Zebra S4M User Manual

S4M™

Industrial/Commercial Printer

User Guide

The copyrights in this manual and the label printer described therein are owned by Zebra Technologies Corporation. Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.

This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element

Energy Equalizer® Circuit; E

; and AGFA fonts. Software © ZIH Corp. All

rights reserved worldwide.

ZebraLink and all product names and numbers are trademarks, and Zebra, the Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit are registered trademarks of ZIH Corp. All rights reserved worldwide.

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

Part Number: 13290L-001 Rev. A

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The Americas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Europe, Africa, Middle East, and India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control Panel LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

New or Modified Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Contents

2 • Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unpack and Inspect the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Inspect the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Report Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Select a Site for the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Types of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Data Cable Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3 • Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Media Loading Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Print Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Starting a Roll of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Inserting Media into the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Load Media in Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Load Media in Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Remove the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Position the Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Select the Transmissive Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Adjust the Reflective Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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Contents

4 • Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Leave Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Password Protection of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Printing Configuration Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Select a Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Control Panel LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Password Level 1 and 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Password Level 3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Clean the Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Clean the Peel-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Troubleshooting Checklists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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

Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

FEED and PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

7 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

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Contents

A • ZPL II Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

13290L-001 Rev. A S4M User Guide 10/21/05

About This Document

This section provides you with contact information, document structure and organization, and additional reference documents.

Contents

Who Should Use This Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

The Americas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Europe, Africa, Middle East, and India. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10/21/05 S4M User Guide 13290L-001 Rev. A

About This Document

Who Should Use This Document

This User Guide is intended for use by any person who needs to operate or troubleshoot problems with the printer.

How This Document Is Organized

The User Guide is set up as follows:

Section Description

Introduction on page 7 This section shows the operational controls and

Printer Setup on page 15 This section provides the tasks that you must

location of major components used when loading media and ribbon. Other features of the printer are discussed.

complete and the issues that you must consider before you load and configure your printer.

Operations on page 29 This section provides the procedures for loading

and calibrating the printer.

Configuration on page 51 This section discusses printer configuration

settings and instructs you how to view or change printer parameters through the control panel.

Routine Maintenance on page 77 This section provides routine cleaning and

maintenance procedures.

Troubleshooting on page 85 This section provides information about errors that

you might need to troubleshoot. Assorted diagnostic tests are included.

Specifications on page 105 This section provides the features of and

specifications for the printer.

ZPL II Commands on page 111 This section provides the ZPL II commands that

were added or changed for the S4M.

13290L-001 Rev. A S4M User Guide 10/21/05

Contacts

Web Site

The Americas

About This Document

You can contact Zebra Technologies at the following.

http://www.zebra.com

Regional Headquarters Technical Support Customer Service Dept.

Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A T: +1 847 793 2600 Toll-free +1 800 423 0422 F: +1 847 913 8766

T: +1 847 913 2259 F: +1 847 913 2578

Hardware: hwtsamerica@zebra.com Software: swtsamerica@zebra.com

For printers, parts, media, and ribbon, please call your distributor, or contact us.

T: +1 866 230 9494 E: VHCustServ@zebra.com

Contacts

Europe, Africa, Middle East, and India

Regional Headquarters Technical Support Internal Sales Dept.

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

T: +44 (0)1494 472872 F: +44 (0) 1494 450103

T: +44 (0) 1494 768298 F: +44 (0) 1494 768210 Germany: Tsgermany@zebra.com France: Tsfrance@zebra.com Spain/Portugal: Tsspain@zebra.com All other areas: Tseurope@zebra.com

Asia Pacific

Regional Headquarters Technical Support Customer Service

Zebra Technologies Asia Pacific, LLC 16 New Industrial Road #05-03 Hudson TechnoCentre Singapore 536204

T: +65 6858 0722 F: +65 6885 0838

T: +65 6858 0722 F: +65 6885 0838 E: tsasiapacific@zebra.com

For printers, parts, media, and ribbon, please call your distributor, or contact us.

T: +44 (0) 1494 768316 F: +44 (0) 1494 768244 E: mseurope@zebra.com

For printers, parts, media, and ribbon, please call your distributor, or contact us.

T: +65 6858 0722 F: +65 6885 0837

10/21/05 S4M User Guide 13290L-001 Rev. A

About This Document

Document Conventions

The following conventions are used throughout this document to convey certain information.

Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location.

LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in

Bubbledot ICG font.

Command Line Examples Command line examples appear in Courier New font. For example, type

Files and Directories File names and directories appear in Courier New font. For example, the

Icons Used

ZTools to get to the Post-Install scripts in the bin directory.

Zebra<version number>.tar file and the /root directory.

Caution • Warns you of the potential for electrostatic discharge.

Caution • Warns you of a potential electric shock situation.

Caution • Warns you of a situation where excessive heat could cause a burn.

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

harm to you.

Caution • (No icon) 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 neutral or positive information that emphasizes or supplements important

points of the main text.

Example • Provides an example, often a scenario, to better clarify a section of text.

Tools • Tells you what tools you need to complete a given task.

13290L-001 Rev. A S4M User Guide 10/21/05

About This Document

Document Conventions

Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example.

Figure 1 • Sample Figure with Callouts

POWER ALERT

FEED button

CANCEL button

CANCEL FEED

PAUSE

ENTER

10/21/05 S4M User Guide 13290L-001 Rev. A

About This Document

Document Conventions

Notes • ___________________________________________________________________

__________________________________________________________________________

13290L-001 Rev. A S4M User Guide 10/21/05

Introduction

This section shows the operational controls and location of major components used when loading media and ribbon. Other features of the printer are discussed.

Contents

External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control Panel LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

New or Modified Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Introduction

External View

Figure 2 shows the outside of the printer.

Figure 2 • Exterior of Printer

ront

Rear

Control panel

Media door

Electronics cover

Power switch (O = Off, I = On)

AC power connector

13290L-001 Rev. A S4M User Guide 10/21/05

Control Panel

All controls and indicators for the printer are located on the control panel (Figure 3).

•The control panel Liquid Crystal Display (LCD) shows the operating status and printer parameters.

•The control panel buttons are used to control the printer operations and to set parameters.

•The control panel lights (LEDs) show the printer’s operating status or indicate which control panel buttons are active.

Figure 3 • Location of Control Panel Buttons and Lights

2 1

POWER ALERT

Introduction

Control Panel

ENTER

CANCEL FEED

PAUSE

Alert light

Power light

LCD

ENTER button

MENU button

Up arrow button

CANCEL or Left Arrow button

FEED or Right Arrow button

PAUSE or Down Arrow button

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Introduction

Control Panel

Control Panel LCD

The control panel LCD functions differently in different printer modes.

•In Operating mode, the LCD displays the printer’s status, sometimes in conjunction with a control panel light (see Control Panel Lights on page 12). When the printer is receiving data, the control panel shows the word spaces.

