Zebra DA402 User Manual

Rev. C
Customer order # 52005L
Manufacturer part # 52005LB
DA402
User's
Guide
®
Proprietary Statement
This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely 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.
Product Improvements
Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are subject to change without notice.
FCC Compliance Statement
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that the interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and the receiver.
Connect the equipment into an outlet on a circuit different than that to which the receiver is connected.
Consult the dealer or an experienced Radio/TV technician for help.
NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the unit to insure compliance.
“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.”
Canadian DOC Compliance Statement
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio interference regulations of the Canadian Department of Communications.
Liability Disclaimer
Zebra Technologies Corporation takes steps to assure 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 disclaims liability resulting therefrom.
No Liability for Consequential Damage
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 of 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.
Copyrights
This copyrighted manual and the label printer described herein are owned by Zebra Technologies Corporation. All rights are reserved. Unauthorized reproduction of this manual or the software in the label printer 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.
All products and brand names are trademarks of their respective companies. All rights reserved. © 1999 Zebra Technologies Corporation
I have determined that the Zebra printers identified as the
®
Stripe Series
DA402 and T402
manufactured by:
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061-3109 U.S.A.
have been shown to comply with the applicable technical standards of the FCC
for Home, Office, Commercial, and Industrial use
if no unauthorized change is made in the equipment, and if the equipment is properly maintained and operated.
Contents
Introduction
Hello! ..................................1
What’s in the Box ............................1
Unpacking and Inspection .......................2
DC Power Supply ............................3
Printer Overview ............................4
Getting Ready to Print
Loading the Media ...........................5
Auto Calibration ...........................18
Operator Controls ...........................19
Printing a Test Label ..........................20
Hooking Up the Printer and Computer ................20
Communicating with the Printer ...................22
Using ZPL II .............................23
Adjusting the Print Width ......................23
Adjusting the Print Darkness ....................23
Adjusting the Print Speed ......................23
Troubleshooting
What the Status LED is Telling You .................25
Print Quality Problems.........................26
Manual Calibration .........................28
Troubleshooting Tests .........................29
Feed Button Modes ..........................31
Maintenance
Cleaning ................................33
Lubrication ..............................33
Parts List ...............................35
Replacing the Printhead .......................36
Specifications
Printing Specifications ........................41
• i
Label/Tag Specifications .......................42
Font/Bar Code Specifications .....................43
Physical/Environmental/Electrical
Specifications .............................43
Agency Approvals ..........................44
Options ................................44
Serial (RS-232) Connector Technical Information .........45
Parallel Interface Technical Information ...............48
ii
Introduction
Hello!
Thank you for choosing the Zebra® DA402™ Printer. This rugged little printer is certain to become a productive and efficient addition to your workplace!
This user’s guide provides the information you will need to operate and maintain the printer.
To create and print label formats, take a look at the ZPL II Programming Guide. If one was not ordered with your printer, simply call your
distributor or visit our web site at www.zebra.com.
NOTE: Many printer settings may also be controlled by your printer’s driver or label preparation software. Refer to the driver or software documentation for more information.
What’s in the Box
• 1
Printer
Sample
Roll of Media
Test
Label
User’s
Guide
Quick
Reference
Guide
Product
Support Services
Brochure
Registration
Card
CD-Rom
Power
Supply
Unpacking and Inspection
In spect the printer for pos si ble ship ping dam age:
Check all exterior surfaces for damage.
Raise the top cover (refer to “Loading the Media” on page 5) and inspect the media compartment for damage.
In case ship ping is re quired, save the car ton and all pack ing ma te rial.
Reporting Damage
If you dis cover ship ping dam age:
Immediately notify and file a damage report with the shipping company.
Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the printer and will not cover the repair of this damage under its warranty policy.
Keep the carton and all packing material for inspection.
Notify your authorized reseller.
2
WARNING: NEVER OPERATE THE PRINTER AND POWER SUPPLY IN AN AREA WHERE THEY CAN GET WET. SERIOUS PERSONAL INJURY COULD RESULT!
DC Power Supply
Refer to Figure 1.
1. The DC power supply has a barrel connector on one end that must be inserted into the power supply receptacle on the back of the printer.
2. Insert the separate AC power cord into the power supply.
3. Plug the other end of the cord into an appropriate AC electrical outlet.
• 3
Plug
Varies by
Country
AC
Power
Cord
Power
Supply
Power
Switch
Power
Supply
Receptacle
Barrel
Connector
Figure 1
Printer Overview
4
Media
Hangers
Printhead
Peel-Off Option
Tear Bar
Peel
Bar
Peel Roller Cutter Unit
Release
Lever
Release
Lever
Platen Roller
Media Guide Adjuster
Media Guides
Lock-down Screw
Status
LED
Feed
Button
Cutter Option
Figure 2
Getting Ready to Print
Loading the Media
You can op er ate this printer in three dif fer ent modes: tear- off, peel- off, or with a cutter.
