changes state.

6 REPR INT Input If the REPRI NT feature is enabled, this input mu st be ass erte d LOW to

cause the print engi ne to reprint the last la bel . (See “Configuration a nd Calibration Sequence” beginning on page 16.) If the REPRINT feature is disabled, this input is ignored.

7+28V

(Fused at

500 mA)

8 POWER GROUND

(+28V Return)

9 RIBBON LOW Output If the RIBBON LOW feature is enabled, and the amount of ribbon

10 SERVICE

REQUIRED

11 END PRINT Output

12 MEDIA OUT Output Asserted LOW while there is no media in the print engine. 13 RIBBON OUT Output Asserted LOW while there is no ribbon in the print engine. 14 DATA_READY Output As serted LOW when su ffi cient da ta ha s bee n received to begin prin ting

15 CLEAN HEAD

NOW

Power Interface Power Supply—Supplies power to external sensors as

required.

Ground Interface Power Ground.

remaining on the supply spool is below a specific threshold level, this output is as serted HIGH. If the RIBBON LOW feature is disabled, this output lead is disabled. (See “Configuration and Calibration Sequence” beginning on page 16.)

Output While either the media cover is open, the printhead is open, the ribbon

is out, the media is out, the print engine is paused, or an operational fault has occurred, this output is asserted LOW. If the applicator RESYNCH mode is set to ERROR mode, this signal also asserts LOW for a RESYNCH error.

OFF: Applicator Port OFF. MODE 1:Asserted LOW only while the print engine is moving the label

forward; otherwise de-asserted HIGH.

MODE 2:Asserted HIGH only while the print engine is moving the label

forward; otherwise de-asserted LOW.

MODE 3:(Default) Asserted LOW for 20 milliseconds when a label has

been completed and pos itioned. Not asserted during continuous printing.

MODE 4:Asserted HIGH for 20 milliseconds when a label has been

completed and positioned. Not asserted during continuous printing.

the next label. De-asserted HIGH whenever printing stops after the current label, due to either a PAUSE condition or the absence of a label format.

Output Asserted LOW every time the advanced counter measures 150 meters

(only resets upon a printhead open condition).

Zebra 116PAX3 User’s G uide 75

Figure 24. Applicator Interface Connections Without Optional Remote Front Panel

76 Zebra 116PAX3 User’s Guide

Figure 25. Applicator Interface Connections with Optional Remote Front Panel

Zebra 116PAX3 User’s G uide 77

78 Zebra 116PAX3 User’s Guide

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Ventilation openings of the print engine mounting enclosure shall be provided by the installer to remove heat and ensure uninterrupted, trouble-free operation of the print engine. Ambient air temperature surrounding the print engine must not exceed 104° Fahrenheit or 40° Centigrade.

When the print engi ne is mount ed, consid eration must be given to t he stabi lity of th e comple te assembl y so that when a full roll of media is loaded, the equipment does not become physically unstable.

Figure 26. Right Side View of Print Engine (RH)

Zebra 116PAX3 User’s G uide 79

Consideration must be given to the current rating of the print engine during installation so that when power is applied to the print engine and the enclosing equipment, an overload condition is not effected on enclosing equipment circuits or supply wiring.

Reliable earthing of the print engine must be maintained. Particular attention must be given to the AC power supply connections so that earth ground is maintained through the AC power input connector.

Figure 27. Front View of Print Engine (RH)

80 Zebra 116PAX3 User’s Guide

NOTE: Mounting hole locations are identified for both the right-hand and left-hand print engines.

Clearance at the rear panel of the electr onics enclo sure must provi de ample space for electronic con nector s and dressing of the following cables: IEC power cord, serial and/or parallel host communication cable, optional host communication cable (Ethernet), and the discrete signal (applicator) interface cable.

The IEC power cord does not have a strain relief on the print engine. If the operating characteristics of the applicator include vibration or strain on the power cord, then the installation shall provide an appropriate clamping mechanism to avoid unintentional disconnection of the power cord from the print engine.

