Zebra KR403 Hardware Integrator Guide

P1016701-001 Rev. C

Zebra® KR403

Kiosk Receipt Printer

Hardware Integrator

Guide

© 2016 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer

described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or
firmware in the 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.

This product may contain ZPL

3®

E

; and Monotype Imaging fonts. Software © ZIH Corp. All rights reserved worldwide.

®

, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit;

ZebraLink and all product names and numbers are trademarks, and Zebra, the Zebra logo, ZPL, ZPL II,
Element Energy Equalizer Circuit, and E

3

Circuit are registered trademarks of ZIH Corp. All rights reserved

worldwide.
All other brand names, product names, or trademarks belong to their respective holders. For additional

trademark information, please see “Trademarks” on the product CD.

Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation

and its subsidiaries (“Zebra Technologies”). It is intended solely for the information and use of parties
operating and maintaining the equipment described herein. Such proprietary information may no t be used,
reproduced, or disclosed to any other parties for any other purpose without the express, written permission
of Zebra Technologies.

Product Improvements Continuous improvement of products is a policy of Zebra Technologies. All

specifications and designs are subject to change without notice.

Liability Disclaimer Zebra Technologies takes steps to ensure that its published Engineering

specifications and manuals are correct; however, errors do occur . Zebra Technologies reserves the right to
correct any such errors and disclaims liability resulting therefrom.

Limitation of Liability In no event shall Zebra Technologies 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, consequential damages including loss of business
profits, business interruption, or loss of business information) arising out of the use of, the results of use of,
or inability to use such product, even if Zebra Technologies has been advised of the possibility of such
damages. Some jurisdictions do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.

Contents

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

KR403 Kiosk Receipt Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Who Should Use This Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 • Design Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Design Considerations Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 • Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Basic Printer Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Printer Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Opening the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

General Printing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

KR403 Media Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Basic Printer Mounting (printe r only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Design Your Own Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Looping Presenter (Kiosk Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Vertical Presenter (Kiosk Mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Receipt (Page) Imaging Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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ii

Contents

Controls, Indicators, and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Feed Button Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Sensing, Status and Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Feed Button Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Ambient Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Manual Printer Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Printer Configuration Methods and Tools. . . . . . . . . . . . . . . . . . . . . . . . . 28

Fonts and Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Identifying Fonts in Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Localizing the Printer with Code Pages . . . . . . . . . . . . . . . . . . . . . . . 30

Asian fonts and Other Large Font Sets . . . . . . . . . . . . . . . . . . . . . . . 30

Getting Asian Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Stand Alone Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 • Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Cabling and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Large Media Roll Adapter Accessory. . . . . . . . . . . . . . . . . . . . . . . . . 33

Attaching Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Electrostatic Discharges and Earth Currents. . . . . . . . . . . . . . . . . . . 35

Connecting the Printer to the Host. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Interface Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Communicating with the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5 • Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Designing Your Own Media Dispensing System . . . . . . . . . . . . . . . . . . . 43

Designing a Roll Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Designing Media Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Designing for Fan-Fold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Basic Media Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Media Supply Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Media Input Aperture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Mounting Orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Media Guide - Required Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Installing the Media Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Determining Thermal Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Black Mark Media Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Preparing a Media Roll for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Automated Media Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Manual Media Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Clearing Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Contents

Printing a Test Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6 • Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Accessories Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Nozzle Bezel – P1011185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Nozzle Bezel Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 64

Shutter Bezel – 104591 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Shutter Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Small Core Media Adapter – G105156. . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Quick-Fit Hubs – 103939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Quick Fit Leaf Spring Retainer – 01473-000 . . . . . . . . . . . . . . . . . . . . . . 67

Roll Support – P1014124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Media Roll Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Universal Roll Holder – P1014125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Printer Mounting Plate – 104208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Wall Mount Roll Holder – P1014123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Printer Power Supply – 808099-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Attaching the Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Universal Serial Bus (USB) Cable – P1027715. . . . . . . . . . . . . . . . . . . . 79

Large Media Roll Adapter – P1026858 . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Attaching to the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Loading Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Mounting Plate for Large Media Roll Adapter – P1027728 . . . . . . . . . . . 83

Attaching to the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Using other Accessories with the Large Media Roll Adapter . . . . . . . . . . 84

Universal Roll Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Routing Cables with the Larg e Me dia Roll A dapter . . . . . . . . . . . . . . . . . 85

Media Roll Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Serial, USB, and Ethernet Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

iii

7 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Status Light Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Application LED States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Application User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Media Sensing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Resetting the Factory Default Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Contact Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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Contents

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

KR403 Kiosk Receipt Printer

The Zebra KR403 model is the best-in-class thermal kiosk printer with the widest range of
features. The KR403 printer provides direct thermal printing at speeds up to 150 mm/s
(5.9 ips) at a 203 dpi print density. The KR403 supports the ZPL printer programming
language and a wide variety of interface and feature options.

1

Introduction

The KR403 printer features:

• Patented Looping Presenter – To reduce jamming and print image distortion
caused by the user attempting to withdraw the receipt before imaging is finished,
the KR403 employs an innovative “looping station”. The receipt is retained inside
the print mechanism until imaging is complete, then it is presented to the user for
removal.

• Media Pull Detection – When the user grasps the receipt and applies force to
remove it, the KR403 senses the force and dispenses the receipt in a controlled
fashion to prevent tearing or jamming.

• Retract and Retain – If the receipt is not taken within a specified time, the KR403
withdraws it and dumps it out the bottom of the printer, typically into a catch bin
within the kiosk. The number of retracts are counted an d reported back to the
host.

• Easy Media Loading – Automatic media loading and preparation for printing.
Optional supply low sensing.

• Flexible Media Support – Supports continuous, fanfold and black line receipt
media and label media with automatic media sensing and calibration.

• Flexible Mounting – Horizontal and vertical printer mounting covering 180° of
printer orientation and up to 360° with optional media adapter.

• Printhead Life Monitoring – Printhead element testing and print length odometer
reporting.

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Introduction

2

KR403 Kiosk Receipt Printer

• Industry Leading Bar Code Support – Largest set of common and specialized
linear and 2-dimensional bar code symbologies resident in a kiosk printer.

• Powerful Font Support – One scalable and 16 bitmap fonts resident with support
for downloadable and Unicode fonts.

• Interface Support – The KR403 is available with two interface configurations:
USB / Serial, and USB / Ethernet.

• Storage – 4MB of flash memory with the largest in class 1.5MB available for
programming, graphics and fonts with 8MB of SDRAM for fast image processing.

The KR403 printers offer a wide range of printer options and accessories:

• 58, 60, 80, and 82.5mm media guide w idth s

• 70 watt external printer power module

• Multiple printer media roll mounting accessory configurations and options

• Media Roll Low Sensor for use with Zebra and custom media roll mounting

• Large Media Roll Adapter to prevent motor strain when using large media rolls

• Full Flash (64MB) memory for storing large Unicode font sets, multiple fonts,
graphics and programming

• Asian Language support with printer configuration options for the large Simplified
and Traditional Chinese, Japanese, Korean, or Thai character sets

• Zebra’s ZBI 2.0 (Zebra BASIC Interpreter) pr ogramming language. ZBI allows you
to create custom printer operations and software language emulation

This integrators guide provides information you will need to install and operate your printer
on a daily basis. To create receipt (label) formats, refer to your programming guides or
receipt (label) design applications such as Zebra Designer.

Your printer, when connected to a host computer, functions as a complete system for
printing receipts and labels.

Note • Many printer settings may also be controlled by your printer’s driver or receipt
(label) design software. Refer to the Software Integrator Guide (P1026208) for more
information.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Package Contents

• The KR403 printer

• Warranty information

Note • To minimize cost and reduce waste, the KR403 does not include unneeded
components or accessories. Additional items are required to make the printer operational.

Unpack and Inspect the Printer

When you receive the printer, immediately unpack it and inspect for shipping damage.

• Save all packing materials.

• Check all exterior surfaces for damage.

• Open and close the printer and remove any media or test prints in the printer.

If you discover shipping damage upon inspection:

Introduction

Package Contents

3

• Immediately notify the shipping company and file a damage report. 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 all packaging material for shipping company inspection.

• Notify your authorized Zebra reseller.

Who Should Use This Document

This guide is intended for use by any person who needs to develop a kiosk using the
KR403 printer and operate, or troubleshoot the printer.

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Introduction

4

How This Document Is Organized

How This Document Is Organized

The manual is set up as follows:

Chapter Description

Introduction What is covered in this document, contact information
Design Overview Introduction to the KR203 Printer and packag e co nt en ts,

design considerations overview

Printer Overview Dimensions, orientation, and other features
Connections Power and communication connections
Media Loading, mounting, and feed angles
Accessories Available options to enhance the kiosk design
Troubleshooting Covers operational issues and resolutions for status

indicator codes and poor print quality

This manual will be updated from time to time as printer functions and features may be
added or amended. You will always find the latest edition on our website
(http://www.zebra.com). If you require information for functions not found in this manual
edition, please contact Technical Support for your region or the Zebra partner the printer
was purchased from.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Contacts

Technical Support

Technical Support is available via Internet 24 hours per day, 365 days per year

www.zebra.com. You can also email or call us using the following contact information.

The Americas - [e-mail]
Europe, Middle East, and Africa (EMEA) - [e-mail]
China - [e-mail]
Asian Pacific (except China) and India - [e-mail]

Zebra Technologies Corporation

Zebra Technologies Corporation
475 Half Day Road, Suite 500
Lincolnshire, IL 60069 USA
T: [phone]
Toll-free [phone]
F: [phone]

Introduction

Contacts

5

Zebra Technologies Europe Limited

Dukes Meadow
Millboard Road
Bourne End
Buckinghamshire, SL8 5XF, UK

T: [phone]
F: [phone]

Zebra Technologies Asia Pacific, LLC

120 Robinson Road
#06-01 Parakou Building
Singapore 068913
T: [phone]
F: [phone]

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Introduction

6

Document Conventions

Document Conventions

The following conventions and symbols are used throughout this document to convey
certain information:

Alternate Color – Cross-references contain links to other sections in this guide. If you are
viewing this guide online, click the blue text to jump to its location.

Caution • Advises you that failure to take or avoid a specific action could result in physical
harm to you.

Caution • Advises you that failure to take or avoid a specific action could result in physical
harm to the hardware.

Important • Advises you of information that is essential to complete a task.
Note • Indicates information that emphasizes or supplements important points of the main

text.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Design Overview

Design Considerations Overview

The kiosk designer needs to consider how the printer is being used, operated (media
supply and maintenance), serviced, integr a ted with othe r kiosk co mp one nt s, an d
integrated into the enclosure itself. The KR403 printer needs some basic design elements
to function properly, safely, and easily for the operator. The general issues are:

2

• The KR403 printer should always be installed in some kind of locking enclosure.
The customer or untrained personnel should not operate or service the printe r.

• Mounting orientation, use of the Loo pin g or Vertical Presenter modes, and media
waste bin considerations. See "Print Modes" on page 20.

• Simple mounting of the printer to the kiosk. See "Basic Printer Mounting (printer

only)" on page 17.

• The printer base plate must be mounted to a flat surface in the kiosk.

• Max. screw penetration 4mm (see "Basic Printer Mounting (printer only)"

on page 17).

• Printer power requirements – use of wired kiosk power (see "Attaching Po wer" on

page 34) or use of the 70 watt power supply accessory ("Printer Power Supply –
808099-004" on page 77).