Tear-off mode allows you to tear off each label (or a strip of labels) after it is printed.
In peel-off mode, the backing material is peeled away from the label as it is printed. After this label is removed, the next one is printed.
In cutter mode, the printer automatically cuts the label after it is printed.
Tear-Off Mode
1. Unlatch the top cover by pulling the two green release levers toward you (refer to Figure 3). Then, lift the top cover to expose the media compartment.
• 5
Release
Lever
Release
Lever
Figure 3
2. Separate and hold open the media hangers (refer to Figure 4).
3. Place the media roll onto the media hangers, ensuring that it is tightly wound (refer to Figure 5).
NOTE: Refer to Figure 6. If you are using labels, make sure the media unwinds from the top of the roll. Tags unwind from the bottom of the roll.
6
Media
Hanger
Media
Hanger
Figure 4
• 7
Figure 5
Labels
Tags
Figure 6
4. Refer to Figure 7. Thread the media through the media guides.
NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 7). The media guides should just touch, but not restrict, the edges of the media.
5. Close the top cover and turn on the printer or press the feed button if the printer is already on (see “Auto Calibration” on page 18 for more information).
8
Media
Guides
Media Guide Adjuster
Wide Media
Narrow Media
Figure 7
Peel-Off Mode (optional)
1. Unlatch the top cover by pulling the two green release levers toward
you (refer to Figure 8). Then, lift the top cover to expose the media compartment.
• 9
Release
Lever
Release
Lever
Figure 8
2. Separate and hold open the media hangers (refer to Figure 9).
3. Place the media roll onto the media hangers, making sure it is tightly wound (refer to Figure 10).
4. Open the peel-off unit by pulling down on its textured top surface (refer to Figure 11).
5. Activate the peel-off unit by moving the peel-off switch to the left (refer to Figure 11 inset).
NOTE: When not operating the printer in peel-off mode, always deactivate the peel-off unit by moving the peel-off switch to the right.
6. Remove approximately 6” (152 mm) of labels from the label backing.
10
Media
Hanger
Media
Hanger
Figure 9
• 11
Figure 10
Peel-off Switch
ON OFF
Figure 11
7. Refer to Figure 12. Thread the label backing through the media guides and over the peel bar.
NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 12). The media guides should just touch, but not restrict, the edges of the media.
12
Media
Guides
Media Guide Adjuster
Wide Media
Narrow Media
Peel Bar
Figure 12
8. Thread the label backing between the black platen roller and white peel
roller until it comes out of the slot beneath the peel-off unit (refer to Figure 13).
9. Close the peel-off unit by pushing in on its smooth side surface.
10. To remove any slack, rewind media onto the roll.
11. Close the top cover and turn on the printer or press the feed button if
the printer is already on (see “Auto Calibration” on page 18 for more information).
• 13
Slot
Platen
Roller
Peel Bar
Peel
Roller
Figure 13
Cutter Mode (optional)
NOTE: The cutter is designed to cut through paper labels or the backing between labels, not the adhesive backing of the label. Adhesive build-up on the cutter blade may cause the cutter to jam.
1. Unlatch the top cover by pulling the two green release levers toward you (refer to Figure 14). Then, lift the top cover to expose the media compartment.
2. Separate and hold open the media hangers (refer to Figure 15).
3. Place the media roll onto the media hangers, ensuring that it is tightly wound (refer to Figure 16).
14
Release
Lever
Release
Lever
Figure 14
• 15
Media
Hanger
Media
Hanger
Figure 15
Figure 16
4. Refer to Figure 17. Thread the media through the media guides.
NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 17). The media guides should just touch, but not restrict, the edges of the media.
5. Refer to Figure 17. Thread the media through the cutter unit.
6. Close the top cover and turn on the printer or press the feed button if the printer is already on (see “Auto Calibration” on page 18 for more information).
16
Media
Guides
Media Guide Adjuster
Wide Media
Narrow Media
Figure 17
Fanfold Media
Fanfold media loads from the outside of the printer. Refer to Figure 18.
1. Thread the media through the access slot in the back of the printer.
2. Separate and hold open the media hangers.
3. Lock the media hangers in position by tightening the screw located on
the right media hanger.
CAUTION: Do not overtighten the screw! Overtightening could pierce the case and damage the printer’s electronics!
4. Thread the media through the media guides.
NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster. Media guides should just touch, but not restrict, the edges of the media.
5. Close the top cover and turn on the printer or press the feed button if
the printer is already on (see “Auto Calibration” on page 18 for more information).