•In Pause mode, the printer stops printing temporarily.

•In Setup mode, you can use the control panel LCD to view or modify printer parameters (see Control Panel LCD Display on page 60).

•In Error mode, the LCD may display an alert or error message (see LCD Error Messages

on page 87).

Control Panel Buttons

The printer has six basic control buttons on the control panel. Some of these buttons also function as navigational keys when the printer is in Setup mode. The current function of a particular button is determined by which light is illuminated next to it (Figure 4).

DATA and cycles through a series of dots and

Figure 4 • Example of Active Control Panel Buttons

1 2

FEED FEED

FEED active Right arrow active

Table 1 describes the function of each button. The

active when the printer is in normal operating mode.

MENU, PAUSE, and FEED buttons are

13290L-001 Rev. A S4M User Guide 10/21/05

Table 1 • Control Panel Buttons

Introduction

Control Panel

Button

ENTER

CANCEL

FEED

PAU S E

Left Arrow

Appearance

ENTER

CANCEL

FEED

PAUSE

Function/Description

Enters and exits Setup mode.

If a parameter or option in Setup mode needs to be selected, pressing

ENTER selects the item. This button is active only when necessary.

CANCEL

functions only in Pause mode. Pressing CANCEL once has these

effects:

• Cancels the label format that is currently printing.

• If no label format is printing, the next one to be printed is canceled.

• If no label formats are waiting to be printed,

CANCEL is ignored.

To clear the printer’s entire label format memory, press and hold

CANCEL.

Advances a blank label.

• If the printer is idle or paused, the label is fed immediately.

• If the printer is printing, the label is fed after printing finishes.

Stops and restarts the printing process or removes error messages and clears the LCD. When the printer is paused, the PAUSE light blinks.

• If the printer is idle, it enters Pause mode immediately.

• If the printer is printing, the label is completed before the printer pauses.

When in Setup mode, scrolls the LCD to the previous parameter.

Right Arrow

Up Arrow

Down Arrow

When in Setup mode, scrolls the LCD to the next parameter.

When in Setup mode, increases values or scrolls to the next option.

When in Setup mode, decreases values or scrolls to the previous option.

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Introduction

Control Panel

Control Panel Lights

Table 2 describes lights on the control panel that indicate different printer conditions.

Table 2 • Control Panel Lights

Light

POWER Indicates that the printer is on.

ALERT In an error or alert situation, the ALERT light operates as follows:

Appearance

POW

LERT

Function/Description

• Remains on (solid) when the printer requires operator attention, such as when the print mechanism is open.

• Flashes when the ribbon or media is out.

PAUSE (part of the

PAU S E button)

FEED (part of the

FEED button)

CANCEL (part of the

CANCEL button)

PAUSE

FEED

CANCEL

Flashes when the printer is in Pause mode unless the printer enters Setup mode and the down arrow becomes active.

On during normal printer operation, indicating that the printer can feed a blank label.

On when canceling a label format is a valid option.

13290L-001 Rev. A S4M User Guide 10/21/05

Printer Media Compartment

Figure 5 shows a simplified view of the media compartment of your printer. Depending on

installed options, your printer may look slightly different.

Figure 5 • Media Compartment

Introduction

Printer Media Compartment

10 8

Printhead assembly

Ribbon supply spindle*

Ribbon take-up spindle*

Media supply hanger

Media supply guide

Fanfold media slot

Dancer assembly

Media guide

Printhead release latch

Peel release lever**

Peel assembly**

* Present only on printers that have the Thermal Transfer option installed.

** Present only on printers that have the Peel option installed.

10/21/05 S4M User Guide 13290L-001 Rev. A

Introduction

Printer Language Modes

Depending on how your printer was ordered, it came from the factory with firmware that operates in or allows you to use certain commands for one of the following printer languages:

• Zebra Programming Language (ZPL)

• Eltron Programming Language (EPL)

• Datamax Programming Language (APL-D)

• Intermec Printer Language (APL-I)

Firmware Downloads

You may download S4M firmware to the printer at any time to change from one printer language to another. For the latest firmware versions and instructions for downloading them, go to http://www.zebra.com/firmware.

Note • When the printer changes from one printer language to another, error messages may

appear on the LCD, and some control panel lights may activate in error mode. You may ignore these error messages and lights. When the firmware download is complete, reboot the printer and load printer defaults to return the printer to Operating mode.

New or Modified Commands

See ZPL II Commands on page 111 for ZPL II commands that changed or that were added specifically for this printer.

Additional Printer Language Information

The following manuals contain specific information about the different printer language modes. Copies of these manuals are on the CD that came with your printer and at

http://www.zebra.com/manuals.

• ZPL II Programming Guide, volumes 1 and 2

• EPL2 Programming Guide

• APL-D Reference Guide

• APL-I Reference Guide

13290L-001 Rev. A S4M User Guide 10/21/05

Printer Setup

This section provides the tasks that you must complete and the issues that you must consider before you load and configure your printer.

Contents

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Report Shipping Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Store the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Data Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power Cord Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Types of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Data Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10/21/05 S4M User Guide 13290L-001 Rev. A

Printer Setup

Before You Begin

Review this checklist, and resolve any issues before you set up or use your printer.

 Unpack and Inspect the Printer Have you unpacked the printer and inspected it for

 Select a Site Have you selected an appropriate location for the printer? If you have not,

 Attach a Power Cord Do you have the correct power cord for your printer? If you are

 Connect to a Data Source Have you determined how the printer will connect to a

 Select Media Do you have the correct media for your application? If you are unsure,

 Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if

damage? If you have not, see Unpack and Inspect the Printer on page 17.

see Select a Site for the Printer on page 18.

unsure, see Power Cord Specifications on page 20. To attach the power cord and connect the printer to a power source, see Connect the Printer to a Power Source on page 19.

data source (usually a computer)? For more information, see Select a Communication

Interface on page 21.

see Types of Media on page 25.

needed? If you are unsure, see Ribbon Overview on page 27.

13290L-001 Rev. A S4M User Guide 10/21/05

Unpack and Inspect the Printer

When you receive the printer, immediately unpack and inspect it for shipping damage. Save all packing materials.

Inspect the Printer

Inspect the printer for possible damage incurred during shipment:

• Check all exterior surfaces for damage.

• Raise the media door, and inspect the media compartment for damage to components.

Report Shipping Damage

Important • Zebra Technologies is not responsible for any damage incurred during the

shipment of the equipment and will not repair this damage under warranty

If you discover shipping damage upon inspection:

Printer Setup

Unpack and Inspect the Printer

• Immediately notify the shipping company and file a damage report.

• Keep all packaging material for shipping company inspection.

• Notify your authorized Zebra reseller.