• Media Handing Roll or fan-fold, roll mounting or fan-fold tray, and media and
printer mounting (design your own or use a KR403 printer mounting accessory ­see "Accessories" on page 61). Media location in the kiosk relative to the printer
(and its effects on maximum media roll diameter).

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Design Overview

8

Design Considerations Overview

• Operator access to the printer. The operator needs to view, service and maintain
the printer. The operator needs access to:

• The operator needs to be able to see the printer' s co ntro l panel for status
lights and also press the Feed button while observing the status lights for
media loading, setup and servicing the printer (see "Controls, Indicators,

and Sensors" on page 24).

• Open and clean the printhead or remove jams. Refer to the Service
Manual (P1026223).

• The media path between the printer and media (roll or fan-fold). A
minimum clearance of 250 mm on one or the other side of the printer,
printer controls, and media is needed.

• Service and printer replacement; access to mounting hardware.

• Designing for the operator; ideas for a more intuitive media loading,
media preparation and use of media loadi ng labe ls an d do cu m en ts .

• Cabling, power and electrical noise sources

• Ambient Lighting and external light sources

• Cooling

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Printer Overview

143

122

45

7.5

5

107

51

45.2

114

64.2

25

25

86

8.25

8

Basic Printer Dimensions

The illustration below outlines the basic printer mounting dimensions to install the printer
in a kiosk. These basic printer dimensions do not illustrate the unique integration
requirements needed to use the printer with specific printer accessories, operator
servicing access, media mounting, power and cabling access, and printer media handling.

3

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Figure 3-1 • Printer Dimensions

Printer Overview

REAR

Media IN

FRONT

Media Out

LEFT

RIGHT

10

Printer Orientation

Printer Orientation

Figure 3-2 • Printer Orientation

Table 3-1 • Printer Orientation

Output Horizontal Mount Output Vertical Mount

Media Exit and Present

Media Retract and Retain

(in kiosk)

Media Retract and Retain

(in kiosk)

Media Exit and Present

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Printer Features

Printer Overview

Printer Features

11

Figure 3-3 • Printer Features

Table 3-2 • Printer Features

Printhead Retractor
Platen (drive) Roller Control Panel (right)
Cutter Retract Sensor
Presenter Media Sensors

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Printer Overview

Figure 3-4 • Printer Features (Serial/USB)

Figure 3-5 • Printer Features (USB/Ethernet)

12

Printer Features

Printer Features (continued)

Table 3-3 • Printer Features

Serial Connection Power Connection
USB Connection Paper Low Sensor Connection
Ethernet Connection Control Panel (left)

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Printer Features (continued)

Figure 3-6 • Printer Features (Serial/USB)

Printer Overview

Printer Features

13

Waste Sensor

Table 3-4 • Printer Features

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Printer Overview

14

Printer Features

Opening the Printer

When cleaning or servicing the printer, it is sometimes necessary to access the printhead.

1. Press the green printhead release bar to unlock the printhead.

2. Rotate the printhead assembly upward.

Figure 3-7 • Opening the Printhead

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General Printing Information

Printer control • Printer Control Panel – Allows very basic printer

configuration setup that include: configuration status
(label) receipt, non-default print widths, print darkness
(density)

• ZPL (Zebra Programming Language), a page (receipt)

description language.
The printer also supports the Zebra SGD (Set Get Do)
printer configuration language that uses a natural
language.

• Windows Driver and Zebra Setup Utility

• Zebra Designer – A receipt (label) design and print

application for Zebra printers. Designer include support
for graphics and logos, barcodes, text, downloading fonts.
etc.

• ZBI 2.0 (Zebra Basic Interpreter) – ZBI allows the

software integrator to create custom commands and
functions, and emulate other programming languages.

Print method Direct thermal page printing using thermal sensitive media

Printer Overview

General Printing Information

15

Resolution 8 dots/mm (203 dpi)
Print speed 150 mm/s (5.9 inches/sec.) – Default

Present speed 300 mm/s in kiosk mode the uses the Looping or Vertical

Print duty cycle Up to 33%
Media Sensors Out of paper, paper in presenter, paper in retract path, black

Maximum print width 80 mm = 640 pixels

Auto Selected Print Widths

58 and 60mm guide 58 mm = 464 pixels maximum
80 and 82.5mm guide 80 mm = 640 pixels maximum

127 mm/sec.(5 inches/sec. )

101.6 mm/sec. (4 inches/sec.)

76.2 mm/sec. (3 inches/sec.)
Note: Printer media is rated for specific speed ranges and
some media types and materials will print better at slower
speeds

Presenter modes.
Non kiosk modes presenter speed matches the print speed.

mark, and an optional external paper-lo w sen so r.

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Printer Overview

16

General Printing Information

KR403 Media Types

Receipt Media Supply Type Outside Wound Continuous Roll: Plain receipt,

receipt with black marks, and pre-printed receipt
media with black marks.
Fanfold: Stacked receipt media with black marks and
pre-printed receipt media with black marks.

Outer Roll diameter 250 mm (9.84 inches) maximum

Note: The maximum roll diameter is dependent upon
roll holder in use and the kiosk design.

Spindle (core) diameter 25 mm minimum (typical core size)

40 mm maximum

12 mm minimum with Small Core Media Roll Adapter
Paper width 58, 60, 80, and 82.5 mm (common receipt roll widths)
Paper Thickness or Caliper 0.054 – 0.11 mm
Paper Density or Grammage 55 –110 g/m

Note - This is an approximate area density

measurement that varies by country, paper type and

measurement method applied.

2

(or gsm)

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Basic Printer Mounting (printer only)

The printer can only be mounted to the kiosk using the four printer mounting screw holes
shown in the illustration below. The printer is most secure when using all four of the
mounting positions connecting the printer’s base to a rigid metal base plate in the kiosk.
The kiosk’s metal printer mounting plate should be connected to the kiosks electrical
(earth) ground for purposes of controlling static discharge and electrical noise.

Printer Overview

Basic Printer Mounting (printer only)

17

Figure 3-8 • Printer Mounting

Table 3-5 • Mounting Configuration

Mounting Positions Kiosk’s Print Base Mounting Variation Details

• Minimum mount positions

and

Full coverage of printer’s
base plate

• Supports the Quick-Fit Hubs

• Supported by most Zebra

accessory mounting solutions
and
and and

Partial (and Full) coverage
of the printer’s base plate

• Minimum three point mounting

to fight torsional forces.

For information on ordering accessories, refer to "Contacts" on page 5.

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Printer Overview

X

YZ

18

Basic Printer Mounting (printer only)

X + Y = minimum length
X + Y + Z = maximum length

Figure 3-9 • Printer Mounting

Table 3-6 • M3 Metric Mounting Screw Length

M3 Screw

X 1.5mm minimum Printer mounting surface
Y 1.5mm Printer base plate thickness
Z 2mm maximum Penetration into circuit board area

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Design Your Own Mounting

20 mm

Paper width

+ 10 mm

44 mm

10 mm



12 mm



6.5 mm

10 mm

90.8 mm

132 mm

156 mm

Leaf spring
01473-000



11 mm

10 mm

1.

5

m

m

Add material for corner radius

Min. 100 mm

Center

10 mm

The illustration below gives an example of a printer-mounting shelf.

Printer Overview

Design Y our Own Mounting

19

Additional space is required for paper loading and ser vice access. Co nsider moun tin g the
printer on a movable platform so that the printer can be maintained outside the printer

Figure 3-10 • Printer Mounting

enclosure.
Note • We recommend making the output slot 97 mm wide. This width should

accommodate all paper widths that the KR403 printers can handle.

Caution • NEVER use screws that go into the printer more than 4 mm! This will damage
the electronics inside.

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Printer Overview

20

Print Modes

Print Modes

The KR403 is a versatile printer and can print in several modes: Kiosk (the default
horizontal with looping presenter or configurable vertica l p rese nter mo de), r ewind (receip t
only with no cut or kiosk mode features supported), and cutter (simple mode to support
label media, many kiosk features are supported, except looping, retract and partial cut)
modes.

In Kiosk mode, the printer stores the printed receipt in the loop area (horizontal mounting)
or hanging below the printer (vertical mounting) while finishing printing and cutting the
receipt. The printer then presents the receipt to the kiosk client . Whe n the c lient pu lls the
receipt, the printer immediately detects the roller movement and causes the printer to
accelerate the receipt out of the printer. This helps prevent damage to the receipt. The
kiosk mode also has programable options to retract the forgotten receipt back into the
kiosk’s internal waste bin below the printer.

Figure 3-11 • Printing Sequence

Table 3-7 • Printing Sequence

Media Input - Use Auto or Manual
media loading procedures

Loop area (horizontal mode) - stores
printed receipt is complete.

Media Present and Retract Roller ­Roller pivots on change of direction.
Detects a media pull with motor.

Media Present Exit (horizontal mode)
Printed Media Storage and Retract to
Waste Bin (vertical mode)

Retract to Waste Bin Exit (horizontal mode) Media Present Exit (vertical mode)

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Printhead and Platen (Drive) Roller
Media Drive Roller and Loop Stop

(forward only)
Media Cutter - Full or partial media

cuts at receipt page or cut immediate.
Internal Media Drive Roll - Ejects the

media out of the printer when
retracting (horizontal mode). Ejects
the paper when pulled (vertical mode).

Cut

Print

Media

In

Loop

Present

Retract

Waste Bin

Area

Print

Cut

Looping Presenter (Kiosk Mode)

The loop generating presenter mechanism has many benefits:

It handles documents of various lengths by
storing the printed paper in a loop.

It holds the printout until fully printed and cut
before presenting the completed printout to the
customer. This eliminates issues many other
printers have when the kiosk client tries to
remove media before printing has finished.

Printer Overview

Looping Presenter (Kiosk Mode)

21

A portion of the printout is presented . When the
customer takes the receipt, the printer detects a
movement and issues the rest of the receipt at
300 mm/s to help ensure receipt is removed
undamaged. The amount of media presented
can be customized to account for differences in
the kiosk wall.

The retract-and-retain function can retract
uncollected printouts and throw them in a
wastebasket inside the kiosk. Retracts are
reported to the driver so any remaining data for
that printout can be deleted. Retraction can be
initiated by an internal timer or issued directly
by the application.

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Printer Overview

Cut

Print

Store

Present

Orient

Retract

Media In

Waste Bin

Area

22

Vertical Presenter (Kiosk Mode)

Vertical Presenter (Kiosk Mode)

The vertical presenter operation has many benefits:

It handles documents of various lengths by
storing the printed paper below the printer.

It holds the printout until fully printed and cut
before presenting the completed printout to the
kiosk client. This eliminates print issues caused
by kiosk clients trying to remove media before
printing has finished.

It stores the entire receipt to re-orient the
printout to face up for presentation to your
client.

A portion of the printout is presented . When the
customer takes the receipt, the printer detects a
movement and issues the rest of the receipt at
a speedy 300 mm/s to help ensure receipt is
removed undamaged. The amount of media
presented can be customized to account for
differences in the kiosk wall.

The retract-and-retain function can retract
uncollected printouts and throw them in a
wastebasket inside the kiosk. Retraction can be
initiated by an internal timer or issued directly
by the application.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Receipt (Page) Imaging Modes

The printer sets the following modes with programming commands or with the Windows
driver.

The KR403 printer uses ZPL ‘Page’ mode programming to assemble and print receipts.
Page mode printing describes the receipt margins and the image to be placed between
the margins and then printed. The image is assembled in the image (memory) buffer and
then printed as one continuous print.