• 17
Media
Hangers
Media
Guides
Media Guide
Adjuster
Lock-down
Screw
Access
Slot
Figure 18
Auto Calibration
NOTE: If you are using pre-printed labels, pre-printed label backing, or continuous media, see “Manual Calibration” on page 28.
An auto calibration is performed when the printer is turned on (if media is loaded) or after a media error is cleared. When it is auto calibrating, the printer sets the sensor levels for, and determines the length of, the label you are using.
If the status LED flashes red, refer to “Manual Calibration” on page 28.
18
Operator Controls
Refer to Figure 19.
Power Switch
Press to turn on and turn off the printer.
CAUTION: The power should be turned off be fore con nect ing or dis con nect ing the com mu ni ca tions and power ca bles.
Feed Button
Forces the printer to feed one blank label.
Takes the printer out of a “pause” condition. (The printer is put into “pause” by either a ZPL II command or an error condition.) See “What the Status LED is Telling You” on page 25.
Used for printer setup and status (see “Feed Button Modes” on page 31).
Status LED
Functions as a printer operational indicator (see “What the Status LED is Telling You” on page 25).
• 19
Status
LED
Feed
Button
Power
Switch
Figure 19
Printing a Test Label
Be fore you con nect the printer to your com puter, make sure that the printer is in proper work ing or der. You can do this by print ing a configuration la bel:
1. Make sure the media is properly loaded and the top cover of the printer is closed. Then, turn the printer power on if you have not already done so.
2. When the status LED is solid green, press and hold the feed button until the status LED flashes once.
3. Release the feed button. A configuration label will print.
If you cannot get this label to print, refer to Troubleshooting.
Hooking Up the Printer and Computer
CAUTION: The power supply barrel connector must be inserted into the power supply receptacle on the back of the printer before connecting or disconnecting the communications cables. (If necessary, refer to Figure 1.)
This printer comes with both a nine-pin Electronics Industries Association (EIA) RS-232 serial data interface and an IEEE 1284-compliant bidirectional parallel data interface. In either case, you must supply the required interface cable for your application.
CAUTION: This printer com plies with FCC “Rules and Regu la tions,” Part 15, for Class B Equip ment, us ing fully shielded six- foot data ca bles. Use of longer ca bles or un shielded ca bles may in crease ra di ated emis sions above the Class B lim its.
Serial (RS-232) Interface Requirements
The required cable must have a nine-pin “D” type (DB-9P) male connector on one end, which is plugged into the mating (DB-9S) serial port located on the back of the printer (refer to Figure 20). The other end of this signal interface cable connects to a serial port at the host computer. Depending on the specific interface requirements, this will most likely be a null modem cable.
For technical and pinout information, refer to page 45.
20
Parallel Interface Requirements
The required cable (IEEE 1284-compliant is recommended) must have a standard 36-pin parallel connector on one end, which is plugged into the parallel port located on the back of the printer (refer to Figure 20). The other end of the parallel interface cable connects to the printer connector at the host computer.
For pinout information, refer to page 48.
Serial and Parallel Cabling Requirements
Data cables must be of fully shielded construction 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 (6’ [1.83 m] recommended).
Do not tightly bundle the data cables with power cords.
Do not tie the data cables to power wire conduits.
• 21
Connects to Parallel Port on Host Computer
Parallel
Port
Serial
Port
Connects to
Serial Port on
Host Computer
Figure 20
Communicating with the Printer
Via the Serial Port
Serial communications between the printer and the host computer can be set by either autobaud synchronization or the ^SC command.
Autobaud
Autobaud synchronization allows the printer to automatically match the communication parameters of the host computer. To autobaud:
1. Press and hold the feed button until the green status LED flashes once, twice, and then three times.
2. While the status LED flashes, send a ZPL II format to the printer.
3. When the printer and host are synchronized, the LED changes to solid green. (No labels will print during autobaud synchronization.)
^SC Command
Use the Set Communications (^SC) command to change the communications settings on the printer.
1. With the host computer set at the same communications settings as the printer, send the ^SC command to change the printer to the desired settings.
2. Change the host computer settings to match the new printer settings.
Refer to the ZPL II Programming Guide for more information about this command.
Setting the Communications Parameters
To reset the communications parameters on the printer to the factory defaults (9600 baud, 8 bit word length, no parity, 1 stop bit, and XON/XOFF), do the following:
1. Press and hold the feed button until the green status LED flashes once, twice, and then three times.
2. While the status LED rapidly flashes yellow and green, press the feed button.
Via the Parallel Port
Typically, no setup is required once the cable is plugged in. If you should encounter any problems, consult the user’s guide that came with your computer.
22
Using ZPL II
For detailed information about creating labels using ZPL II, refer to the ZPL II Programming Guide or visit our web site at www.zebra.com.