Store the Printer

If you are not placing the printer into immediate operation, repackage it using the original packing materials. You may store the printer under the following conditions:

• Temperature: –40°F to 140°F (–40°C to 60°C)

• Relative humidity: 5% to 85%, non-condensing

Shipping

If you must ship the printer:

• Remove any media or ribbon from the printer to avoid damaging the printer.

• Carefully pack the printer into the original container or a suitable alternate container to avoid damage during transit. A shipping container can be purchased from Zebra if the original packaging has been lost or destroyed.

10/21/05 S4M User Guide 13290L-001 Rev. A

Printer Setup

Select a Site for the Printer

Consider the following when selecting an appropriate location for your printer.

Select a Surface

Select a solid, level surface of sufficient size and strength to accommodate the printer and other equipment (such as a computer), if necessary. The choices include a table, countertop, desk, or cart.

Provide Proper Operating Conditions

This printer is designed to function in a wide range of environmental and electrical conditions, including a warehouse or factory floor. For more information on the required conditions, see

General Specifications on page 106.

Table 3 shows the temperature and relative humidity requirements for the printer when it is

operating.

Table 3 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

Thermal Transfer 40° to 104°F (5° to 40°C) 20 to 85% non-condensing

Direct Thermal 32° to 104°F (0° to 40°C) 20 to 85% non-condensing

Allow Proper Space

The printer should have enough space around it for you to be able to open the media door. To allow for proper ventilation and cooling, leave open space on all sides of the printer.

Caution • Do not place any padding or cushioning material behind or under the printer

because this restricts air flow and could cause the printer to overheat.

Provide a Data Source

If the printer will be located away from the data source, the selected site must provide the appropriate connections to that data source. For more information on the types of communication interfaces, see Select a Communication Interface on page 21.

Provide a Power Source

Place the printer within a short distance of a power outlet that is easily accessible.

13290L-001 Rev. A S4M User Guide 10/21/05

Connect the Printer to a Power Source

The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 20.

Caution • For personnel and equipment safety, always use an approved three-conductor

power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific three-conductor grounded plug configuration.

To connect the printer to a power source, complete these steps:

1. Turn the printer power switch to the Off (O) position.

2. Refer to Figure 6. Plug the power cord into the AC power connector on the rear of the

printer.

3. Plug the other end of the power cord into a power outlet near the printer.

Printer Setup

Connect the Printer to a Power Source

Figure 6 • Power Connection

Power switch

AC power connector

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Printer Setup

Connect the Printer to a Power Source

Power Cord Specifications

Caution • For personnel and equipment safety, always use an approved three-conductor

power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration.

Depending on how your printer was ordered, a power cord may or may not be included. If one is not included or if the one included is not suitable for your requirements, refer to the following guidelines:

• The overall cord length must be less than 9.8 ft. (3.0 m).

• The cord must be rated for at least 10 A, 250 V.

• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic interference. The third wire in the power cord grounds the connection (Figure 7).

Figure 7 • Power Cord Specifications

AC power plug for your country—This should bear the

certification mark of at least one of the known international safety organizations (Figure 8).

3-conductor HAR cable or other cable approved for

your country. IEC 320 connector—This should bear the certification

mark of at least one of the known international safety organizations (Figure 8).

Length ≤ 9.8 ft (3 m). Rating 10 Amp, 250 VAC.

Figure 8 • International Safety Organization Certifications

13290L-001 Rev. A S4M User Guide 10/21/05

Select a Communication Interface

The way that you connect your printer to a data source depends on the communication options installed in the printer. You may use any available connection to send commands and label formats from a host computer to the printer.

Caution • Connecting a data communications cable while the power is ON may damage

the printer.

Note • You must supply all interface cables for your application. Refer to Data Cable

Requirements on page 24 for specific cable requirements.

Connector Locations

Refer to Figure 9. The printer comes standard with an Electronics Industries Association (EIA) RS-232 serial interface (DB-9 connector), an IEEE 1284 bidirectional parallel interface (unless replaced with an optional print server port), and a USB 1.1 port. You may use any of these interface methods to send commands and label formats from a host to the printer.

Operations

Select a Communication Interface

Figure 9 • Cable Connections

Parallel interface connector (not available on units

that have an optional print server port) DB-9 serial interface connector

USB 1.1 connector

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Operations

Select a Communication Interface

Types of Connections

The method of connecting the printer to a data source depends on the communication options installed in the printer and the host. This section provides basic information about common interfaces.

When communicating via the serial data port (RS-232), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control should be set to match those of the host computer. See Password Level 3 Parameters on page 65 to configure these parameters. When communicating via the parallel port or the USB port, the previously mentioned parameters do not apply.

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

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

• Disadvantages: Slower than the parallel connection; limited to 50 feet (15.24 m) of cable.

Figure 10 • Communicating Using a Serial Data Port

Printer Computer

Male

Null modem adaptor (if using a standard modem cable)

50 ft. (15 m) maximum

13290L-001 Rev. A S4M User Guide 10/21/05

Operations

Select a Communication Interface

IEEE 1284 Bidirectional Parallel A common communication method available on most PCs and other hosts.

• Advantages: Fastest of the communication interfaces; cables and connectors are readily available from computer equipment stores and suppliers; two-way communication between the host and the printer; easy to connect.

• Disadvantages: Shorter recommended cable length of 6 feet (1.83 m) with a maximum of length 10 ft (3 m); many computers are equipped with only one parallel port, allowing only one IEEE 1284 bidirectional device to be connected at a time.

Figure 11 • Communicating Using a Parallel Port

Printer Computer

36-pin male

25-pin male

10 ft. (3 m) maximum

USB 1.1 Port Communicating using the USB port (see Figure 12) does not require special settings.

• Advantages: Many computers are equipped with more than one USB port, allowing multiple USB devices to be connected at one time; cables and connectors are readily available from computer equipment stores and suppliers; two-way communication between the host and the printer; easy to connect.

• Disadvantages: Cable length limited to 16.4 ft (5 m).

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Operations

Select a Communication Interface

Figure 12 • Communicating Using a USB Port

16.4 ft (5 m) maximum

Optional Print Servers Ethernet-based print severs also are available to connect your printer to a data source. Both wired and wireless options are available.

• With the ZebraNet Wireless Print Server board installed, a wireless PCMCIA card can be used to communicate with a network. For more information on this option, see the ZebraNet Wireless Print Server User Guide.

• ZebraNet 10/100 Print Server (10/100 PS). For more information on 10/100 PS, see the ZebraNet 10/100 Print Server User and Reference Guide.

Data Cable Requirements

Data cables must be fully shielded 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.

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

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

Note • Zebra printers comply with FCC Rules and Regulations, Part 15 for Class B

Equipment using fully shielded, 6.5 ft (2 m) data cables. Use of unshielded cables may increase radiation above the Class B limits.