Printer Overview

Receipt (Page) Imaging Modes

23

Continuous

(Kiosk Mode)

Continuous - Variable

(Default - Kiosk Mode)

Black Mark or Line

(Kiosk Mode)

Cut Only

(Cutter Mode)

Basic Printing

(Rewind mode)

Table 3-8 •

Prints the image buffer and cuts the media at the end of the
image defined by Label Length parameter.

If the image is larger that the preset image buffer size, then
the printer expands the image buffer to accommodate the
larger image up to the printer’s maximum allowed size (set by
programming, available memory, and print with). The printer
then prints the larger image with print margin and cut the
receipt. The next receipt will return to the preset image/receipt
size if the next image is the same size or smaller.

Prints receipts that match the receipt length set by the
distance between the black marks or lines, and cuts the
receipt at the black mark or line by default.

Can be used for printing labels, but it is not recommended for
receipt use.

Typica lly used for printing liner backed labels that use black
marks or black lines media to identify label ‘gap’ boundaries.
Requires additional programming to ensure that only the
media liner is cut. Cutting labels and their adhesive backing
will eventually jam the cutter and require a service technician
to correct.
Prints the image and cuts the receipt. Does not use the kiosk
mode ‘Looping’ or ‘Vertical’ presenter functions.
Cut mode does not support the ‘Retract’ media function.
Does not do ‘partial’ cut in Cutter Mode.

Not Recommended for kiosk use.
Rewind Mode has a deceptive name, it could be described as
Rewind Disabled as it relates to other Zebra tabletop printers
that share the ZPL programming language. Rewind Mode
does not allow cutting the media (including Cut Now
commands), the kiosk mode ‘Looping’ or ‘Vertical’ presenter
operations, retract or eject command options.

Receipt Imaging Modes

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Printer Overview

24

Controls, Indicators, and Sensors

Controls, Indicators, and Sensors

The KR403 printer has integrated controls, indicators, and sensors to enhance the
usability of the printer for the client’s kiosk experience, the kiosk operator’s service and
maintenance duties, and expand the developer’s ability to provide printing and service
information to the host kiosk system. The controls, indicators and sensors include:

• Media ‘Feed’ button with configuration and diagnostic functionality.

• Media detection and control sensors.

• Printhead temperature, sensor operation failure, and printhead testing.

• Cutter operation sensing and jam detection.

• Media output pull detection sensing.

• Support for an external low media (roll) detection sensor accessory option.

• Virtual sensing and report of printer operations to the host to simplify reporting and
kiosk integration and design process.

• Programming configurable maintenance and service warnings for printhead cleaning,
printhead life, printer life, and count of media retracted back into the kiosk. These
features are off by default and must be set by Set/Get/Do (SGD) or ZPL programming.

The printer has redundant printer control and indicator panels on each side of the printer
to provide the integrator greater flexibility for designing printer mounting for servicing the
printer.

Feed Button Control

The Feed button has several functions:

• Press and Release will feed media, cut, and present a
complete receipt page in the default kiosk mode. All the other
integrator set modes and variations of the kiosk mode will at
minimum, feed a page length of media when the Feed button is
pressed and released.

• Any data in the print buffer will be printed.
If the buffer is empty the page will be blank.
In black-mark mode, the page will be synchronized with the black-mark.

• Press and Hold with the Printer ON will cause the printer to enter the user interface
mode, a set of manual setup and configuration operations used by the integrator.
Refer to Table 7-2, “Application User Interface,” on page 89.

Power Indicator

The Power Indicator is green when the printer has the 24 VDC power applied to the
printer.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Status Indicator

Immediately after power is applied to the printer, a brief self test is performed and the
status light will report the status of the printer.

Status conditions are reset and rechecked when:

• The conditions causing them are removed.

• The printer has power removed and reapplied.

• The printhead is opened or closed.

Refer to Table 7-1, “Application LED States,” on page 87 for condition descriptions.

Sensing, Status and Error Reporting

The KR403 has sensing and error reporting capability available to the printer for internal
process control, status reporting to the host and custom printer software development by
the software integrator. Many of these features and functions are supported directly by the
Windows Driver and Zebra Designer via the driver.

Printer Overview

Sensing, Status and Error Reporting

25

• The printer monitors the printhead, motors, cutter and a variety of internal main board
functions.

• The KR403 printer has virtual sensors and error flags’ that use combinations of
sensors and status flags to create additional error reporting flags to simplify the
software integrators task of monitoring the printer.

• The KR403 printer also has an odometer for mainten ance alerts for printhead clea ning
and printhead low life warning (printhead will need replacement soon). This feature is
off by default.

• The KR403 printer also does power-up printhead testing, printhead critical fault testing
for safety and has a programming accessible printhead pixel test that reports the
functionality of individual pixels. This feature is off by default.

The following tables and illustration shows an excerpt from ZPL programmers manual of
the error tables for the ^HQ status report. Please see the ZPL programmers guide for
more details and related commands.

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Printer Overview

26

Sensing, Status and Error Reporting

Table 3-9 • Error Flags (~HQES)

Group 2

(X = Value can be any hexadecimal number [0-9, A-F])

Error Flags Flag

Nibble8

Nibbles16-9

No Error
Error Present
Printhead Thermistor

Open
Invalid Firmware Config.

Printhead Detection Error
Bad Printhead Element
Motor Over Temperature
Printhead Over

Temperature
Cutter Fault

Head Open
Ribbon Out
Media Out
Clear Paper Path Failed
Paper Feed Error
Presenter Not Running
Paper Jam during

Retract
Black Mark not Found

Black Mark Calibrate
Error

Retract Function timed
out

Paused

b

a

a

a

a

a

a. This error flag is supported only on KR403 printers.
b. This error is not supported by the KR403 printer.

00000000000000000
100000000XXXXXXXX

100000000XXXXX2XX
100000000XXXXX1XX

100000000XXXXXX8X
100000000XXXXXX4X
100000000XXXXXX2X

100000000XXXXXX1X
100000000XXXXXXX8

100000000XXXXXXX4
100000000XXXXXXX2
100000000XXXXXXX1

a

1a00000000XXXX8aXXX
1a00000000XXXX4aXXX

a

1a00000000XXXX2aXXX
1a00000000XXXX1aXXX

a

1a00000000 X X X 8
1a00000000 X X X 4

1a00000000 X X X 2
1a00000000 X X X 1

Nibble7

Nibble6

Group 1

Nibble5

a

a

a

a

Nibble4

Nibble3

Nibble2

Nibble1

XXXX
XXXX

XXXX
XXXX

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Table 3-10 • Warning Flags (~HQES)

Printer Overview

Sensing, Status and Error Reporting

27

Group 2

(X = Value can be any hexadecimal number [0-9, A-F])

Warning Flags Flag

Nibble8

Nibbles16-9

No Warning
Warning Present
Paper-near-end Sensor
Replace Printhead
Clean Printhead
Need to Calibrate Media
Sensor 1 (Paper before

c

head)
Sensor 2 (Black mark)

Sensor 3 (Paper after

c

head)
Sensor 4 (loop ready)

Sensor 5 (presenter)
Sensor 6 (retract ready)
Sensor 7 (in retract)
Sensor 8 (at bin)

c. This error flag is supported only on KR403 printers.

c

c

c

00000000000000000
100000000XXXXXXXX

c

1c00000000XXXXXXX8

100000000XXXXXXX4
100000000XXXXXXX2
100000000XXXXXXX1

1c00000000XXXXXX1cX

c

1c00000000XXXXXX2cX
1c00000000XXXXXX4cX

c

1c00000000XXXXXX8cX
1c00000000XXXXX1cXX

c

1c00000000XXXXX2cXX
1c00000000XXXXX4cXX
1c00000000XXXXX8cXX

Nibble7

Nibble6

Group 1

Nibble5

Nibble4

Nibble3

Nibble2

Nibble1

c

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Printer Overview

28

Feed Button Modes

Feed Button Modes

Ambient Light

There is an optical sensor 20 mm behind the paper exit at the front of the printer. Other
sensors can also be affected by internal lights (and bright outside light sources entering
through seams, vents, etc.) in the kiosk. To ensure proper printer operation, design the
printer enclosure so that it prevents direct sunlight or light from indoor lamps from reaching
the sensor through the paper exit.

See the "Shutter Bezel – 104591" on page 65 for an accessory option that has been used
to shield the media output sensor from external light sources.

Cooling

The printer needs space on both sides of the printer to allow for convection cooling of the
printer. This become more important with kiosk installing that have extreme environments
and high printer use.

Manual Printer Reset

The KR403 printer does not have a power switch or reset button. To manually reset the
printer, disconnect the power from the printer. Wait a few seconds for the Power LED to
turn off and reconnect the power plug. The printer will take around a 25 seconds to reboot
and initialize.

The printer can also be reset with the ZPL ~JR command when sent by the kiosk
application. This is equivalent to cycling the printer power for the printer’s internal
programming.

Printer Configuration Methods and Tools

The KR403 printer has many printer configuration methods for the software and hardwar e
integrator. Each is designed to assist you with various kiosk design and integration tasks.
These integration tasks include printer startup, proof of concept, receipt design, status
reporting, multi-printer configuration, and kiosk application design. The configuratio n
methods from hardware to programming application include:

• Media Guides – Sets the printer’s maximum print width. See "Media Guide - Required

Accessory" on page 50 and "Installing the Media Guide" on page 50.

• Control Panel – The printer’s control panel when using the Feed Button modes,
provides the access or settings to automated media calibration routines, print
darkness, print width (on receipt), autom ated serial port setup, and resetting the
printer to factory defaults. See the "Feed Button Modes" on page 28 and the "Printing

a Test Receipt" on page 59 for a view of one printer’s printer configuration status label.

• Windows Zebra Setup Utility and Windows Drivers – Quickly allows the developer to
use the printer, test configuration options, send programming commands or files, and
print directly from Windows applications.

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Printer Overview

Fonts and Your Printer

• Zebra Designer – A receipt and label design program that works with the Windows
printer driver to help you quickly develop receipt layouts, and manage fonts and
objects (graphics, logos and receipt forms) during proof of concept process.

• ZPL, SGD (Set-Get-Do), and ZBI (Zebra Basic Interpreter) Programming Languages
– The ZPL printer programming printer page description language allows the
application developer to configure and control all aspects of your printer with ASCII
based text programming. The SGD object based programming language is used to
set and check printer configuration status and configuration. These three
programming languages should be used in separate command lines or files when
sending commands to your printer. The ZPL Programming Guide for the KR403
printer covers all three languages in a single manual at this time. See the KR403
Software Integrator’s Guide for assistance in quickly developing and integrating the
printer.

• ZebraLink (File and) Firmware Downloader – This tool is used to initialize ZBI
programming capability and download files to the printer. ZBI allows the software
developer to emulate other programming and create custom commands. Can be used
in a printer configuration workstation to send configuration files, firmware updates, and
files (programming, graphics, logos and receipt forms). Use the full featur ed ZebraNet
Bridge instead for everything but ZBI activation

29

• ZebraNet Bridge – Zebra Net Bridge is a printer maintenance tool for use with local
and network based printers. The KR403 printer can only be managed as a locally
connected printer (the KR403 printer does not have a Ethernet printer option). This
Windows application is the ideal tool to use as a workstation for configuring your
printer prior to installing it into a kiosk. Use it to duplicate configurations, send
configuration files, firmware updates, and files (programming, graphics, logos and
receipt forms). At the time of release, the KR403 Windows driver or the Setup Utility
can not be loaded in the PC when using ZebraNet Bridge. It is scheduled for an
update to remove the conflict with the driver and local printer management in 2010.