Adjusting the Print Width
Print width must be calibrated when:
You are using the printer for the first time.
There is a change in the width of the media.
Print width may be set by way of the five-flash sequence in “Feed Button Modes” (see page 31) or refer to the Print Width (^PW) command (consult your ZPL II Programming Guide).
Adjusting the Print Darkness
The relative darkness setting is controlled by either the six-flash sequence in “Feed Button Modes” (see page 31) or the Set Darkness (~SD) ZPL II command (follow the instructions in the ZPL II Programming Guide).
Adjusting the Print Speed
Print quality is affected by print speed and the media you are using. Only by experimenting will you find the optimal mix for your application.
If you find that the print speed needs to be adjusted, refer to the Print Rate (^PR) command in the ZPL II Programming Guide.
• 23
24
Troubleshooting
What the Status LED is Telling You
RESOLUTIONS:
1. The printer is not receiving power.
Have you turned on the printer power?
Check power connections from the wall outlet to the power supply, and from the power supply to the printer.
2. The printer is on and in an idle state.
3. The printer has failed its power on self test (POST).
If this error occurs right after you turn on the printer, contact an authorized reseller for assistance.
There is a shortage of memory.
If this error occurs after you have been printing, turn the printer power off and on. Then, resume printing.
4. The printer is receiving data.
As soon as all of the data has been received, the status LED will turn green; then, the printer will automatically resume operation.
• 25
Status LED
Condition and Color
Printer Status
For a Resolution,
Refer to:
Off Off 1
Solid Green On 2
Flashing Yellow Stopped 3
Flashing Green Normal Operation 4
Flashing Red Stopped 5
Double Flashing Green Paused 6
Solid Yellow Various 7
Alternately Flashing Green and Red Needs Service 8
5. The media is out.
Load a roll of media, following the instructions in “Loading the Media” on page 5. Then, press the feed button to resume printing.
The printhead is open.
Close the top cover. Then, press the feed button to resume printing.
The cutter is jammed.
Turn off the printer and remove any jammed labels from the cutter unit. Then, turn on the printer to resume printing.
6. The printer is paused.
Press the feed button to resume printing.
7. The printhead is under temperature.
Continue printing while the printhead reaches the correct operating temperature.
The printhead is over temperature.
Printing will stop until the printhead cools to an acceptable printing temperature. When it does, the printer will automatically resume operation.
8. FLASH memory is not programmed.
Return the printer to an authorized reseller.
Print Quality Problems
No print on the label.
Make sure the correct media (direct thermal) is loaded. Try this: Quickly rub your nail or a blunt object over the label surface. If it does not produce dark marks, the wrong media (thermal transfer) is loaded.
Is the media loaded correctly? Follow the instructions in “Loading the Media” on page 5.
The printed image does not look right.
The printhead is dirty. Clean the printhead according to the instructions on page 33.
The printhead is under temperature.
26
Adjust the print darkness and/or print speed. Refer to the six-flash sequence in “Feed Button Modes” on page 31, or the ^PR and ~SD commands in the ZPL II Programming Guide.
The media being used is incompatible with the printer. Be sure to use the recommended media for your application, and always use Zebra-approved labels and tags.
There are long tracks of missing print (blank vertical lines) on several labels.
The printhead is dirty. Clean the printhead according to the instructions on page 33.
The printhead elements are damaged. Replace the printhead (see “Replacing the Printhead” on page 36).
The printing does not start at the top of the label, or misprinting of one to three labels.
The media may not be threaded under the media guides. Refer to “Loading the Media” on page 5.
The printer needs to be calibrated. Refer to “Auto Calibration” on page 18.
The correct media sensor may not be activated. Manual calibration selects the media sensing method for the labels being used (refer to the ^MN command in the ZPL II Programming Guide).
Verify that the Label Top (^LT) command is correctly set for your application (consult the ZPL II Programming Guide).
A label format was sent to, but not recognized by, the printer.
Is the printer in pause mode? If so, press the feed button.
If the status LED is on or flashing, refer to “What the Status LED is Telling You” on page 25.
Make sure the data cable is correctly installed.
A communications problem has occurred. First, make sure that the correct communications port on the computer is selected. Next, verify that the same handshaking is in use by both the printer and the computer. Then, ensure that the baud rates of the printer and the computer match. Refer to “Communicating with the Printer” on page 22.
• 27
Manual Calibration
Manual calibration is recommended whenever you are using pre-printed labels (or label backing) or if the printer will not correctly auto calibrate.
1. Turn on the printer power.
2. Remove approximately 4” (102 mm) of labels from a section of backing material. Load the media so that only the backing material is threaded through the printer and under the printhead.