13290L-001 Rev. A S4M User Guide 10/21/05

Types of Media

The printer can use various types of media (Table 4). Zebra strongly recommends the use of Zebra-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to ensure against premature printhead wear.

Table 4 • Types of Media

Media Type How It Looks Description

Printer Setup

Types of Media

Non-Continuous Roll Media

Roll media is wound on a core that can be 1 in. to 3 in. (25 to 76 mm) in diameter. Labels have adhesive backing that sticks them to a liner, and they are separated by gaps, holes, notches, or black marks. Tags are separated by perforations.

Figure 13 • Non-Continuous Web Media

Figure 14 • Black Mark Media

Figure 15 • Tag Stock

10/21/05 S4M User Guide 13290L-001 Rev. A

Printer Setup

Types of Media

Table 4 • Types of Media (Continued)

Media Type How It Looks Description

Non-Continuous Fanfold Media

Continuous Roll Media

Fanfold media is folded in a zigzag pattern. Fanfold media can the same label divisions as non-continuous roll media. The divisions would fall on or near the folds.

Continuous media is wound on a core and is without gaps, holes, notches, or black marks. This allows the image to be printed anywhere on the label. With continuous media, use the transmissive sensor so the printer can detect when the media runs out.

13290L-001 Rev. A S4M User Guide 10/21/05

Ribbon Overview

Note • This section applies only to printers that have the Thermal Transfer option installed.

Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be.

When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.

When to Use Ribbon

Thermal transfer media requires ribbon for printing while direct thermal media does not. To determine if ribbon must be used with a particular media, perform a media scratch test.

To perform a label scratch test, complete these steps:

Print Engine Setup

Ribbon Overview

1. Scratch the print surface of the media rapidly with your fingernail.

2. Did a black mark appear on the media?

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

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

Appears on the media Direct thermal. No ribbon is required.

Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside (Figure 16). This printer can only use ribbon that is coated on the outside. If you are unsure which side of a particular roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to determine which side is coated.

Figure 16 • Ribbon Coated on Outside or Inside

Outside Inside

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Print Engine Setup

Ribbon Overview

Adhesive Test

If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed.

To perform an adhesive test, complete these steps:

1. Peel a label from its liner.

2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.

3. Peel the label off of the ribbon.

4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?

If ink from the ribbon...

Then...

Adhered to the label The ribbon is coated on the outer surface.

Did not adhere to the label

The ribbon is coated on the inner surface and cannot be used in this printer. To verify this, repeat the test on the other surface of the roll of ribbon.

Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.

To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon.

2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the

ribbon in contact with the paper.

3. Scratch the inner surface of the unrolled ribbon with your fingernail.

4. Lift the ribbon from the paper.

5. Observe the results. Did the ribbon leave a mark on the paper?

If the ribbon... Then...

Left a mark on the paper The ribbon is coated on the outer surface.

Did not leave a mark on the paper

The ribbon is coated on the inner surface and cannot be used in this printer. To verify this, repeat the test on the other surface of the roll of ribbon.

13290L-001 Rev. A S4M User Guide 10/21/05

Operations

This section provides the procedures for loading and calibrating the printer.

Note • Complete the tasks and resolve the issues in Printer Setup on page 15 before

operating the printer.

Contents

Media Loading Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Starting a Roll of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Inserting Media into the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Load Media in Tear-Off Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Load Media in Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Remove the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Position the Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Select the Transmissive Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Adjust the Reflective Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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Operations

Media Loading Overview

The printer can print on roll or fanfold media and use different print modes for label removal.

Print Modes

The methods for loading media for each print mode follow in this section. Use a print mode that matches the media being used and the printer options available (Table 5). For more information on the types of media, see Types of Media on page 25.

Mode When to Use Printer Action

Table 5 • Print Mode Options

Tear-Off (default setting) Use for most applications.

Peel-Off Use only if printer has the

Starting a Roll of Media

Exposed media may become dirty when handled or stored. To start a roll of media, remove and discard one full revolution of labels or tags and any liner.

Labels Tag Stock

Remove all labels that are held by adhesives or tape.

See Load Media in Tear-Off

Mode on page 33.

Peel-Off option. See Load

Media in Peel-Off Mode on page 36.

Detach all exposed tags.

Each label or strip of labels can be torn off after printing.

The liner is peeled away from the label during printing. When the printed label is removed, the next label prints.

13290L-001 Rev. A S4M User Guide 10/21/05

Inserting Media into the Printer

This section shows how to insert roll or fanfold media into the printer. Fanfold media is loaded the same way as roll media, except the media is stored outside of the printer. See Figure 17

on page 33 for an illustration.

Note • Depending on the media hanger that came with your printer, the size of the media

core that can be used may vary. See Media Specifications on page 109 for the core sizes that your printer supports.

Roll Media

To insert roll media, complete these steps:

1. Flip down the media supply guide.

Operations

Media Loading Overview

2. Place the roll of media on the media supply hanger. Push the roll as far back as it will go.

3. Flip up the media supply guide, and then slide it in until it touches, but does not restrict,

the edge of the roll.

4. Continue with the media loading procedure for the desired print mode.

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Operations

Media Loading Overview

Fanfold Media

To insert fanfold media, complete these steps:

1. Flip down the media supply guide.

2. Thread the fanfold media through the fanfold media slot on the rear of the printer.

3. Drape the media over the media supply hanger.

4. Flip up the media supply guide, and then slide it in until it touches, but does not restrict,

the edge of the media.

5. Continue with the media loading procedure for the desired print mode.

13290L-001 Rev. A S4M User Guide 10/21/05

Load Media in Tear-Off Mode

Tear-Off is the default mode. Figure 17 shows roll and fanfold media loaded in Tear-Off mode.

Figure 17 • Tear-Off Mode

Roll Media

Operations

Load Media in Tear-Off Mode

5678

Fanfold Media

5678

Printhead assembly

Transmissive sensor

Media supply guide

Media supply hanger

Dancer

Media guide

Printhead release latch

Printed label

To load media in Tear-Off Mode, complete these steps:

1. Set the printer to Tear-Off mode. See Select the Label Removal Method on page 63 for

instructions.

2. Insert the media in the printer. See Inserting Media into the Printer on page 31 for

instructions.

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Operations

Load Media in Tear-Off Mode

3. Press the printhead release latch to open the printhead assembly. Lift the printhead until it

latches open.

4. Slide out the media guide.

5. Feed the media under the dancer assembly (1), through the slot in the transmissive

sensor (

2), and under the ribbon sensor (3). Push the media to the back of the transmissive

sensor.

123

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Load Media in Tear-Off Mode

6. Slide in the media guide until it just touches the edge of the media.

7. Close the printhead assembly.

Operations

8. If the printer is paused (the PAUSE light is blinking), press PAU SE to enable printing.

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Operations

Load Media in Peel-Off Mode

This section applies only if the Peel-Off option is installed (Figure 18).