Fonts and Your Printer

The KR403 printer supports your language and font require ments with a variety of internal
fonts, on-board font scaling, international font sets and character code page support,
Unicode support, and font download.

The KR403 printer’s font capabilities are programming language dependent. The ZPL
programming language provides advanced font mapping and scaling technology to
support outline fonts (TrueType™ or OpenType™) and Unicode character mapping as
well as basic bitmapped fonts and character code pages. The ZPL programming guide
describes and documents fonts, code pages, character access, listing fonts, and
limitations of ZPL. See the printer programmi ng guides for information on Text, Fonts and
Character support.

The KR403 printer includes utilities and application software that support font download
into the printer for both printer program ming lang ua g es .

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Printer Overview

30

Fonts and Your Printer

Identifying Fonts in Your Printer

Fonts and memory are shared by the programming languag es in the prin ter. Fonts can be
loaded in many memory areas in the KR403 printer. ZPL programming can recognize EPL
and ZPL fonts. See the respective programmer guides for more information on fonts and
printer memory.

• To manage and download fonts for ZPL print operation, use ZebraNet Bridge.

• To display all of the fonts loaded in your KR403 printer, send the printer the ZPL
command ^WD. See the ZPL Programmers Guide for details.

• Bitmap fonts in the various printer memory areas are identified by the.FNT file
extension in ZPL.

• Scalable fonts are identified with the.TTF,.TTE or.OTF file extensions in ZPL.

• The six fonts LMu.FNT through LMz.FNT are EPL Line Mode fonts and are not
available for use.

Localizing the Printer with Code Pages

The KR403 printer supports localization with common international character map code
pages.

• For ZPL code page support, including Unicode, see the ^CI command in the ZPL
programmer’s guide.

Asian fonts and Other Large Font Sets

Asian language pictographic fonts have larg e character sets with thousands of characters
that support single language code page. In order to support the large Asian ch aracter sets,
the industry adopted a double-byte (67840 maximum) character system instead of the
single-byte characters (256 maximum) used by Latin based language characters to
address large font sets. In order to address multiple languages with a single font set,
Unicode was invented. A Unicode font supports one or more code points (relate these to
code page character maps) and is accessed in a standard method that resolves character
mapping conflicts. ZPL supports Unicode and has support for the large pictographic
double-byte character Asian font sets.

Asian language support requires additional memory support by the KR403 printer
configured with the Full Flash Memory factory option. The number of fonts that can be
downloaded is dependent upon the amount of available flash memory not already in use
and the size of the font to be downloaded.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Getting Asian Fonts

Asian font sets are downloaded into the printer by the user or integrator. The fonts are
purchased separately from the printer.

• Simplified and Traditional Chinese

• Japanese – JIS and Shift-JIS mappings

• Korean

•Thai

Stand Alone Printing

Your KR403 printer can be configured to work without being attached to a computer. The
printer has the ability to automatically run a single receipt form. One or more downloaded
receipt forms can be accessed and run with a terminal or wedge device to call a receipt.
These methods allow the developer to incorporate data input devices, such as scanners
or weight scales, to the printer via the serial port.

Printer Overview

Fonts and Your Printer

31

Receipt formats can be developed and stored in the printer to support receipts that have:

• One or more data variables to be entered via the terminal or wedge device. The
receipt will print after the last variable data field has been input.

• One or more receipts formats that are called by scanning bar codes containing
programming to run a receipt form.

• Receipt forms designed to work as a process chain with each receipt including a bar
code containing the programming t o run the ne x t re ce ip t in th e pr oc ess sequence.

The printer supports a special receipt form that will automatically run after a power cycle or
reset. The ZPL looks for a file named AUTOEXEC.ZPL. The files must be deleted from
the printer followed by a reset or a power cycle to completely remove the file.

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Printer Overview

32

Fonts and Your Printer

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Cabling and Cable Routing

Always tie cable down, use locking connectors where possible, allow for kiosk component
servicing, and avoid electrical noise sources.

4

Connections

• Tie all cables to the kiosk chassis or printer mou nting hardware that are near the
printer, th e media path or media. The operator can accidentally disconnect the printer
or other kiosk components when maintaining the kiosk. Cabling must not in terfere with
the proper operation of the printer and media. The operator can become caught on
cabling and drop heavy media damaging the kiosk or hurting themselves.

• Service Loops – There should be enough slack in the cabling to not put pressure on
the cable connectors or the circuit boards. Also enough slack is needed to disconn ect
the printer (or their kiosk components) for servicing. Allow for movement needed to
access the cable locks or slide the printer out when using the Quick-fit hubs.

• Avoid electrical noise sources: fluorescent lighting and balla st, powe r su pplies, fans,
AC power lines, CRT monitors, etc.

• Avoid twisting power and communication cables together. This can cause spurious
noise on the communication port or raise emissions levels.

Large Media Roll Adapter Accessory

The large media roll adapter accessory adds an additional 10 cm to the front of the printer.
It is therefore necessary to route cables differently when using this accessory. See

"Routing Cables with the Large Media Roll Adapter" on page 85 for additional information.

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Connections

34

Attaching Power

Attaching Power

CAUTION • Never operate the printer and power supply in an area where they can get
wet. Serious personal injury could result!

The KR403 printer has unique power requirements to op erate efficiently, safely and within
safety and compliance regulation guidelines. To achieve optimum performance, an
approved power supply should be used to operate the KR403 printer. Refer to "Printer

Power Supply – 808099-004" on page 77.

If a non-Zebra supplied power supply is used with the KR403, it must comply with the
following requirements.

Table 4-11 • Power Supply Output Characteristics

Output Rating 24.0 Volts. 2.92 Amps and 2.5 Amps, +5° to +40° C
Voltage 24.0 Vdc +5/-2% Initial Tolerance, No Load)
Current 2.92A and 2.5AMaximum

Output Requirement When Printing (worst case conditions)
Max Output Power 24.0 Vdc x 2.92A = 70 Watts typical
Peak Power (90VA Cin, 47Hz) 243W

Output Regulation
Line Regulation ±0.5% over AC input operation range.
Ripple & Noise 240mVpp at lout = 2.92 Amps, Resistive Load (4.7µF/50V

ceramic Cap. On output, 20MHz BW)
Transient Load Response < 5mS Recovery, 40% to 80% Load Change
Overshoot, Power-Ip 10% Max at power-on or power-off
Holdup Time 20ms Minimum, Rated DC Load, 120VAC/60Hz
Over-Voltage Output Limited to +28V max.
Fuse Yes
Thermal Allowed, Not Required
Remark:

When short circuit protection or over-current protection is activated, the power supply will shutdown
automatically. Once the condition resulting in the failure is cleared, the power supply will restart.

Automatic Recovery:
Over-voltage protection is activated, the power supply will shutdown. The power supply is fully protected

against short circuits and automatically recovers upon removal of the short without the need for re-cycling
the AC input voltage.

Note • The printer does not have an integrated power switch.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

DC Power Plug Requirement

+24 VDC

Ground

The KR403 printer uses a locking two pin connector. The mating connector is Tyco part
number 1445022-2. The wiring for this connector and to meet the power requirements
should be 20 AWG insulated wiring (UL type 1007).

Figure 4 • Power Plug

Connections

Attaching Power

35

Electrostatic Discharges and Earth Currents

The printer should have a dedicated earth ground connection. Preventing ESD and earth
currents from affecting the printer operation requires proper connection to the printer
chassis via a 12 AWG wire to protective earth.

The ground wire should be connected to the printer as follows:

1. Using a #8 Torx driver, remove the screw shown.

2. Attach the 12 AWG ground wire with cable lug to the printer chassis.

3. Connect the other end of the ground wire to a protective earth ground.

Figure 5 • Grounding

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Connections

36

Connecting the Printer to the Host

Connecting the Printer to the Host

The KR403 printer has a Universal Serial Bus (USB), an RS232 Serial port interface, and
an Ethernet interface.

CAUTION • Keep the kiosk OFF when attaching the interface cable. The power cord
must be inserted into the power supply and the power receptacle on the back o f the printer
before connecting or disconnecting the communications cables.

CAUTION • This printer complies with FCC “Rules and Regulations,” Part 15, for Class
B Equipment, using fully shielded data cables. Use of un-shielded cables may incr ease
radiated emissions above the Class B limits.

Interface Cable Requirements

Data cables must be of fully shielded construction and fitted with metal or metallized
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 foot [1.83 m] recommended).

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

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

• Avoid fluorescent lighting and power supply components.

USB Interface Requirements

Universal Serial Bus (version 2.0 compliant) provides a fast interface that is compatible
with your existing PC hardware. USBs “plug and play” design makes installation easy.
Multiple printers can share a single USB port/hub.

Additionally, the USB cable should include a ferrite located at the end of the cable closest
to the host computer. This is to prevent any electrical noise generated by the printer from
affecting the host computer.

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Connections

Pin 1

Connecting the Printer to the Host

Refer to Figure 6. On the USB / Ethernet configuration , the USB connection is to the
left of the ethernet connection. On the USB / Serial configuration , the USB connection
is to the right of the serial connection.

37

Figure 6 • USB Connection

When using a USB cable (not supplied with your printer), verify that the cable or cable
packaging bears the “Certified USB™” mark to guarantee USB 2.0 compliance.

The figure below displays the cable wiring required to use the printer’s USB interface.

Pin Signal

1 Vbus - N/C
2D­3D+
4 Not connected
5Ground

Shell Shield / Drain Wire

For printer supported operating systems and to download the latest driver, visit the Zebra
printer web site at: (http://www.zebra.com).

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Connections

38

Connecting the Printer to the Host

Serial Communications

Refer to Figure 7. 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 p ort located on the
back of the printer . 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 (cross-over) cable.

Figure 7 • Serial Connection

The serial port communication settings between the printer and host (typically a PC) must
match for reliable communication. The Bits per second (data or Bau d ra te ) an d Flo w
control are the most common settings that get changed. The host (typically a Windows
PC) needs to have the data rate and data Flow control changed to match the printer’s
default communication method:

• Bits per second – 115K is the printer’s default Baud Rate (Bits per second). The
printer and host can not communicate unless these match.

• Flow control – Software and is noted by the printer’s Host Handshake setting of
Xon/Xoff. The printer may communicate if these do not match, but it may not be
reliable.

• Data bits: 8 – Default (Windows and printer)

• Parity: None – Default (Windows and printer)

• Stop bits: Doesn’t care

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Connections

Connecting the Printer to the Host

Serial communications between the printer and the host computer can be set by:

• Autobaud synchronization

• ZPL programming ^SC command

• Resetting the printer to its default printer configuration.

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 the ^XA^XZ command sequence to the printer.

3. When the printer and host are synchronized, the LED changes to solid green. (No

receipts will print during Autobaud synchronization.)

39

ZPL ^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 Software Integrator Guide (P1026208) for more information about this
command.

Resetting the Default Serial Port Parameters

Do the following to reset the communications parameters on the printer to the factory
defaults (serial communication settings are: 115k baud, 8 bit word length, NO parity, 1
stop bit, and XON/XOFF data flow control).