3. Press and hold the feed button until the green status LED flashes once, then twice. Release the feed button.
4. The printer will set the media sensor for the label backing being used. After it is done making this adjustment, the roll will automatically feed until a label is positioned at the printhead.
5. A profile of the media sensor settings (similar to the example in Figure 21) will print. Upon completion, the printer will save the new settings in memory and the printer is ready for normal operation.
6. Press the feed button. One entire blank label will feed. If this does not happen, try defaulting (refer to the four-flash sequence in “Feed Button Modes” on page 31) and recalibrating the printer.
NOTE: Performing a manual calibration disables the auto calibration function. To return to auto calibration, default the printer (see the four-flash sequence in “Feed Button Modes” on page 31).
28
Figure 21
Troubleshooting Tests
Printing a Configuration Label
To print out a list ing of the printer’s cur rent con figu ra tion (an exam ple is shown in Fig ure 22), re fer to the one-flash sequence in “Feed But ton Modes” on page 31.
Recalibration
Re cali brate the printer if it starts to dis play un usual symp toms, such as skip ping la bels. See “Auto Calibration” on page 18.
• 29
Figure 22
Resetting the Factory Default Values
Some times, re set ting the printer to the fac tory de faults solves some of the prob lems. Fol low the four-flash sequence instructions in “Feed But ton Modes” on page 31.
Communications Diagnostics
If there is a problem transferring data between the computer and printer, try putting the printer in the communications diagnostics mode. The printer will print the ASCII char ac ters and their respective hexade ci mal val ues (a sample is shown in Figure 23) for any data re ceived from the host com puter. To find out how, re fer to the power off mode procedure in “Feed But ton Modes” on page 31.
30
Figure 23
Feed Button Modes
• 31
Power Off Mode (Communications Diagnostics Mode)
With the printer power off, press and hold the feed button while you turn on the power. The printer prints out a listing of its current configuration (see Figure 22). After printing the label, the printer will automatically enter a diagnostic mode in which the printer prints out a literal representation (see Figure 23) of all data subsequently received. To exit the diagnostic mode and resume printing, turn off and then turn on the printer.
Power On Modes
With the printer power on and top cover closed, press and hold the feed button for several seconds. The green status LED will flash a number of times in sequence. The explanation at the right (Action) shows what happens when you release the key after the specific number of flashes.
Flash
Sequence Action
* A configuration label prints. *
**
The media sensor calibrates and a media sensor profile prints (see “Manual Calibration” on page 28).
* ** ***
To reset the communication parameters: Press and release the feed button while the LED rapidly flashes yellow and green. The serial communication parameters reset to 9600 baud, 8 bits per character, no parity, 1 stop bit, and XON/XOFF.
For autobaud synchronization: Send a ZPL II format to the printer while the LED rapidly flashes yellow and green. When the printer and host are synchronized, the LED changes to solid green. NOTE: No
labels will print during autobaud synchronization.
* ** *** ****
Resets the factory defaults, auto calibrates, and saves settings into memory.
* ** *** **** *****
The print width calibrates. While the status LED alternately flashes green and yellow, a series of stacking rectangles print on the label. When the rectangle prints to the outer edges of the label, press and release the feed button. The label width and current communication parameters will be saved into memory.
* ** *** **** ***** ******
The print darkness calibrates. A series of nine samples print, starting with the lightest and ending with the darkest image. When the desired print darkness is achieved, press and release the feed button. The print darkness will be saved into memory.
If the feed button remains pressed after a 7-flash sequence, the printer will ignore the button when it is released.
32
Maintenance
Cleaning
CAUTION: Use only the clean ing agents in di cated. Ze bra Tech nolo gies Cor po ra tion will not be re spon si ble for dam age caused by any other clean ing ma te ri als used on this printer.
If necessary, refer to Figure 2 for part locations.
Lubrication
CAUTION! No lu bri cat ing agents of any kind should be used on this printer! Some com mer cially avail able lu bri cants, if used, will dam age the fin ish and the me chani cal parts in side the printer.
• 33
Area Method Interval
Printhead
After allowing the printhead to cool for approximately one minute, use 70% isopropyl alcohol on a cotton swab to clean the print elements from end to end (the print elements are located in the thin gray line on the printhead).
NOTE: You do not have to turn off the printer to do this.
If print quality has not improved after performing this procedure, try cleaning the printhead with Save-a-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized reseller for more information.
After every five rolls of media
Platen roller
Manually rotate the platen roller. Clean it thoroughly with 70% isopropyl alcohol and a cotton swab or lint-free cloth.
Peel bar
Clean it thoroughly with 70% isopropyl alcohol and a cotton swab.
As needed
Tear bar
Clean it thoroughly with 70% isopropyl alcohol and a cotton swab.