Figure 28. Rear View of Print Engine (RH)

Zebra 116PAX3 User’s G uide 81

Figure 29. Top View of Print Engine (RH)

82 Zebra 116PAX3 User’s Guide

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Alphanumeric—Indicating letters, numerals, and characters such as punctuation marks. Backfeed—When the print engine pulls the media and ribbon (if used) backward into the print engine so that

the beginning of the label to be printed is properly positioned behind the printhead. Backfeed occurs when operating the print engine in tear-off and applicator mode.

Bar code—A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths. Many different code schemes exist, such as the universal product code (UPC) or Code 39.

Black mark—A registration mark found on the underside of the print media that acts as a start-of-label indication for the print e ngine. (See continuous media.)

Calibration (of a print engine)—A process in which the print engine determines some basic information needed to print accurately with a particular media and ribbon combination. To do this, the print engine feeds some media and ribbon (if used) through the print engine and senses whether to use the direct thermal or thermal transfer print method, and (if using non-continuous media) the length of individual labels or tags.

Character set—The set of a ll letters, numerals, punctuation marks, and oth er cha racters that can be expressed by a particular font or bar code.

Check digit—A character added to a bar code symbol that indicates to the scanner that it has read the symbol correctly.

Configuration—The prin t e ngi ne configuration is a gr oup o f op erating parameters sp eci fi c to t he print engine application. Some parameters are user-selectable, while others are dependent on the installed options and mode of operation. Parameter s may be switc h-sel ectab le, fro nt panel programmab le, or downl oaded as ZPL II commands. A configuration label listing all the current prin t engine parameters may be printed for reference.

Continuous media—Label or tag-s tock medi a that has no notch, gap, or web (media l iner only) to separat e the labels or tags. The media is one long piece of material.

Core diameter—The inside diameter of the cardboard core at the center of a roll of media or ribbon. Diagnostics—Information about which print eng ine fu nct ions are not working t ha t i s us ed f or troubleshooting

print engine problems. Die-cut media—A type of label stock that has individual labels stuck to a media liner. The labels may be

either lined up against each other or separated by a small distance. Typically the material surrounding the labels has been removed. (See non-continuous media.)

Direct thermal—A printing method in which the printhead presses directly against the media. Heating the printhead elemen ts cause s a dis colorat ion of t he heat -sensit ive coat ing on t he media. By s electiv ely heat ing the printhead elements as the media moves past, an image is printed onto the media. No ribbon is used with this printing method. Contrast this with thermal transfer.

Direct thermal media—Media th at is co ated wit h a subs tance t hat re act s to th e appli catio n of dir ect hea t from the printhead to produce an image.

Dynamic RAM—The memory devices used to store t he label formats in electronic form while they are being printed. The amount of DRAM memory available in the print engine determines the maximum size and number of label formats that can be printed. This is volatile memory that loses the st ored information when power is turned off.

Zebra 116PAX3 User’s G uide 83

Fanfold media—Media that comes folded in a rectangular stack. Contrast th is with roll media. Firmware—This is the term used to specify the print engine’s operating program. This program is

downloaded to the print engine from a host computer and stored in FLASH memory. Each time the print engine power is turned on, this operating program starts. This program controls when to feed the media forward or backward and when to print a dot on the label stock.

Flash memory—FLASH memory is non-volatile and maintains the stored information intact when power is off. This memory area is used to store the print engine’s operating program. In addition, this memory can be used to store optional print engine fonts, graphic formats, and complete label formats.

Font—A complete set of alphanumeric characters in one style of type. Examples include CG Times™ and CG Triumvirate Bold Condensed™.

Ips “inches-per-second”—The speed at which the label or tag is printed. Zebra offers print engines that can print from 2 ips to 12 ips.