Figure 18 • Peel-Off Mode

Peel lever

Tear-off/peel-off bar

Printhead assembly

Transmissive sensor

Media supply guide

Media supply hanger

Liner take-up spindle

9 10 11 12 13

8910

Dancer Media guide Printhead release latch Peel assembly Label Label liner

To load media in Peel-Off mode, complete these steps:

1. Set the printer to Peel-Off mode. See Select the Label Removal Method on page 63 for

instructions.

2. Insert the media in the printer. See Inserting Media into the Printer on page 31 for

instructions.

13290L-001 Rev. A S4M User Guide 10/21/05

Load Media in Peel-Off Mode

3. Press the printhead release latch to open the printhead assembly.

4. Lift the printhead until it latches open.

5. Slide out the media guide.

Operations

10/21/05 S4M User Guide 13290L-001 Rev. A

Operations

Load Media in Peel-Off Mode

6. Feed the media under the dancer assembly, through the slot in the transmissive sensor, and

under the ribbon sensor. Push the media to the back of the transmissive sensor.

123

Dancer assembly

Transmissive sensor

Ribbon sensor

7. Push down the peel-off mechanism release lever to open the peel assembly.

8. Pull approximately 18 in. (500 mm) of media through the front of the printer.

9. Remove the exposed labels so that only the liner remains.

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Operations

Load Media in Peel-Off Mode

10. Feed the liner over the tear-off/peel-off bar and behind the peel assembly. Make sure that

the end of the liner falls outside of the printer.

Tear-off/peel-off bar

Peel assembly

11. Slide in the media guide until it just touches the edge of the media.

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Operations

Load Media in Peel-Off Mode

12. Close the printhead assembly.

13. Close the peel assembly using the peel-off mechanism release lever.

14. If the printer is paused (the PAUSE light is blinking), press PAU SE to enable printing.

Peeling starts automatically.

13290L-001 Rev. A S4M User Guide 10/21/05

Load Ribbon

Note • This section applies only to printers that have the Thermal Transfer option installed.

The ribbon supply spindle in your printer is a dual-tension variety. Most applications require the spindle to be in the normal position. The low tension position is recommended only when a narrow ribbon is used or if normal tension hampers the ribbon movement.

Note • Always use ribbon that is wider than the media to protect the printhead from wear.

For direct thermal printing, do not load ribbon in the printer.

Figure 19 • Ribbon Path

Operations

Load Ribbon

Printhead assembly

Ribbon supply spindle

Ribbon take-up spindle

Tension blades

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Operations

Load Ribbon

To load ribbon, complete these steps:

1. Set the ribbon supply spindle for normal or low tension.

• To place the ribbon supply spindle in the normal position, firmly pull out the spindle end cap until it extends and clicks in place, as shown in Figure 20.

• To place the ribbon supply spindle in the low-tension position, firmly push in the end cap until it retracts and clicks in place, as shown in Figure 20.

Figure 20 • Ribbon Spindle—Normal and Low Tension

1 2

Normal Position (Spindle End Cap Extended)

Low-Tension Position (Spindle End Cap Retracted)

2. Press the printhead release latch to open the printhead assembly. Lift the printhead until it

latches open.

3. Orient the ribbon with the loose end unrolling clockwise.

13290L-001 Rev. A S4M User Guide 10/21/05

Operations

Load Ribbon

4. Place the ribbon roll onto the ribbon supply spindle (1) and push it all the way back.

5. Pull the end of the ribbon under the printhead assembly (2) and out the front of the printer.

6. Close the printhead assembly.

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Operations

Load Ribbon

7. Wind the ribbon clockwise onto the ribbon take-up spindle (3).

Remove the Ribbon

To remove used ribbon, complete these steps:

1. If the ribbon has not run out, cut or break it before the ribbon take-up spindle.

Caution •

damage the spindle.

Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may

13290L-001 Rev. A S4M User Guide 10/21/05

Operations

Load Ribbon

2. Squeeze the ribbon against the ribbon take-up spindle tension blades (1). At the same

time, turn the ribbon take-up spindle release knob counterclockwise (

2).

The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.

1 2

3. Slide the ribbon off of the ribbon take-up spindle.

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Operations

Calibrate the Printer

Auto Calibration

By default, the printer automatically calibrates on power up or when the printhead is closed. During auto calibration, the printer determines the label length and sensor settings.

The results of the auto calibration are stored in the printer’s memory and are retained even if printer power is removed. These parameters remain in effect until the next calibration is performed.

Manual Calibration

Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the media and ribbon are detected more accurately. If you change the type of ribbon or media, your printer may operate better if you perform this calibration.

For instructions, refer to Calibrate Media and Ribbon Sensors on page 72.

13290L-001 Rev. A S4M User Guide 10/21/05

Position the Media Sensors

This printer uses two types of media sensors: transmissive and reflective.

Select the Transmissive Sensor

The standard transmissive sensor (Figure 21) is in a fixed position and enabled from the control panel. For more information about the operation of this sensor, see Select the Media

Sensor on page 62.

Figure 21 • Transmissive Sensor

Operations

Position the Media Sensors

Adjust the Reflective Sensor

The reflective sensor is compatible with most types of media. With non-continuous media, the reflective sensor detects the start-of-label indicator (the notch, hole, black mark, or gap between die-cut labels). With both continuous media and non-continuous media, the sensor detects an out-of-paper condition. If you have difficulties with calibration while using this sensor, use the transmissive sensor (see Select the Transmissive Sensor on page 47).

Position the reflective sensor in the following way:

• directly under the notch, hole, or black mark with these types of labels

• anywhere along the width of the media if there is a gap between labels

• anywhere under the media for continuous media

The glow of the red light through the media may help you accurately position the sensor.

Standard transmissive sensor

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Operations

Position the Media Sensors

Figure 22 • Adjusting the Reflective Sensor

Printhead assembly

Reflective sensor

Adjustment lever

Printhead release latch

To adjust the reflective sensor, complete these steps:

1. See Figure 22. Press the printhead release latch.

2. Lift the printhead until it latches open.

3. Locate the reflective sensor positioning lever.

4. Move the reflective sensor positioning lever across the width of the media until the

reflective sensor aligns with the gap or notch.

5. Close the printhead assembly.

13290L-001 Rev. A S4M User Guide 10/21/05

Adjust Printhead Pressure

See Figure 23. You may need to adjust printhead pressure if printing is too light on one side or if you use thick media.

Figure 23 • Printhead Pressure Adjustment Dials

Operations

Adjust Printhead Pressure

1 2

Right dial Left dial

The smallest block (fully counterclockwise) is considered position 1 and the largest block (fully clockwise) is considered position 4.