As needed
Cutter
Turn off the printer power. Use tweezers to remove the media.
As needed
Exterior Water-dampened cloth
As needed
Interior Brush/air blow
As needed
34
1
2
3
4
5
6
7
8
9
Figure 24
Parts List
Refer to Figure 24.
• 35
Item
Number Description
Part
Number
1
Feed Switch Assembly (set of 3)
105910-004
2
Printhead and Latch Assembly
105910-042
3
Printhead Assembly Printhead Cable Set
105910-010 105915-091
4
Media Sensor PCB Assembly (set of 3)
105910-011
5
Platen Roller Kit, Standard (set of 3)
105910-001
Platen Roller Kit, Linerless
105910-002
6
Front Bezel, Standard (set of 10)
105910-005
Front Bezel, Peel-Off
105910-022
Peel-Off Sensor PCB Assembly (set of 3)
105910-013
7
Rubber Foot Kit (set of 24)
105910-007
8
Main Logic Board Kit, Maintenance
52050M
9
Bottom Frame Assy.
105910-018
10
Upper Cover Assy.
105910-017
Not
shown:
Stepper Motor, (set of two)
105910-009
Power Supply Assembly (90-264 VAC, 47-63 Hz)
105950-043
Power Cord, 110V (set of 5)
105950-038
Power Cord, 230V European (set of 5)
105950-039
Power Cord, 230V UK (set of 5)
105950-040
Power Cord, 230V Australian (set of 5)
105950-041
Cutter
105910-028
Shipping Pack (box, inserts, bags)
105950-050
4M FLASH Memory w/Real Time Clock Option Assembly
52088M
8M FLASH Memory w/Real Time Clock Option Assembly
52054M
User’s Guide
52005L
Quick Reference Guide
52006L
Replacing the Printhead
Removing the Printhead
1. Turn printer power off and unplug the printer.
2. Refer to Figure 25. Remove the four screws that secure the printhead and latch assembly to the top cover.
3. Refer to Figure 26. Slide the tension bar all the way to the right in its mounting bracket (1). Then, while gently pressing on the opposite mounting bracket (2), lift and remove the tension bar (3).
4. Refer to Figure 27. Remove both printhead wire harness connectors from their receptacles.
5. Refer to Figure 27. Remove the two screws and washers that secure the printhead to the printhead bracket. Then, lift the lip on the front of the printhead bracket to remove the printhead.
36
Printhead and Latch Assembly
Top Cover
Screws (4)
Figure 25
• 37
Tension Bar
Tension Bar
Mounting
Bracket
Tension Bar
Mounting
Bracket
1
2
3
Figure 26
Printhead
Bracket Lip
Printhead
Screw
and
Washer
Screw
and
Washer
Connector
Connector
Receptacle
(shown hidden)
Receptacle
(shown hidden)
Figure 27
Installing the Printhead
1. Ensure that the printer is turned off and unplugged.
2. Refer to Figure 28. Route the two printhead wire harness connectors as shown. Then, insert the connectors into their receptacles.
3. Insert the printhead into the printhead bracket.
4. Refer to Figure 29. Reinstall the two screws and washers that secure the printhead to the printhead bracket.
NOTE: The green grounding cable, which attaches to the feed switch assembly PC board, must also be secured by one of the screws.
5. Refer to Figure 30. Insert one end of the tension bar into its mounting bracket (1). Then, gently push down on the opposite end of the tension bar until it locks into place (2).
NOTE: Make sure the “V” of the tension bar fits into the notch in the printhead bracket.
6. Insure that all cables are properly dressed between the printhead and latch assembly and the top cover.
7. Reinstall the four screws that secure the printhead and latch assembly to the top cover. Then, plug in the printer and turn on the power.
38
Printhead
Connector
Connector
Receptacle
(shown hidden)
Receptacle
(shown hidden)
Figure 28
• 39
Printhead
Bracket
Printhead
Screw
and
Washer
Green
Grounding
Cable
Screw
and
Washer
Figure 29
Tension Bar
“V” of Tension Bar
Printhead
Bracket
Notch
1
2
Figure 30
40
Specifications
NOTE: Printer specifications are subject to change without notice.