1. Press and hold the feed button until the green status LED flashes once, waits a

moment and flashes twice, and then waits again before flashing three times (release
immediately).

2. While the status LED rapidly flashes amber and green, press the feed button.

Serial communications between the printer and the host computer can be set by the
ZPL ^SC command.

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Connections

40

Connecting the Printer to the Host

Ethernet Interface

Refer to Figure 8. The USB/Ethernet KR403 includes an RJ45 Ethernet connection
resident on the main logic board . It is compatible with CAT5, CAT5e, and CAT6 cables.
Cables are not supplied with the printer, the integrator should supply an 802.3 compliant
cable.

Figure 8 • Ethernet Connection

Communicating with the Printer

The easiest way to begin using your complete kiosk printing solution is to utilize the Zebra
Designer Windows Driver in PC based systems. With the driver loaded; you can test the
kiosk printing system, configure your printer, send programming commands, use Windows
applications to print directly to the printer, and download files (fonts, graphics, logos,
update firmware, etc.). The Zebra Designer driver works directly with the free suite of
Zebra application software to design and create receipts (Zebra Designer) and manage
one or more printers locally. All are available on the Zebra Web site at www.zebra.com

Use the Zebra Setup Utility to load the driver and configure your printer. If the operating
system automatically starts a ‘Add new hardware’ wizard, then close the wizard and
continue installing the driver.

USB Printer Detection and Windows® operating systems

Windows XP, Windows Vista, Windows 7, Windows Server 2003, and Windows Server
2008 operating systems support the USB port communications with this printer when
using the Zebra Setup Utility or the ZD (Zebra Designer) Windows Driver.

.

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These operating systems automatically detect the printer when connected via the USB
interface. The operating system automatically starts a “Add new hardware’ wizard when
connecting the printer for the first time to the PC. Close the wizard. Install the printer
following the wizard. The latest driver is found at www.zebra.com
then media size (closest match). Click on the ‘Print test page’ button to verify a successful
installation.

The Windows operating system will detect and re-link a previously installed printer if it is
reconnected to the USB interface or power is turned on after the PC has finished its restart
of the operating system. Ignore the new device detected warnings and close the Task bar
prompts. Wait several seconds for the operating system to match the printer to the driver
software. The warnings will quit and the printer now should be ready to begin printing.

Serial Port and Windows® operating systems

The Windows operating system default settings for the serial port communication closely
match the printer’s defaults settings with two exceptions; the data Baud Rate and Flow
Control settings. The Windows default data Baud Rate (Bits per second) setting is 9600.
The KR403 printer requires data Baud Rate set to 115k. The Windows default data Flow

Control setting is NONE. The KR403 printer requires data Flow Control set to Software.

Connections

Connecting the Printer to the Host

. Select the USB and

41

Note • The KR403 printer does not support Windows Serial Port Plug and Play (PnP)
device detection at this time.

Ethernet Port and Windows® operating systems

Windows XP, Windows Vista, Windows 7, Windows Server 2003, and Windows Server
2008 operating systems support the ethernet port communications with this printer when
using the Zebra Setup Utility or the ZD (Zebra Designer) Windows Driver.

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Connections

42

Connecting the Printer to the Host

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Media

Designing Your Own Media Dispensing System

Properly dispensing the media to the printer is critical to the operation of the printer and
quality print. The media, roll or fan-fold, needs to flow smooth and free with minimal drag
or binding. Ideally it should have a clean and cool location for dispensing and storing
media. Loading or dispensing media to the printer should not have interference or access
restrictions with the kiosk enclosure or internal components.

5

• The media entering the printer should be aligned to the center of the printer.

• The printer and roll media should be level to prevent dr ag on th e side of the ro ll and
damage to the receipt edges. This can cause ja ms a nd pr inter stalls in th e worst case
conditions.

• The media should never touch or rest on cabling, kiosk walls and components,
exhaust fans (dust and heat), heat sinks, etc.

• The media should be easy to reach and see inside the kiosk. Do not force the operator
to bend or extend their arms too far into the kiosk to load media or service the printer.

• Optional Media Storage — Media stored in the kiosk should have a dark cool area
separate from the rest of the kiosk enclosure that can be closed off from the heat of
the kiosk components, moisture, and cleaning chemical vapors used near the kiosk.

Designing a Roll Support

The design elements needed for a good media roll suppor t are:

• Simple design with no loose parts that can get misplaced, installed incorrectly, or
require special techniques that can, when done incorrectly or carelessly, have the
operator drop the media in the kiosk.

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Media

44

Designing Your Own Media Dispensing System

• Minimal drag. Do not use wires, cables or bars as a roll hold er - all of the se cause the
roll to stop and start and rock back and forth. Narrow radius roll supports case these
behaviors to a lesser extent. Some media vendors use roll cores made of fiberboard
that can have seams. The KR403 Roll Support accessory minimizes the media
contact area (only makes contact with the outside edges) and a large enough radius to
smooth over seams (see "Roll Support – P1014124" on page 68). The larger the roll
(more mass), the greater the effect it has on drag.

• Leave plenty of access room to load media when designing the area for your roll
support. Leave additional clearance for the roll swinging on the support and hands
that hold the media to load it.

Designing Media Guides

The media guides need to have a minimum radius of 10 mm. The surface should be
smooth and not touch the edges of the media (causes drag or edge damage). The media
should only touch radius surface and not the edge of the radius for all roll sizes that may
be used (full or nearly empty). See the "Wall Mount Roll Holder – P1014123" on page 76
and the "Universal Roll Holder – P1014125" on page 71 side views to illustrate roll size
and contact with a media guide.

Designing for Fan-Fold Media

Fan-fold media creates unique challenges. It has square edges that can get caught and
the stack can fall into other components and cabling.

Make a tray to hold the fan-fold media unless it is being pulled straight up. Always test and
observe with the actual media. Fan-fold media can un-fold erra tica lly and act differently at
the beginning and end of the stack.

Design a tray a little higher than the height of a full stack of media. Fan-fold media tray
should keep the media stacked and never allow the media to be pulled into the kiosk.

When using a media guide, the guide should ideally be twice the distance of the length of
the media stack away from the media guide and aligned to the center of the stack. This
allows the media to completely unfold and minimizes the chances of having it bind in other
components or printing multiple receipt or tickets.

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Basic Media Mounting Considerations

The KR403 printer has a few basic requirements for dispensing the media to the printer
from a roll or fan-fold media. The KR403 printer exclusively uses dir ect thermal media and
it is chemically treated to react to heat. Some of these basic considerations include:

• Align Printer with Media – The center line of the media roll or fan-fold stack should
align with the center of the printer to provide the best image quality and keep the
media un-damaged. Always use a media guide when printing!

• Media Only Contacts Media Mounting and Printer in Kiosk – Th e media should not
touch cables, other kiosk components, or surfaces other than media guid es or the fan­fold media tray.

• Do Not Blow Air on Media – Air should be pulled out of the media area of the ki osk to
keep dust (shortens printhead life and affects print quality), aerosol bourn chemicals
(such as cleaning solutions like ammonia) and exhaust heat from other kiosk
components and power supplies.

• Direct Sunlight, Incandescent or Infrared Lighting or Heat Sources – These light
sources can come from kiosk vents and other kiosk components. Incandescent light
bulbs and heat sinks are examples of heat sources that shouldn’t be near the printer,
media or media storage areas.

Media

Basic Media Mounting Considerations

45

• Media Dispensing Must Be Smooth and Easy – Roll media must be able to turn
with little or no drag, and allow the printer to smoothly pull media without jerking and
stopping. Larger, heavier media rolls are more susceptible to these issues. Minimize
roll to roll holder contact and avoid sharp cont act surfaces. Fan-fo ld media must have
sufficient room to unfold and not bind on media guid e surfaces or at the perforations or
sides. The printer can get distorted print (e.g. compressed print, short receipts, etc.),
motor stalls, and jamming if media dispensing to the printer is not smooth and easy for
the printer.

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Media

Top of Printer

(Any Orientation)

Printing
Surface

Printing

Surface

25°

59°

Side Panel Cut Away

Media In

Minimum Clearance Area for

Printer Power and Cabling

46

Basic Media Mounting Considerations

Media Supply Method

The KR403 printer supports two basic media supply method types: outside wound roll
mount and stacked fan-fold receipt media. The media printing surface faces up towards
the ‘top’ of the printer and away from the body of the printer.

Media Input Aperture

The KR403 printer has a wide aperture to support a wide range of media mounting
locations. The media can enter the printer directly or indirectly with the addition of custom
media guides or printer roll or mounting accessory kits.

Figure 5-1 • Media Supply

Figure 5-2 • Media Input Aperture

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Basic Media Mounting Considerations

Minimum Clearance Area for

Printer Power and Cabling

This area should have a continuous physical barrier separating the med ia and

folds from binding in the cabling, printer body, kiosk chassis seams, etc.

The direct media input (or angle of contact with media guides - not shown here) will
change as the media is being consumed.

Media

47

Figure 5-3 • Media Aperture

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Media

VerticalHorizontal

Horizontal

Vertical

48

Basic Media Mounting Considerations

Mounting Orientations

The printer has two basic kiosk operation modes and orientations: Horizontal and Ve rtical.

Figure 5-4 • Mounting Orientations

The maximum angle that the printer can operate from the nominal vertical or horizontal
orientations is dependent upon environmental conditions and the media in use.

• Environmental conditions that can affect operation include : humidity (and
temperature), circulating air in the kiosk, static buildup on adjacent kiosk components
and surfaces, etc.

• Media considerations can include: length of receipt, partial cut of receipt in receipt
design, media curving at the end of the media roll, media thickness and weight,
perforations on fan-fold or receipt media, etc.

• Other considerations that affect your printer mounting are also in this section include:
media mounting, media path, media access, printer maintenance, cabling, etc.

Acceptable Verify Operation Unacceptable

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Media

Figure 5-5 • Small Core Media Adapter

Horizontal

Vertical

Basic Media Mounting Considerations

The areas of primary concern are the horizontal operation’s ‘loop area’ and ‘waste bin’ ,
and vertical operations ‘receipt presented storage’, ‘waste bin’ and open ‘loop area’ (with
no loop). These two areas can require special attention when designin g the inside of the
kiosk. The printer needs the space to store the printed receipt before presenting it to the
customer. The long er the receipt, th e greater the area need ed. When mounting the printer
at angles other than the nominal vertical or horizontal orientations, simulated receipt
printing operations should be observed with ideally the chosen media for use in the kiosk
and in the environmental conditions that it will operate on-site.

The KR403 mounting becomes even more versatile if the Small Roll Media Roll Adapter
accessory is used to guide the leading edge of receipt into the input of the media drive
rollers. This allows the printer to be mounted in a wider range of mounting orientations
shown below

49

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Media

50

Media Guide - Required Accessory

Media Guide - Required Accessory

For the printer to operate correctly, at minimum you must order and install at least one of
the four (4) media guides listed below.

Width (mm) Part Number Width (mm) Part Number

58 09170-058-3 80 09170-080-3

Figure 5-6 • Media Guide

60 09170-060-3 82.5 09170-082-3

A printer evaluation kit is available for the KR403 printer that includes all four media
guides.

Installing the Media Guide

A calibration routine is required after inst alling the appropriate media guide. See "Media

Guide Calibration" on page 51 for details.