Label—An adhesive-backed piece of paper, plastic, or other material on which information is printed. Label backing (label liner) —The materi al on which l abels are af fix ed dur ing manufac ture that is d iscar ded or

recycled by the end-users. Liquid crystal display (LCD)—The LCD is a back-lit display that provides the user with either operating

status during normal operation or option menus when configuring the print engine to a specific application. Light emitting diode (LED)—Indicators of specific print engine status conditions. Each LED is either off,

on, or blinking, depending on the feature being monitored. Lock-up—This is the term generally used to describe a fault condition that, for apparently no reason, causes

the print en gine to stop working. Media—Material onto which data is printed by the print engine. Types of media include tag-stock, die-cut

labels, continuous (with and without media liner), fanfold, and roll. Media sensor—This sensor is located behind the printhead to detect the presence of media and, for non-

continuous media, the position of the web, hole, or notch used to indicate the start of each label.

Media supply hanger—The stationary arm that supports the media roll. Non-continuous media—Consumable printing stock that contains an indication of where one label/printed

format ends and the next one begins. Examples are die-cut labels, notched tag-stock, and stock with black mark registration marks.

Non-volatile memory—Electronic memory that retains data even when the power to the print engine is turned off.

Notched media—A type of tag stock c ontainin g a cuto ut area t hat can be sensed as a star t-of-label indicat or by the print engine. This is typically a heavier, cardboard- like material that is either cut or torn away from the next tag. (See non-continuous media.)

Print speed—The speed at which printing occurs. For thermal transfer print e ngines, this speed is expressed in terms of ips (inches per second). Zebra offers print engines that can print from 2 ips to 12 ips.

Print engine configuration—See configuration. Printhead wear—The degradation of the surface of the printhead and/or the print elements over time. Heat

and abrasion can cause printhead wear. Therefore, to maximize the life of the printhead, use the lowest print darkness setting (sometimes called burn temperature or head temperature) and the lowest printhead pressure necessary to produce good print quality. In the thermal transfer printing method, use ribbon that is as wide or wider than the media to protect the printhead from the rough media surface.

84 Zebra 116PAX3 User’s Guide

Registration—Alignment of prin ting with respect to the to p of a label or tag. Ribbon—A band of material consisting of a base film coated with wax or resin “ink.” The inked side of the

material is pressed by the printhead against the media. The ribbon t ransfers ink onto the media when heated by the small elements within the printhead. Zebra ribbons have a coating on the back that protects the printhead from wear.

Ribbon wrinkle—A wrinkling of the ribbon caused by improper alignment or improper printhead pressure. This wrinkle can cause voids in the pri nt and/or the used ribbon to rewind unevenly. This condition should be corrected by performing adjustment procedures.

Roll media—Media that comes supplied rolled onto a core (usually cardboard). Contrast this with fanfold media.

Supplies—A general term for media and ribbon. Symbology—The term generally used when referring to a bar code. Tag—A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung

on something. Tags are usually made of cardboard or other durable material. Tear-off—A mode of operation in which the user tears the label or tag stock away from the remaining media

by hand.

Thermal direct—See direct thermal. Thermal transfer—A printing method in which the print head presse s an in k or resin coat ed ri bbon a gainst the

media. Heating the printhead elements causes the ink or resin to transfer onto the media. By selectively heating the printhead elements as the media and ribbon move past, an image is printed onto the media. Contrast this with direct thermal.

Void—A space on which printing should have occurred, but did not because of an error condition such as wrinkled ribbon or fault y pri nt ele m ent s. A void c an ca use a pri nte d bar code symbol to be read incorrectl y or not at all.