To set printhead pressure, complete these steps:

1. Use Tabl e 6 to select the initial dial settings for your media.

Table 6 • Printhead Pressure

Media Width Left Dial Right Dial

1 in. (25.4 mm)

2 in. (51 mm)

3 in. (76 mm)

3.5 in. and up (89 mm and up)

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Operations

Adjust Printhead Pressure

2. If necessary, adjust the pressure adjustment dials as follows:

If the media... Then...

Requires higher pressure to

Increase both dials one position.

print well

Shifts left while printing Increase the right dial setting one position, or

decrease the left dial setting one position.

Shifts right while printing Increase the left dial setting one position, or decrease

the right dial setting one position.

13290L-001 Rev. A S4M User Guide 10/21/05

Configuration

This section discusses printer configuration settings and instructs you how to view or change printer parameters through the control panel.

Contents

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Leave Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Password Protection of Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Printing Configuration Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Control Panel LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Password Level 1 and 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Password Level 3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Setup Mode

Enter Setup Mode

After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays application using the control panel LCD and the buttons directly below it. If it becomes necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 103.

Important • Certain printing conditions may require that you adjust some printing

parameters, such as print speed or darkness. These conditions include (but are not limited to):

• printing at high speeds

• peeling the media

• the use of extremely thin, small, synthetic, or coated labels

Because these and other factors affect print quality, run tests to determine the best combination of printer settings and media for your application. A poor match may limit print quality or print rate, or the printer may not function properly in the desired print mode.

PRINTER READY. You may now set printer parameters for your

To enter Setup mode, complete these steps:

1. Press MENU.

2. Use the left or right arrow to scroll through the parameters.

Leave Setup Mode

You can leave Setup mode at any time. As you leave Setup mode, you may choose to save or discard changes that you made, or you may return to where you were in Setup mode.

To exit Setup mode, complete these steps:

1. Press MENU.

The printer displays

2. Do you wish to save changes that were made since you entered Setup mode?

If you wish to... Then...

Save changes a. Press ENTER.

SAVE CHANGES and activates the ENTER button.

The printer saves changes and exits Setup mode.

13290L-001 Rev. A S4M User Guide 10/21/05

If you wish to... Then...

Discard changes a. Press the up or down arrow to select NO.

b. Press ENTER.

The printer discards changes and exits Setup mode.

Configuration

Setup Mode

Return to Setup mode

a. Press MENU or any arrow button.

• MENU returns you to the same parameter.

• The left arrow takes you to the previous parameter.

• The right arrow takes you to the next parameter.

• The up or down arrow scroll to other options in the same parameter.

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Configuration

Password Protection of Parameters

The printer has four levels of passwords. When you enter Setup mode on the control panel, only those parameters that are not password-protected are displayed. To see more parameters, you must enter an appropriate password at the password correctly, you do not have to enter it again until you leave and reenter Setup mode.

When you are prompted for a password, enter the password for the level displayed or for a higher level. Entering a higher level password will unprotect the parameters for that level and for all levels below it (for example, unprotecting level 4 parameters also unprotects levels 1, 2, and 3).

The password levels and default passwords are shown in Table 7. To change the password for any level, use the

on page 112.

^KP ZPL II command. For more information, see ^KP, Define Password

Table 7 • Password Levels and Defaults

ADVANCED SETUP prompt. After you enter a

Password

Level

4 All features, including sensor adjustments

3 Installation and reconfiguration. The printer

2 Label configuration operations (media type,

1 Darkness, Tear-Off position, label top

Features Controlled Default Password

and other sensitive parameters

web-page interface also uses this password.

label removal method, label length)

To enter a password when prompted, complete these steps:

1. When the printer displays ADVANCED SETUP X, press ENTER.

The printer displays

2. Enter the four-digit password for the password level displayed or for a higher level.

• The left and right arrows change the selected digit position.

• The up and down arrows change the value of the selected digit.

PASSWORD and the number 0000.

For advanced use only. See the Maintenance Manual or contact technical support.

1234

0000 (unprotected)

3. After entering the password, press ENTER.

If you entered a valid password, additional parameters are displayed.

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Configuration

Password Protection of Parameters

Note • When you enter a password at an ADVANCED SETUP prompt, the first parameter

that you see is determined in part by whether you pressed the right arrow or the left arrow to get to the

ADVANCED SETUP prompt:

• If you used the right arrow, the first parameter that you see is based on the password level that the printer prompted for (see Tabl e 8).

• If you used the left arrow, the first parameter that you see is based on which password you enter at the prompt, regardless of which password level the printer prompted for (see Table 9).

Table 8 • Right Arrow Used to Reach

Advanced

Setup Level

Prompted

Password

Level

Entered

First Parameter Seen

ADVANCED SETUP Prompt

1 1, 2, 3, or 4 DARKNESS (top of level 1)

2 2, 3, or 4

33 or 4

Table 9 • Left Arrow Used to Reach

Advanced

Setup Level

Prompted

Password

Level

Entered

MEDIA TYPE (top of level 2)

PRINT OUT (top of level 3)

LABEL LEVEL (top of level 4)

ADVANCED SETUP Prompt

First Parameter Seen

11 LABEL TOP (ZPL, EPL, APL-D)

(bottom of level 1)

Y FORMS ADJUST (APL-I)

(bottom of level 1)

1, 2 2

LENGTH

(bottom of level 2)

1, 2, 3 3

LANGUAGE

(bottom of level 3)

1, 2, 3, or 4 4

LANGUAGE

(bottom of level 4;

LANGUAGE parameter appears in

both level 3 and 4)

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Configuration

Printing Configuration Labels

After you load the media and ribbon (if necessary), print a printer configuration label and a network configuration label as records of your printer’s current settings. Keep the labels to use when troubleshooting printing problems. The options to print these labels are located in password level 3.

A configuration label lists the printer settings that are stored in configuration memory. A network configuration label lists the print server settings. For the correct settings, print a network configuration label after the printer connects to the network.

Note • If the printer is paused when you enter Setup mode, these labels will print after you exit

Setup mode and resume printing.

To print a printer configuration label or a network configuration label, complete these steps:

1. On the control panel, press MENU.

The printer enters Setup mode and displays

DARKNESS.

2. Press the left arrow.

If a password is set for any levels, the printer displays number, and the

ENTER button is enabled. If no passwords are set, the printer displays

LANGUAGE.

3. What does the printer display?

If the printer displays... Then...

ADVANCED SETUP 1 ADVANCED SETUP 2 ADVANCED SETUP 3

ADVANCED SETUP 4

LANGUAGE

a. Press ENTER.

The printer displays

b. Use the left and right arrows to enter the password for

level 3 or 4.

c. Press ENTER.

The printer displays

d. Use the left or right arrow to scroll through the

parameters until you reach

a. You do not need to enter a password to access this

parameter. Use the left or right arrow to scroll through the parameters until you reach

a. Use the left or right arrow to scroll through the

parameters until you reach

ADVANCED SETUP with the level

PASSWORD 0000.