Printing Specifications
• 41
Print Density 203 dots/inch (8 dots/mm) Print Speed 1.5” (38 mm), 2” (51 mm), and 2.5” (64 mm) per second
Print Width
1” to 4.09” (25.4 mm to 104 mm)
1” to 2.25” (25.4 mm to 57 mm) for tag stock Print Length .005” to 22” (.125 mm to 559 mm) with standard memory Registration
Tolerance
Horizontal: +/- 0.0591” (1.5 mm)
Vertical: +/- 0.0393” (1 mm) FLASH Memory
(User Available)
1 MB
DRAM Memory (User Available)
1 MB
Label/Tag Specifications
42
Label/Tag Width
1” to 4.25” (25.4 mm to 108 mm) 1” to 2.25” (25.4 mm to 57 mm) for tag stock
Label/Tag Length 0.5” to 22” (13 mm to 559 mm) with standard memory
Interlabel Gap
0.08” to 0.16” (2 mm to 4 mm)
0.118” (3 mm) recommended
Label/Tag Thickness
.003” to .007” (.08 mm to .18 mm) .003” to .0053” (.08 mm to .135 mm) for cutter option
Label Roll Size
Max. Outer Diameter
5” (127 mm)
Inner Core
1” (25.4 mm) or 1.5” (38 mm)
Media Requirements
Use Zebra-brand direct thermal media that is outside
wound. Media may be reflective (black mark) sensing or transmissive sensing, die-cut, notched, or continuous.
For die-cut labels, use only full auto dies.Notched media must have a 0.5” (13 mm) wide x
0.094” (2.4 mm) long cutout located in the center of the roll. The reflective media black marks must be located in the center of the roll.
Minimum Black Mark Dimensions:
Mark width: 0.5” (13 mm) centered and perpendicular
to the edge of the media.
Mark length: 0.094” (2.4 mm) parallel to the bottom
edge of the media.
Font/Bar Code Specifications
Physical/Environmental/Electrical Specifications
• 43
Fonts Available
CG Triumvirate Bold Condensed scalable smooth (0)Zebra fonts A-H, GS, P-VIBM Code Page 850 International Symbols
Bar Codes Available (1D)
Codabar (supports ratios
of 2:1 to 3:1)
Code 11Code 128/USD 8
(supports serialization in all subsets and UCC Case Codes)
Code 39 (supports ratios
of 2:1 to 3:1)
Code 93EAN 8/JAN 8EAN 13/JAN 13EAN 14/UPC-A
Industrial 2 of 5Standard 2 of 5Interleaved 2 of 5
(supports ratios of 2:1 to 3:1, Modulus 10 Check Digit)
LOGMARSMSIPlesseyPOSTNETUPC-EUPC/EAN Extensions
Bar Codes Available (2D)
CodablockCode 49Data MatrixMaxiCode
MicroPDF417PDF 417QRcode
Rotation Angles 0°, 90°, 180°, and 270°
Physical Size (L x W x H) 8.5” x 7.6” x 6.6” 216 mm x 193 mm x 167 mm
Weight
Printer
3 lbs. 1.4 kg.
Shipping
9 lbs. 4.1 kg.
Temperature Range
Operating
40° to 105° F 5° to 41° C
Storage
-40° to 140° F -40° to 60° C
Relative Humidity
Operating
10% to 90% (non-condensing)
Storage
5% to 95% (non-condensing)
Electrical
External 90-264 VAC, 47-63 Hz universal power supply. Regional line cords are available.
Agency Approvals
UL 544 Medical Equipment Standard Part 42.5
CSA 22.2 No. 950-95 Canadian Safety Standard
IEC 950/EN 60950 International Safety Standard
FCC Class B
UL 1950 Domestic Safety Standard, 3rd Ed.
Canadian DOC Class A
EN50082-1:1997 International Immunity Standard
EN55022 Class B European Electromagnetic Radiation Standard
EN61000-3-2, 3 Powerline Disturbance
AS/NZS 3548 Australia EMC
CE Compliant
EMC Taiwan
CB Scheme Documents
Options
Peel-off
Cutter
Linerless
4 MB FLASH memory
8 MB FLASH memory
Real time clock with 4 MB FLASH
Real time clock with 8 MB FLASH
Power rewinder, 110 VAC
Power rewinder, 230 VAC
For details, call your author ized reseller.
44
Serial (RS-232) Connector Technical Information
NOTES: The maximum current available through the serial and/or parallel port is not to exceed a total of 0.75 Amps.
When XON/XOFF handshaking is selected, data flow is controlled by the ASCII control codes DC1 (XON) and DC3 (XOFF). The DTR control lead will have no effect.
Interconnecting to DTE Devices
The printer is configured as data terminal equipment (DTE). To connect the printer to other DTE devices (such as the serial port of a personal computer), use an RS-232 null modem (crossover) cable. Figure 31 shows the required cable connections.
Interconnecting to DCE Devices
When the printer is connected via its RS-232 interface to data communication equipment (DCE) such as a modem, a STANDARD RS-232 (straight-through) interface cable must be used. Figure 32 shows the connections required for this cable.