Zebra 116PAX3 User’s G uide 85

86 Zebra 116PAX3 User’s Guide

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AC Power Cord

Requirements, 60 Specifications, 60

Adjustments

Printhead Pressure, 43 Toggle Positioning, 42

Applicator Interface Connector, 74–77

Bar Code Specifica tio ns , 59

Cabling Requirements, 74 CANCEL Key Self Test, 50 Cleaning

Printhead and Platen Roller, 38

Save-a-Printhead Cleaning Film, 40–42 Communications Diagnostics Self Test, 54 Communications Specifications, 59 Configuration and Calibration Sequence, 16–36 Control Panel Keys

BLACK OVAL, 12

NEXT, 12

PREVIOUS, 12

SETUP/EXIT, 12

Damage, 1

Interfaces

IEEE 1284 Bi-directional Parallel, 70 RS-232, 69 RS-422, 69 RS-485, 69

International Safety Organi zatio n Symbo ls, 60

Light Emitting Diode (LED), 13 Liquid Crystal Display (LCD), 12 Loading

Media, 5 Ribbon, 7

Media Loading, 5 Media Sensor Position

Reflective, 9

Transmissive, 9 Media Specifications, 58 Memory Specifications, 59

Options

PCMCIA Memory Card, 55

Remote Front Panel, 55

Single In-line Memory Module (SIMM), 55

ZebraNet PrintServer II, 55

Electrical Specifications, 59 Environmental Oper ating Range Spec ifications, 57

Features (Standard), 57 FEED Key and PAUSE Key Self Test, 53 FEED Key Self Test, 52 Front Panel Ind icator Lights, 13 Front Panel K e ys

CALIBRATE, 11 CANCEL, 11 FEED, 11 PAUSE, 11

Fuses

Replacement, 60 Specifications, 59

Parallel Data Port, 73 Password-Protected Parameters, 15 PAUSE Key Self Test, 51 PCMCIA Memory Card Option, 55 Physical Characteristics (Specifications), 57 Power On/Off Switch, 11 Power-On Self Tests, 45–49 Print Engine Installation, 79–82 Printhead and Platen Roller Cle aning, 38 Printhead Pressure Adjustment, 43 Printing Considerations (Specifications), 57

Glossary, 83–85

Zebra 116PAX3 User’s G uide 87

Reflective Media Sensor Position, 9 Remote Front Panel Option, 55 Reporting Dama ge, 1 Ribbon

Loading, 7

Removal, 8 Ribbon Specifications, 58 RS-232 Interface, 69 RS-422 Interface, 69 RS-485 Interface, 69

Save-a-Printhead Cleaning Film, 40–42 Self Tests

CANCEL Key, 50

Communications Diagnostics, 54

FEED Key and PAUSE Key, 53

FEED Key, 52

PAUSE Key, 51

Power-On, 45–49 Serial Data Ports, 70–72 Setup Mode

Entering, 15

Exiting, 16

Passwords, 15 Shipping, 61 Single In-line Memory Module (SIMM) Option, 55 Specifications

Bar Codes, 59

Communicati ons, 59

Electrical, 59

Environmental Operating Range, 57

Fuses, 59

Media, 58

Memory, 59

Physical Characteristics, 57

Printing Considerations, 57

Ribbon, 58

Standard Feat ures, 57

Zebra Programmin g Language (ZPL), 58 System Considerations

Communications Code, 69

Data Specifications, 69

Interfaces, 69

Toggle Positioning, 42 Transmissive Media Sensor Position, 9 Troubleshooting

Power-On, 46 Print Engine, 46–49

Unpacking, 1

Warranty Information, 63

Zebra Programming Language (ZPL) Specifications, 58 ZebraLink License Agreement, 65–68 ZebraLink Management Tool, 3 ZebraNet PrintServer II Option, 55

Zebra 116PAX3 User’s G uide 88

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Phone Number: +1 847.634.6700 Fax Number: +1 847.913.8766

Zebra House The Valley Centre, Gordon Road High Wycombe, Buckinghamshire HP13 6EQ, UK

Phone Number: +44 (0) 1494 472872 Fax Number: +44 (0) 1494 450103

Zebra 110PAX3 Users Guide

Specifications and Main Features

Frequently Asked Questions

User Manual