Caution • Before proceeding, always disconnect the printer from power. If the printer is
installed in the kiosk, then all kiosk power should be turned off. This is to prevent
accidentally having the screw or media guide bracket fall into the printer or other powered
up kiosk components. The screw or bracket may fall and bounce into kiosk components
mounted adjacent to or mounted below the printer.

1. Select the media guide that matches the width of the me d ia yo u wan t to use fo r you r

application. Loosen or remove the media guide screw, if present.

Note • Media guides are ordered separately. Only the KR403 Demo Kit (P1021954)
contains all input guides available for the KR403.

2. Open the printhead by pushing green printhead release push-bar back towards the

rear of the printer and lift up the printhead.

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Media

Media Guide - Required Accessory

3. Insert the media guide under the printhead. Insert the T -shaped tab of the media guide

into the “T”-hole, slide it forward, and fasten the screw. The screw is pre-installed at
the factory on the printer. One is included in the bag with the media guide in case the
screw is damaged or lost. Many times, the installer will only need to loosen the
attached screw.

4. Close the printhead. Push down on the push-bar to securely latch the printhead

closed.

51

5. Re attach the printer’s power if needed.

Media Guide Calibration

When the media guide is changed, the printer will signal media present even when none is.
You must instruct the printer to detect the sensor it should use again. This is accomplished with
the two flash function (see Table 7-2, Application User Interface on page 89).

This process must be done without media in the printer. If the process is attempted with media
in the printer an error will occur. Upon successful detection of the guide, guide settings are
stored.

Figure 5-7 • Media Guide Installation

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Media

52

Media Guide - Required Accessory

Determining Thermal Media Types

The KR403 printer uses direct thermal media. Direct thermal media has a chemically
treated print surface that uses heat to expose or darken the area where heat is applied.
Thermal transfer media or ordinary un-treated paper requires ribbon or ink for printing
while direct thermal media does not. To determine what type of media is being used and
print surface of the media, perform a media scratch test:

1. Scratch the print surface of the media with a finger nail or pen cap. Press firmly and

2. Did a black mark appear on the media?

quickly while dragging it across the media surface. Direct thermal media is chemically
treated to print (expose) when heat is applied. This test method uses friction heat to
expose the media.

If a black mark... Then the media is...

Does not appear on the media Thermal transfer. A ribbon or ink is required and

is not support for use by the KR403.

Appears on the outside of the
media.

The KR403 printer only uses outside wound roll media or fan-fold media. The print surface
faces away from the center of the printer. Media with black marks

Direct thermal. No ribbon or ink are required.

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Black Mark Media Requirements

Cut Line

No Print Zone

Feed

Direction

Feed

Direction

58 and 60mm

Media Width

80 and 82.5mm

Media Width

Example shown from printed side. Black marks shown are

on opposite side.

The printer is optimized to detect black marks printed with IR sensitive ink and ignore pre­print in IR blind ink.

For 80 and 82.5mm media, the black marks will be centered 30mm to the right of the
paper center when viewing the imaged side of the receipt and print direction is downwar d;
for 58 and 60mm media, the black marks will be centered 22mm to the left of the paper
when viewing the imaged side of the receipt and the print direction is downward.

The printer will support media with black mark thickness in printing direction of 2.5 –

9.0mm, and a width of 5.0 – 10.0mm when the blac k ma rk is cen te re d on the sen so r.
In the figure below, th e “No Print Zone” is the ar ea on the ba ckside of the me dia where no

marks (other than the black marks for sensing) should be printed.
For media that has both perforations and black marks, perforations should be positioned

in the middle of the black mark. By default, the printer will cut the media in the middle of
the black mark.

Media

Black Mark Media Requirements

53

Dimension 58 and 60mm Width 80 and 82.5 Width

22 mm 30mm

2.5mm – 9.0mm 2.5mm – 9.0mm

5.0mm – 10.0mm 5.0mm – 10.0mm

92mm – 600mm 92mm – 600mm

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Media

Temperature-sensitive
coating

SW96074C

1

SW96075C

2

Glue or similar
substance

54

Preparing a Media Roll for Use

Preparing a Media Roll for Use

1. Orient the roll as shown below.

2. Tear off a full turn of paper from the new roll.

Figure 5-8 • Paper Roll Orientation

Caution • This is important since the outer end of the paper is usually fixed to the roll with
some type of glue or self-adhesive substance that might otherwise cause paper jam or
even print head damage.

Figure 5-9 • Full Turn Paper Removal

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Media

Auto Loads

Wide Media
Auto Loads

Narrow Media

Auto Loads

Auto Loads

Fails Auto Load

Media Contact

Leads

Media Sensing

Preparing a Media Roll for Use

3. The loading process works best with the cut as a square, straig ht edge. Cut the paper

in a suitable angle.
If the media is not cut square and the operator does not have the ability to cut or tear

a straight edge, then the printer can fail to lo ad the me dia or even cause a media jam.
The media should not make contact with the platen roller before the sensor detects
the media. The distance between the platen roller and media sensor is approximately
10 mm (0.39 inches).

55

Figure 5-10 • Suitable Paper Edge for Auto Load

Important • The wide media sensor (88 and 82.5 mm) and printer's power connector are
both located on the right side of the printer when looking into the printer from the rear. The
media sensor for narrow media (58 and 60 mm) is located on the left side when looking
into the media input slot from the rear of the printer.

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Media

Media Feeds
to Presenter

Insert Media

Media Presented

Remove presented

media to print or

feed media

Cut Media

56

Automated Media Loading

Automated Media Loading

The printer is designed to detect media when it is inserted into the empty media input slot
at the front of the printer. The printer begins turning the platen (drive) roller when the
leading edge of the media passes over the media sensor.

1. Insert the paper through the paper entry opening at the front of the printer.

The printer will now feed, cut and eject a blank receipt or a printout of the last print job
in the print buffer, and then automatically go to a Ready state (solid green status
indicator).

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Figure 5-11 • Automated Media Loading

Manual Media Loading

Manual media loading is intended for maintenance ope rations, such as printh ead cleaning
and removing media jams. Please use the Auto Load procedure (page 56) to load media
for normal operations.

1. Open the printhead.

2. Insert the media through the front of the pr inter and under the op en printhead. Pull the

media just past the cutter and platen (drive) roller.

3. Close the printhead. Push down on the push-bar to securely latch the printhead

closed.

4. Press the Feed button once to get the printer out of Pause mode (double blinking

green status indicator. The printer will feed 70 mm of media and cut the media.
Discard the receipt scrap.

Pressing the Feed once more will reprint that image to the proper paper size.

Media

Manual Media Loading

57

Figure 5-12 • Manual Media Loading

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Media

58

Clearing Paper Jams

Clearing Paper Jams

Should a paper jam occur, follow the procedure below:

1. Cut or tear the media off the front of the printer.

2. Open the printhead.

3. Remove and discard the damaged media.

4. Close the printhead and reload the media using the Auto Load media loading method

(page 56).

Figure 5-13 • Clearing Paper Jams

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Printing a Test Receipt

Figure 5-14 • Test Receipt

Before you connect the printer to your computer, make sure that the printer is in
proper working order.

You can do this by printing a test (printer
configuration) receipt.

1. Make sure the media is properly loaded and

Ready with the printhead closed. Then, turn the
printer power on if you have not already done
so. If the printer initializes with the status light
blinking green (pause mode), press the Feed
button once to set the printer in Ready (to print)
mode.

2. Press the Feed button to print, present and

removal of receipts two to three times to allow
the printer to calibrate the printer for the
installed media. The printer may feed several
extra receipts during this process if media
calibration needs to be adjusted (this is an
automatic printer feature).

Media

Printing a Test Receipt

59

3. When the status light is solid green, press and

hold the Feed button until the status light flashes
once.

4. Release the Feed button. A printer configuration

receipt will print (example shown).

The configuration status receipt will print as two or
more receipts if the receipt size is not large enough
to contain all of the status information as shown
above.

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Media

60

Printing a Test Receipt

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Accessories Overview

The KR403 printer has a wide range of accessories designed and tested to work with your
printer. The accessories can be used by themselves, combined with other printer
accessories, or as part of your own unique printer integration design. At the time of this
guides release, the following accessories are available for your printer:

6

Accessories

• Nozzle Bezel – A translucent media exit bezel styled after common credit card
input bezels used in ATM (Asynchronous Transfer Mode) machines and other
kiosks.

• Shutter Bezel – The shutter bezel is a light weight door designed to prevent the
kiosk user from easily inserting foreign objects into the printer, dust, or block
external light sources from interfering with the printer’s ability to detect when is
media exiting the printer.

• Small Core Media Roll Adapter – Designed to guide the leading edge of receipt
into the input of the media present rollers. Allows the use of media roll inside
diameters less than 25 mm (typically POS media) and increases the operational
range of printer in a given mounting orientation (see "Mounting Orientations" on

page 48).

• Quick-Fit Printer Mounting – A quick printer release mounting system that can be
used with KR403 mounting accessories or with your own d esign. Th e service tech
can pull the leaf spring (latch) to unlock the printer and quickly slide it out for easy
replacement or service. the parts can be ordered separately as:

• Quick-Fit Hubs – Flanged hubs and printer mounting screws

• Leaf Spring Retainer – Spring and two M3 x 3 mm screws

• Roll Support – A rugged media roll support bracket designed to provide minimal
friction and self centering of the media roll.

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Accessories

62

Accessories Overview

• Media Roll Low Sensor – Optical sensor designed to mount into the Roll Support
accessory or other KR403 printer mounting accessory and plug directly into the
rear of the printer.

• Universal Roll Holder – This versatile mounting accessory supports three roll
positions with the ability to mount it on either side of the printer.

• Printer Mounting Plate (for roll holder mounted below printer) – This mounting
plate assembly is designed to work with the Universal Roll Holder accessory when
the roll is in the Low and Under holder positions. It includes a inertia dampening
spring roller to optimize printer performance when using the large 250 mm
diameter rolls.

• Wall Mount Roll Holder – The wall mount supports a maximum media roll
diameter of 150 mm. The wall mounting bracke t attaches at the front of the printe r
flush to the kiosk wall.

• Printer Power Supply (70 watts) – This printer accessory has been optimized for
use with thermal printers and in particular your KR403 printer. It has been
designed and tested to meet or exceed most international safety and compliance
standards. Please check for more detailed safety and compliance information for
the printer and this power supply at the Zebra Web site: www.zebra.com.

• USB Cable – This accessory has been thoroughly tested for use with the 2824
Plus printer.

• Large Media Roll Adapter and Mounting Plate – Designed for use with the printer
when using large (200mm) media rolls to prevent excessive pulling force by the
feed motor.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Nozzle Bezel – P1011185

The nozzle bezel is used not only as a decorative accessory, but also serves to prevent
customers from unknowingly inserting payment cards into the printer; which could cause
damage to the printer and the customer’s payment card.

The nozzle bezel is installed on the front of the printer (at the media exit) using two 2.5mm
hex screws.

The nozzle bezel kit comes with screws and 10 bezels per kit.

Accessories

Nozzle Bezel – P101 1185

63

Media Exit
Horizontal Mounting

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Media Exit
Vertical Mounting

Accessories

64

Nozzle Bezel – P1011185

Nozzle Bezel Mounting Dimensions

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Shutter Bezel – 104591

Supports vertical mounting orientations only.