• 45
Pin No. Description
1
Not used
2
RXD (receive data) input to the printer
3
TXD (transmit data) output from the printer
4
DTR (data terminal ready) output from the printer -- controls when the host may send data
5
Chassis ground
6
DSR (data set ready) input to the printer
7
RTS (request to send) output from the printer -- always in the ACTIVE condition when the printer is turned on
8
Not used
9
+5 V @ 0.75 A fused
46
Connecting the Printer to a DTE Device
DB-25S
Connector
to DTE Device (PC)
DB-9S
Connector
to DTE Device (PC)
DB-9P
Connector
to Printer
DB-9P
Connector
to Printer
2 3 4 5 6 7
8 20 22
1 2 3 4 5 6 7 8 9
TXD
TXD
RXD RXD RTS
RTS
CTS
CTS
DSR
DSR
GND
GND
DCD
DCD
DTR
DTR
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
TXDTXD
RXDRXD
RTS
RTS
CTS
CTS
DSRDSR
GNDGND
DCD
DCD
DTRDTR
Figure 31
• 47
Connecting the Printer to a DCE Device
DB-25S
Connector
to DCE Device
DB-9S
Connector
to DCE Device
DB-9P
Connector
to Printer
DB-9P
Connector
to Printer
2 3 4 5 6 7
8 20 22
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1
2
3
4
5
6
7
8
9
TXD
TXD
TXD
TXD
RXD
RXD
RXD
RXD
RTS
RTS
CTS
CTS
CTS
CTS
RTS
RTS
DSR
DSR
DTR
DTR
GND
GND
GNDGND
DCD
DCD
DCD
DCD
DTR
DTR
DSR
DSR
Figure 32
Parallel Interface Technical Information
NOTE: The maximum current available through the serial and/or parallel port is not to exceed a total of 0.75 Amps.
48
Pin No. Description
1
nStrobe/Host Clk
2-9
Data Bits 1-8
10
nACK/PtrClk
11
Busy/Per Busy
12
PError/ACK Data Req.
13
Select/Xflag
14
nAuto Fd/Host Busy
15
Not Used
16 & 17
Ground
18
+5 V @ 0.75 A Fused
19-30
Ground
31
nInit
32
nFault/nData Avail.
33 & 34
Not Used
35
+5V through 1.8 K Ohm Resistor
36
nSelectin/1284 active
Index
A
Ad just ments
Print dark ness ........23
Print speed .........23
Print width .........23
Agency ap prov als........44
Auto cal i bra tion.........18
Autobaud ............22
C
Cal i bra tion
Auto.............18
Man ual ...........28
Clean ing
Cut ter ............33
Ex te rior ...........33
In te rior ...........33
Peel bar ...........33
Platen roller .........33
Printhead ..........33
Tear bar ...........33
Com mu ni ca tion pa ram e ters, set ting
.................22
Com mu ni ca tions di ag nos tics ..30 Com mu ni ca tions pa ram e ters, set -
ting ...............22
Con fig u ra tion la bel .......29
Cut ter mode ...........14
D
Dam age, ship ping ........2
Dark ness, ad just ing .......23
DCE de vices, in ter con nect ing . 45
De fault ing the printer ......30
DTE de vices, in ter con nect ing . 45
F
Fac tory de faults, re set ting ..30,31
Fanfold me dia..........17
Feed but ton ...........19
Feed but ton modes .......31
I
In spec tion ............2
L
Load ing the me dia
Cut ter mode .........14
Fanfold ...........17
Peel-off mode ........9
Tear-off mode ........5
Lu bri ca tion ...........33
M
Main te nance parts .......35
Man ual cal i bra tion .......28
Me dia load ing
Cut ter mode .........14
Fanfold ...........17
Peel-off mode ........9
Tear-off mode ........5
•49
O
Op er a tor con trols ........19
Op tions .............44
P
Par al lel con nec tor pinouts ...48
Parts list.............35
Peel-off mode ..........9
Pinouts
Par al lel ...........48
Se rial ............45
Power switch ..........19
Print dark ness, ad just ing ..23,31
Print speed, ad just ing ......23
Print width, ad just ing ....23,31
Printhead, re plac ing.......36
R
Recalibrating the printer ....29
Re pair parts ...........35
Re plac ing the printhead.....36
Re port ing dam age, ship ping ...2 Re set ting the fac tory de faults 30,31
S
Se rial con nec tor pinouts ....45
Set com mu ni ca tions (^SC) ...22 Spec i fi ca tions
Font/bar code ........43
La bel/tag ..........42
Phys i cal/en vi ron men tal/elec tri -
cal ..............43
Print ing ...........41
Sta tus LED .........19,25
T
Tear-off mode ..........5
Trou ble shoot ing ........25
Trou ble shoot ing tests ......29
U
Un pack ing ............2
Z
ZPL II..............23
ZPL II Pro gram ming Guide . 1,23
50
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