LANGUAGE.

PRINT OUT.

13290L-001 Rev. A S4M User Guide 10/21/05

4. Select the type of label to print.

To print a... Then...

Printer configuration label a. Scroll to SETTINGS.

b. Press ENTER.

A printer configuration label prints (Figure 24).

Figure 24 • Printer Configuration Label

Configuration

Printing Configuration Labels

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Configuration

Printing Configuration Labels

To print a... Then...

Network configuration label a. Scroll to LIST NETWORK.

b. Press ENTER.

A network configuration label prints (Figure 25). An asterisk designates whether the wired or wireless print server is active. If no wireless print server is installed, the wireless portion of the label does not print.

Figure 25 • Network Configuration Label

13290L-001 Rev. A S4M User Guide 10/21/05

Select a Display Language

The LANGUAGE parameter is included in password level 3 and level 4 so you can easily reach the parameter to select a familiar language if you cannot read the one being displayed.

To change the language displayed, complete these steps:

1. On the control panel, press MENU.

The printer enters Setup mode.

2. Press the left arrow.

If a password is set for level 3 or 4, the printer displays level number, and the the printer displays

3. What does the printer display?

If the printer displays... Then...

ADVANCED SETUP 1 ADVANCED SETUP 2 ADVANCED SETUP 3 ADVANCED SETUP 4

LANGUAGE

* Displays in the last language selected.

ENTER button is enabled. If no passwords are set for level 3 or 4,

LANGUAGE.

Select a Display Language

ADVANCED SETUP with the

a. Press ENTER.

The printer displays

b. Use the left and right arrows to enter the password

for level 3 or 4.

c. Press ENTER.

The printer displays

Continue with the next step.

PASSWORD 0000

LANGUAGE

Configuration

4. Use the up and down arrows until you reach the language of your choice.

5. Press MENU.

The printer prompts you to accept changes.

6. Press ENTER to accept the language that you selected.

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Configuration

Control Panel LCD Display

Use the LCD display on the control panel to adjust printer settings.

Password Level 1 and 2 Parameters

Table 10 shows parameters in the order in which they appear when you press the right arrow

after entering Setup mode. Throughout this process, press the right arrow to continue to the next parameter or the left arrow to return to the previous parameter in the cycle.

Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 1 of 5)

Parameter Explanation

DARKNESS

(ZPL, APL-D, and APL-I modes)

DENSITY

(EPL mode only)

Adjust Print Darkness

The best darkness setting depends on a variety of factors, including ribbon type, labels, and the condition of the printhead. You may adjust the darkness for consistent high-quality printing.

Important • Set the darkness to the lowest setting that provides

good print quality. If the darkness is set too high, the ink may smear, the ribbon may burn through, or the printhead may wear prematurely.

Note • The printer applies and saves the darkness setting

immediately. Exiting Setup mode without saving changes does not restore the previous value.

If printing is too light or if there are voids in the printed areas, increase the darkness. If the printing is too dark or if there is spreading or bleeding of printed areas, decrease the darkness. Darkness settings also may be changed by the driver or software settings.

The FEED Self Test on page 100 can be used to determine the best darkness setting. Because the darkness setting takes effect immediately, you can see the results on labels that are currently printing.

Range (ZPL, APL-D, APL-I): 0.0 to +30.0

Default Value (ZPL, APL-D, APL-I): +10.0

Range (EPL): 7

Default Value (EPL): 0 to 15

To modify this parameter:

• Press the up arrow to increase value.

• Press the down arrow to decrease value.

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Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 2 of 5)

Parameter Explanation

Configuration

Control Panel LCD Display

TEAR OFF

LABEL TOP

(ZPL, EPL, and APL-D modes)

X FORMS ADJUST

(APL-I mode only)

Adjust Tear-Off Position

This parameter establishes the position of the labels over the tear-off/peel-off bar after printing. Each press of a button adjusts the tearoff position by one dot row.

Note • The printer applies and saves the tear-off setting

immediately. Exiting Setup mode without saving changes does not restore the previous value.

Range (ZPL, EPL, APL-I): -120 to +120

Default Value (ZPL, EPL, APL-I): 0

Range (APL-D): +00i to +999i (inches), 0m to 2537m (metric)

Default Value (APL-D): +128i

Note • The APL-D default value does not position the label over

the tear-off/peel-off bar. This is done to work with existing DPL label formats that account for this positioning.

To modify this parameter:

• Press the up arrow to increase value.

• Press the down arrow to decrease value.

Adjust Label Top Position

The label top position adjusts the print position vertically on the label. Positive numbers adjust the label top position farther down the label (away from the printhead), and negative numbers adjust the position up the label (toward the printhead).

The displayed value represents dots.

Range (ZPL, EPL, and APL-I): -120 to +120

Default Value (ZPL, EPL, and APL-I): 0

Range (APL-D): -0.64i to 0.64i (when printer is set to operate in inches)

Default Value (APL-D): 0

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Y FORMS ADJUST

(APL-I mode only)

Adjust Label Left Position

The label left position adjusts the print position horizontally on the label. Positive numbers move the left edge of the image toward the center of the label by the number of dots selected while negative numbers shift the left edge of the image toward the left edge of the label.

Range: -120 to +120

Default Value: 0

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

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Configuration

Control Panel LCD Display

Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 3 of 5)

Parameter Explanation

MEDIA TYPE

SENSOR SELECT

Set Media Type

This parameter tells the printer whether you are using continuous media, non-continuous media or tag stock, or non-continuous black mark media (see Types of Media on page 25).

Selections:

• GAP/NOTCH—Used for non-continuous web media,

non-continuous fanfold media, and tag stock. Use the SENSOR

SELECT

When using the transmissive sensor with media that has holes or notches, position the media so that the transmissive media sensor hole or notch. If the holes or notches cannot be positioned this way for a particular type of media, use the reflective sensor.

• CONTINUOUS—Used for media that does not have divisions between labels.

setting that gives the best results.

SENSOR SELECT should be set to DEFAULT or

TRANSMISSIVE.

• MARK—Used for non-continuous black mark media.

SELECT

Default Value: GAP/NOTCH

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Select the Media Sensor

You may allow the printer to select a media sensor based on the media type, or you may select a specific media sensor to be used if the sensor that was selected by the printer does not detect media correctly.

Selections:

• DEFAULT—The printer selects a sensor based on the setting specified for

should be set to DEFAULT or REFLECTIVE.

MEDIA TYPE:

SENSOR

Media Type Sensor Used

GAP/NOTCH

CONTINUOUS

MARK

• TRANSMISSIVE—Use with all continuous media or with most types of non-continuous media.

• REFLECTIVE—Use with black mark media or with non-continuous media that does not work well with the transmissive sensor.