Accessories

Shutter Bezel – 104591

65

Shutter Mounting Dimensions

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Accessories

66

Small Core Media Adapter – G105156

Small Core Media Adapter – G105156

The KR403 mounting becomes even more versatile if the Small Roll Media Roll Adapter
accessory is used to guide the leading edge of receipt into the input of the media drive
rollers. This allows the printer to be mounted in a wider range of mounting orientations
shown below.

The small core media roll adapter accessory is used to prevent the page curl that occurs
at the end of a tightly wound media roll. It is used to keep the media in position to feed into
the presenter.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Quick-Fit Hubs – 103939

The quick-fit hubs are designed to use the printer’s mounting holes when mounted on
a sheet metal surface 1.5 mm thick. See the "Design Your Own Mou nting" on page 19 for
more details.

Accessories

Quick-Fit Hubs – 103939

67

Quick Fit Leaf Spring Retainer – 01473-000

The leaf spring retainer is designed to be used as a locking mechanism when using the
quick-fit hubs on a custom mounting surface.

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Accessories

C

C

3

Roll Core ID

20

Roll Core ID

Media Widths
58 & 60

Media Widths
80 & 82.5

(used for Media Low Sensor mounting)

Wide Media

(80 or 82.5 mm)

Narrow Media

(58 or 60 mm)

All Media

Wide

Narrow

68

Roll Support – P1014124

Roll Support – P1014124

The roll support bracket and mounting are designed (and tested) to mount to a sheet
metal wall 1.5 mm thick for media rolls up to 250 mm O.D. (Outer Diameter) with media
roll cores of 25.4 mm I.D. (Inner Diameter). The wider approved media roll widt hs (8 0 a nd

82.5 mm) align to the vertical centerline of the roll support bracket. The diagrams below
show the how the narrower approved media roll widths are offset lower by 3.2 mm. To
install a roll of media in the printer , the roll must clear the lip. The media roll needs to move
up nearly 4 mm above the centerline of the roll support bracket for loading.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Media Roll Low Sensor

The media roll low sensor is available in two lengths:

• 01890-300 – KIT PAPER-LOW SENSOR 300MM CBL

• 01890-500 – KIT PAPER-LOW SENSOR 500MM CBL

The sensor alerts the system when a fixed level of media is remaining on the roll.

The media roll low sensor operates by reflecting a light against the white side of a media
roll to detect it. When the media is low, no light is reflected. After three successive media

low conditions are noted by the printer, a media low flag is set. Installing a new roll of
media will reset the flag.

Note • Black marks or dirt on the side of the media roll may signal false media low
conditions.

Accessories

Media Roll Low Sensor

69

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Accessories

External

Media Low

Sensor

Port

Mounts on top of

the Roll Support

as show here

Sensor Cable

70

Media Roll Low Sensor

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Universal Roll Holder – P1014125

Mounts on
either side

Æ200 mm Roll

and ‘Low’ Roll

Support

Position Shown

High and Low - 150 mm max.roll

Under 200 mm max.roll

Arm Positions

High and Low - 200 mm max.roll

Under - 250 mm max.roll

Arm Positions

This roll holder can be fitted on the right or left side of the printer. The arm can be set at
three different angles. This makes make integration in the kiosk easy.

• 58 mm, 60 mm, 80 mm, and 82.5 mm media widths can be used withou t
adjustments.

• The universal roll holder supports up to Ø200 m m rolls in th e ‘high’ and ‘low’ arm
positions, and Ø250 mm rolls in the ‘under’ position with clearance for cabling.

• No other accessories are required for the ‘high’ arm position, while the Print er
Mounting Plate with the inertia dampening sprin g guid e an d ca ble s hield is
needed in the two other positions.

• The optional media roll low sensor can be added to the roll support.

Accessories

Universal Roll Holder – P1014125

71

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Accessories

‘High’ Position (No Mounting Plate)

‘Low’ Position with Mounting Plate

Mounting Plate

Minimum Printhead Access Clearance

Minimum Printhead Access Clearance

72

Universal Roll Holder – P1014125

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

‘Under’ Position with Mounting Plate

Mounting Plate

Minimum Printhead Access Clearance

Accessories

Universal Roll Holder – P1014125

73

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Accessories

‘High’ Position (No Mounting Plate)

‘Low’ Position with Mounting Plate

‘Under’ Position with Mounting Plate

For illustration purposes:
— ‘High’ position - media is not shown
— ‘High’ position - both roll supports are shown

Mounting Plate

74

Universal Roll Holder – P1014125

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Printer Mounting Plate – 104208

The Printer Mounting Plate preforms several functions:

• Provides a solid printer mounting base.

• Designed to work with the Universal Roll Holder accessory for the ‘Low’ and
‘Under’ the printer mounting positions.

• This plate or an equivalent custom design is required to protect the cables and
media from interfering with each other and the operator when the media roll is
mounted under the printer.

• Includes a inertia dampening spring roller to optimize printer performance when
using the large 250 mm diameter media rolls.

Accessories

Printer Mounting Plate – 104208

75

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Accessories

Roll center

Leaf Spring

Hub Lock

Media Roll

Support

76

Wall Mount Roll Holder – P1014123

Wall Mount Roll Holder – P1014123

The Wall Mount Roll Holder attaches at the front face of the printer to the kiosk wall. It is
designed to handle 150 mm diameter media rolls.

58 mm, 60 mm, 80 mm, and 82.5 mm media widths can be used without adjustments.
Include the Quick-Fit printer release and mounting system. The service tech can pull the

leaf spring (latch) to unlock the printer and quickly slide it out for easy replacement or
service.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Printer Power Supply – 808099-004

The DC power filter and cable

length is a minimum of 174 mm

EMI Power Filter

Power ON LED

The KR403 power Supply accessory can easily be incorporated into a kiosk design. The
power supply is easily attached to the kiosk with tie wraps.

The power supply has been tested to work with the KR403 printer and complies wi th all of
the same safety and compliance regulations.

See "Attaching Power" on page 34 for a simple power connection illustration.

• Output voltage: 24 VDC

• 70 Watts, 90-264 VAC at 47-63 Hz

• Peak Power 330 Watts

• Input Current: 1.5 Amp max.

• Inrush Current: 40 Amp max.115 VAC or 80 Amp max.230 VAC

Accessories

Printer Power Supply – 808099-004

77

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Accessories

Printer Power

Connector

Plug Varies
by Country

Active Power Light

Printer

Optional Power Supply

Accessory

IEC 60320 C-13 Plug (70W)

AC

Power

Cord

78

Printer Power Supply – 808099-004

Attaching the Power Supply

1. Make sure the printer’s power supply is turned off. Or if you are using the optional

2. Insert the 24 VDC power supply’ s power connector into the printer’s power receptacle.

3. Insert the AC power cord into the power supply. Plug the other end of the cord into an

4. With the power supply on and connected to the printer, the printer’s power status

power supply accessory shown in the illustration below, make sure the power supply’s
AC power cord is unplugged. Note the printer does not have an integrated power
switch.

Verify the power plug’ s latch has locked to the co nnector b y giving it a slo w gentle pull.

appropriate AC electrical outlet. The active power light will go on if power is on at the
AC outlet.

indicator will light up green. The printer will begin the printer initialization process
which takes approximately 25 seconds. The printer will test the cutter and check for
the presence media. The status indicator will be green if media is loaded and flashing
red (single blink) if media is not loaded.

Figure 6-15 • Attaching Power

Note • Ensure the appropriate power cord with a three (3) prong plug and an IEC 60320­C13 connector are used at all times. These power cords must bear the relevant
certification mark of the country in which the prod uc t is bein g us ed .

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Universal Serial Bus (USB) Cable – P1027715

Universal Serial Bus (USB) Cable – P1027715

The KR403 power USB Cable accessory can easily be incorporated into a kiosk design.
The cable easily be attached to the kiosk with tie wraps.

The USB cable has been tested to work with the KR403 printer and complies with all
safety and compliance regulations.

Accessories

79

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Accessories

80

Large Media Roll Adapter – P1026858

Large Media Roll Adapter – P1026858

The large media roll adapter is used to prevent excessive pulling force on the printer feed
motor when large roll (250mm (10 inch)) media is used. In some cases, when a large
media roll is used, the feed motor may stall when slack has built up between the roll and
the printer.

Note • Make sure you have installed the correct media guide for the width of media
selected before installing the adapter.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Attaching to the Printer

1. Place the adapter on the printer at an angle as shown.

Accessories

Large Media Roll Adapter – P1026858

81

2. Rotate the adapter upwards as shown and install the screws (1).

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Accessories

82

Large Media Roll Adapter – P1026858

Loading Media

1. Open the adapter tensioner assembly by pushing the locking tab .

2. Insert the media through the adapter and into the printer. For narrow media, the printer

will load automatically. For wide media, manual media loading may be required (see

"Manual Media Loading" on page 57).

3. Close and lock the adapter tensioner assembly.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Mounting Plate for Large Media Roll Adapter – P1027728

Mounting Plate for Large Media Roll Adapter –
P1027728

When the large media roll adapter is used with the printer, the standard mounting plate
cannot be used.

Attaching to the Printer

Attach the plate to the printer and the adapter using the screws as shown.

Accessories

83

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Accessories

84

Using other Accessories with the Large Media Roll Adapter

Using other Accessories with the Large Media Roll
Adapter

Universal Roll Holder

The universal roll holder (page 71) can be attached to either side of the large media roll
adapter. Additionally, the media roll low sensor (page 69) can still be used in this
configuration (see "Routing Cables with the Large Media Roll Adapter" on page 85).

1. Attach the mounting block to the large media roll adapter as shown using the two

screws .

2. Attach the universal roll holder to the mounting block with the screw .

Note • Printer not shown attached for clarity.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Routing Cables with the Large Media Roll Adapter

Routing Cables with the Large Media Roll Adapter

Media Roll Low Sensor

When the universal roll holder is attached to the large medial roll adapter, the 500mm
media roll low sensor should be used (see "Media Roll Low Sensor" on page 69).

Left Side Routing

1. Plug the media roll low sensor into the printer.

2. Secure the wiring to the tie-down point on the large media roll adapter using a plastic

cable tie .

Accessories

85

3. Route the wiring under and to the outside of the universal roll holder and secure it

using plastic cable ties .

4. Attach the sensor to the roll support using the screw.

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Accessories

86

Routing Cables with the Large Media Roll Adapter

Right Side Routing

1. Plug the media roll low sensor into the printer.

2. Secure the wiring to the tie-down points on the large media roll adapter using plastic

cable ties as shown.

3. Route the wiring under and to the outside of the universal roll holder and secure it

using plastic cable ties.

4. Attach the sensor to the roll support using the screw.

Power Cable

Because of the ferrite attached to the power cable accessory, it is necessary to route it so
that it does not interfere with the function of the large media roll adapter.

When using a power source other than the power supply accessory, routing the wiring is
done along the left side of the large media roll adapter using a plastic cable tie at the tie­down point.

Serial, USB, and Ethernet Cables

Data cables are routed along the right side of the large media roll adapter. Secure the
cables to the tie-down point on the large media roll adapter using plastic cable ties.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Troubleshooting

Status Light Descriptions

Application LED States

7

Immediately after power is applied to the printer, a brief self test is performed and the
status light will report the following conditions:

Table 7-1 • Application LED States

This code is reported when no other

Solid Green 0 - OK

One Red Flash

Two Red Flashes 2 - Cutter Jam

1 - Paper Jam in
Presenter

codes are active. It indicates the
printer is functioning normally.

This code indicates that media is stuck
in the presenter . This error is set when
the printer attempts to eject the media
but cannot complete the operation.
This error is cleared by removing the
media from the presenter sensor.

This code indicates that the printer
could not find the cutter blade or could
not properly manage its position. The
error is set when the printer attempts
to cut but fails after three retries. This
error is cleared by cycling the power
off and on.

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Troubleshooting

88

Status Light Descriptions

Table 7-1 • Application LED States

Three Red Flashes 3 - Out of Paper

Four Red Flashes 4 - Print Head Lifted

Five Red Flashes 5 - Paper Feed Error

This code indicates that the selected
EOP sensor has detected no media
present. This value is signaled wither
when the mark engine has detected a
mark larger than "TOF marker length”
plus 5mm, or when the A/D reading of
the EOP sensor drops below the “End
of paper threshold”. This error is
cleared after successful media load
(either via calibration of via regular
media load).

This code indicates that the print head
has been lifted. This error is cleared
by returning the print head to its
locked position.

This code indicates that the paper
failed to reach the presenter sensor
within the expected amount of time.
The error is signaled if the media does
not reach the presenter sensor after
feeding the length from the cuter to the
sensor plus 15mm. This error is
cleared by opening and closing the
print head, or by cycling power off and
on.

Yellow Flashing

Rapid Amber
Flashing

6 - Head T e mperature
Error

Firmware missing or
corrupt

This code indicates that the print head
has exceeded the maximum permitted
temperature. This status code is set
when the print head temperature
exceeds 65° C (149° F). When this
condition occurs, the printer feeds
100mm (4 inches) of blank media,
cuts, and presents. This error is
cleared automatically when the print
head temperature falls below 55° C
(131° F).

This code indicates that the bootware
has detected an incorrect or missing
checksum in the firmware. This error is
cleared when the firmware is reloaded
or updated. Refer to the Software
Integrator Guide for firmware upload
procedure.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Application User Interface

With the printer power on, press and hold the feed button. Continue holding the feed
button until the status indicator flash sequence occurs. The next flash sequence occurs
after completion of the previous flash sequence. The flash sequences perform the
following functions:

Table 7-2 • Application User Interface

Troubleshooting

Status Light Descriptions

89

Status Flash

Sequence

One Flash, then Solid
Green

Two Flash, then So lid
Green

Three Flash, then
Solid Green

Four Flash, then Solid
Green

Five Flash, then Solid
Green

If the feed button remains pressed after the five flash sequence, the status light goes of f.

Printer status is also reported during normal operation when an error occurs, or a status
request can be sent to the printer via the Windows dr iver. Refer to the Software integrator
Guide for error codes reported by the Windows driver.

Appears for one second. This will print an internal self-test
page.

Appears for one second. Performs system calibration – must
be started with paper out of presenter and from under
printhead, and with no error signaled.

Appears for one second. Performs a simulated USB cable
connect and reconnect causing a USB plug-and-play event to
occur.

Appears for one second. Sets all printer settings to the default
with the exception of media guide calibration, then it will
perform the media guide calibration.

Appears for one second. Prints a 50% gray pattern, ejects it
and then prints a diagonal line pattern and ejects it.

Action

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Troubleshooting

90

Print Quality Problems

Print Quality Problems

No print on the label.

• The media may not be direct thermal media, or the thermal media coating is not facing
upward. "Determining Thermal Media Types" on page 52.

• Is the media loaded correctly? Is the thermal media coating facing upward?

"Determining Thermal Media Type s" on page 52.

• The printhead may be dirty or damaged.

• The printhead is dirty. Clean the printhead. Refer to the Service Manual
(P1026223) for instructions.

• The printhead is damaged. Replace the printhead. Refer to the Service Manual
(P1026223) for instructions.

• The printhead wiring may be damaged or not connected properly.

• Check the wiring connections at the printhead and the main logic board. Refer to
the Service Manual (P1026223) for instructions.

• Check for damage to the wiring. Replace the wiring if damaged. Refer to the
Service Manual (P1026223) for instructions.

The printed image does not look right.

• The printhead is dirty. Clean the printhead. Refer to the Service Manual (P1026223)
for instructions.

• The printhead has worn out. The printhead is a consumable item and will wear out
due to friction between the media and printhead. Using unapproved media may
shorten life or damage your printhead. Replace the printhead. Refer to the Service
Manual (P1026223) for instructions.

• Adjust the print darkness and/or print speed. Refer to the Software Integrator Guide
(P1026208) for instructions.

• The Windows printer driver or application software may change these settings
and may require a change to optimize print quality.

• The media being used is incompatible with the printer. Be sure to use the
recommended media for your application, and always use Zebra-approved media.

• The platen (driver) roller maybe losing traction due to:

• Foreign objects attached to its surface.

• The rubbery smooth surface has become polished and slippery.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

Troubleshooting

Media Sensing Problems

• The platen may need cleaning or replacement. Refer to the Service Manual
(P1026223) for instructions.

There are long tracks of missing print (blank vertical lines) on

several labels.

• The printhead may be dirty or damaged.

• The printhead is dirty. Clean the printhead. Refer to the Service Manual
(P1026223) for instructions.

• The printhead is damaged. Replace the printhead. Refer to the Service Manual
(P1026223) for instructions.

• The printhead has worn out. The printhead is a consumable item and will wear out
due to friction between the media and printhead. Using unapproved media may
shorten life or damage your printhead. Replace the printhead. Refer to the Service
Manual (P1026223) for instructions.

The printing does not start at the top of the receipt or misprinting of

one to three receipts.

91

• The printer needs to be calibrated (refer to the two-flash sequence of Table 7-2

“Application User Interface” on page 89).

• Reload the media. "Automated Media Loading" on page 56 or "Manual Media

Loading" on page 57.

Media Sensing Problems

The KR403 printer default media mode is Continuous. The printer will remain in this mode
until it is changed by the Windows Driver.

The KR403 printer has automatic media calibration capability for black mark media. Once
the printer is printing or feeding media, the printer continually checks and adjusts the
media sensing to accommodate for minor changes in media parameters from page to
page on a roll, and from roll to roll of media. The printer will automatically initiate a media
length calibration if the expected media length or the page to page gap distance has
exceeded the acceptable variation range when starting a print job or feeding media.

If the printer does not detect blacklines (or notches with black mark sensing) afte r feedin g
the media the default maximum label length distance of 24 inches (610mm), then the
printer will report a media error.

Optionally, the printer can be set to do a short media calibration after loading media or
when closing the printhead with power on. The printer will then feed up to three labels
while calibrating.

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Troubleshooting

92

Media Sensing Problems

The printer will not load the media.

• The media has changed, or a different media guide has been installed.

• Make sure the appropriate me d i a gu ide is installed for the media being used.
Refer to "Media Guide - Required Accessory" on page 50.

• Perform the two-flash procedure to recalibrate the printer. Refer to "Application

User Interface" on page 89. Reload the media (refer to the Hardware Integrator

Guide for media loading procedures).

• Load the media manually. Refer to "Manual Media Loading" on page 57.

• The platen (driver) roller maybe losing traction due to:

• Foreign objects attached to its surface.

• The rubbery smooth surface has become polished and slippery.

• The platen may need cleaning or replacement. Refer to the Service Manual
(P1026223) for instructions.

• The media sensor may be dirty or damaged. Refer to th e Service Manu al (P1026223)
for instructions.

• The printhead assembly is not closed.

• Check the status light on either side of the printer . If the status light is showing four
red flashes then the printhead is not closed. Push down on the printhead
assembly until it locks into place.

• There is a jam under the printhead. Refer to the Service Manual (P1026223) for
instructions.

• The large media roll may be over torquing the feed motor. Install the large media roll
adapter. See "Large Media Roll Adapter – P1026858" on page 80.

The printer will not eject the media.

• The presenter rollers are dirty or damaged.

• The presenter rollers are dirty. Refer to the Service Manual (P1026223) for
instructions.

• The presenter rollers are damaged. Refer to the Service Manual (P1026223) for
instructions.

• There is a jam under the presenter. Refer to the Service Manual (P1026223) for
instructions.

• The presenter sensor may be dirty or damaged.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12

• The presenter sensor is dirty. Refer to the Service Manual (P1026223) for
instructions.

• The presenter sensor may be damaged and need to be replaced. Refer to the
Service Manual (P1026223) for instructions.

• The presenter has not cleared the previous receipt.

• Check the status light on either side of the printer. If the sta tus light is showing one
red flash then the printer is reporting media in the presenter. Remove any media
that may be in the presenter.

• The presenter motor may need to be replaced. Refer to the Service Manual
(P1026223) for instructions.

• The presenter drive gears may be damaged or worn. Refer to the Service Manual
(P1026223) for instructions.

Other Problems

Troubleshooting

Other Problems

93

The receipts are not cutting properly.

• The cutter blade may be worn. Replace the cutter blades. Refer to the Service Manual
(P1026223) for instructions.

• The cutter tensioner may be worn or damaged. Replace the cover plate assembly.
Refer to the Service Manual (P1026223) for instructions.

• Check the Cutter Mode setting, and the Partial Cut Width setting in the Windows
driver. Refer to the Software Integrator Guide (P1026208).

• The cutter motor may need to be replaced. Refer to the Service Manual (P1026223)
for instructions.

• The cutter drive gear, drive pin, or cutter actuator may be damaged or worn. Refer to
the Service Manual (P1026223) for instructions.

• Check for the latest firmware and driver version.

There are no lights on the printer.

• Make sure there is power applied to the printer.

• The control panel may be dirty or damaged. Refer to the Service Manual (P1026223)
for instructions.

• The main logic board may be damaged. Refer to the Service Manual (P1026223) for
instructions.

• Check for the latest firmware and driver version.

2016/4/12 KR403 Hardware Integrator Guide P1016701-001 Rev. C

Troubleshooting

94

Resetting the Factory Default Values

A receipt format was sent to, but not recognized by, the printer.

• If the status LED is on or flashing, refer to Table 7-1 “Application LED States” on

• Make sure the USB cable is correctly installed. Refer to "Connecting the Printer to the

• A communications problem has occurred. Perform a USB detect (refer to the three-

The receipts are not cutting at the black mark.

• Make sure you are using the appropriate media guide for the desired media width.

• Perform a media guide calibration. Refer to the four-flash sequence of "Application

page 87.

Host" on page 36.

flash sequence of Table 7-2 “Application User Interface” on page 89).

See "Media Guide - Required Acce ssory" on page 50.

User Interface" on page 89.

• Make sure you are using the appropriate media. See "Determining Thermal Media

Types" on page 5 2.

• Use the Windows driver to set the printer to black mark mode. Refer to the Software
Integrator Guide (P1026208) for instructions on setting black mark mode.

• Reload the media. Refer to "Automated Media Loading" on page 56.

Resetting the Factory Default Values

• Sometimes, resetting the printer to the factory defaults may solve some problems.
Refer to the two-flash sequence of Table 7-2 “Application User Interface” on page 89.

• Use the Windows driver to perform a printer reset. Refer to the Software Integrator
Guide (P1026208) for instructions.

Contact Technical Support

Technical Support via the Internet is available 24 hours per day, 365 days per year.

www.zebra.com

For questions on the operation of Zebra equipment and software, please call your
distributor. For additional assistance, contact us.

Please have your model and serial numbers available.
For contact information, refer to "Contacts" on page 5.

P1016701-001 Rev. C KR403 Hardware Integrator Guide 2016/4/12