Default Value: DEFAULT

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

13290L-001 Rev. A S4M User Guide 10/21/05

Transmissive

Reflective

Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 4 of 5)

Parameter Explanation

Configuration

Control Panel LCD Display

REMOVAL

PRINT SPEED

PRINT WIDTH

Select the Label Removal Method

The label removal must correspond to the print mode (see Print Modes

on page 30). Be sure to select a label removal mode that your hardware

configuration supports because some of the selections displayed are for optional printer features.

Selections: TEAR, PEEL, CUTTER, REWIND, DELAYED CUT Default Value: TEAR

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Adjust Print Speed

Adjusts the speed for printing a label (given in whole numbers of inches per second). Slower print speeds typically yield better print quality. Print speed changes take effect upon exiting Setup mode.

Range: 2 to 6 IPS

Default Value (ZPL, APL-I): 2 IPS

Default Value (EPL, APL-D): 6 IPS

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Set Print Width

Print width determines the printable area across the width of the label.

Important • Setting the width too narrow can result in portions of

the label not being printed on the media. Setting the width too wide wastes formatting memory and can cause printing off the label and on the platen roller. This setting can affect the horizontal position of the label format if the image was inverted using the ^POI ZPL II command.

Range: 2 to 832 for 8 dots/mm, 2 to 1248 for 12 dots/mm

Default Value: 832 for 8 dots/mm, 1248 for 12 dots/mm

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

COMPAT. MODE

(APL-D mode only)

Set APL-D Compatibility Mode

Sets compatibility with DPL printers.

Selections: ON, OFF Default Value: OFF

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Control Panel LCD Display

Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 5 of 5)

Parameter Explanation

CONTROL CODES

(APL-D mode only)

MODULE A

(APL-D mode only)

MODULE B

(APL-D mode only)

RESOLUTION

(APL-I mode only)

Set APL-D Control Codes

Selections: STANDARD, MAINFRAME Default Value: STANDARD

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Module A Storage Device for APL-D

Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2 Default Value: NONE

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Module B Storage Device for APL-D

Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2 Default Value: NONE

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Printer Resolution for APL-I

Sets the dot size for backward compatibility with some older APL-I printers.

Selections: 5 MIL, 10 MIL, 15 MIL Default Value: 5 MIL

LENGTH

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Maximum Label Length

Maximum label length is used in conjunction with the calibration procedure. The value of this setting is the maximum label length that is used during the media portion of the calibration process. Only a few labels are required to set media sensors. Always set the value that is at least 1 in. (25.4 mm) longer than the longest label to be used on the printer.

Selections: Default Value:

To modify this parameter:

AUTO, < 1 INCH (25.4 mm) to < 39 INCH (991 mm)

AUTO

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

13290L-001 Rev. A S4M User Guide 10/21/05

Password Level 3 Parameters

Table 11 shows parameters in the order in which they appear when you press the right arrow

after entering the Level 3 password. Throughout this process, press the right arrow to continue to the next parameter or the left arrow to return to the previous parameter in the cycle.

Table 11 • Printer Parameters, Level 3 (Page 1 of 9)

Parameter Explanation

Configuration

Control Panel LCD Display

PRINT OUT

Print Selected Labels

This parameter allows you to print certain types of labels with information about the printer.

Selections:

SETTINGS—Prints a printer configuration label. See Printing

•

Configuration Labels on page 56.

FONTS (ZPL, EPL, APL-D)—Prints a label that lists the available

• fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM, Flash memory, optional memory cards, or font cards.

FORMATS (ZPL, EPL, APL-D)—Prints a label that lists the

• available formats stored in the printer’s RAM, Flash memory, or optional memory card.

BARCODES (ZPL only)—Prints a label that lists the available bar

• codes in the printer.

ALL (ZPL, EPL)—Prints labels that list the available fonts, bar

• codes, images, formats, and the current printer and network configurations.

•

IMAGES (ZPL, EPL, APL-D)—Prints a label that lists the images

currently stored in the printer’s RAM, Flash memory, or optional memory cards.

•

NETWORK (ZPL only)—Prints a network configuration label. See

Printing Configuration Labels on page 56.

•

APLI SW SETUP (APL-I only)

•

APLI HW SETUP (APL-I only)

• APLI PRT QUAL (APL-I only)

•

APLI PITCH (APL-I only)

To print labels:

1. Press the up or down arrow to display label choices.

2. Press ENTER to print the desired label.

PARALLEL COMM.

10/21/05 S4M User Guide 13290L-001 Rev. A

Set Parallel Communications

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

Selections: UNIDIRECTIONAL, BIDIRECTIONAL Default Value: UNIDIRECTIONAL

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Configuration

Control Panel LCD Display

Table 11 • Printer Parameters, Level 3 (Page 2 of 9)

Parameter Explanation

PRINT PAGE

(APL-I mode only)

PRINT FORMAT

(APL-I mode only)

BAUD

Print Stored APL-I Page

Up to 20 pages can be stored and printed.

Selections: 0 through 19 Default Value: 0

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Print Stored APL-I Format

Up to 100 formats can be stored and printed.

Selections: 0 through 99 Default Value: 0

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Set Baud

The baud setting of the printer must match the baud setting of the host computer for accurate communications to take place. Select the value that matches the one being used by the host computer.

Selections: 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600, 115200

Default Value: 9600

DATA BITS

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Data Bits

The data bits of the printer must match the data bits of the host computer for accurate communications to take place. Set the data bits to match the setting being used by the host computer.

Note • Code Page 850 requires the data bits to be set to 8 bits.

Selections: 7BITS, 8BITS Default Value: 8BITS

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

13290L-001 Rev. A S4M User Guide 10/21/05

Table 11 • Printer Parameters, Level 3 (Page 3 of 9)

Parameter Explanation

Configuration

Control Panel LCD Display

STATUS RESPONSE

(APL-I mode only)

RESPONSE FORMAT

(APL-I mode only)

PARITY

Send APL-I Status Response

Determines if a response is sent after inquiry commands. The format is set with the

RESPONSE FORMAT parameter.

Selections: ON, OFF Default Value: ON

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Select APL-I Response Format

STATUS RESPONSE is set to ON, this parameter determines the

If format of the response.

Selections: ASCII, BINARY Default Value: ASCII

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Parity

The parity of the printer must match the parity of the host computer for accurate communications to take place. Select the parity that matches the one being used by the host computer.

Selections: NONE, ODD, EVEN Default Value: NONE

HOST HANDSHAKE

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set Host Handshake

The handshake protocol of the printer must match the handshake protocol of the host computer for proper communications to take place. Select the handshake protocol that matches the one being used by the host computer.

Selections (ZPL, APL-D): XON/XOFF, DSR/DTR, RTS/CTS

Selections (EPL): DTR & XON/XOF, DTR, XON/XOFF

Selections (APL-I): XON/XOFF, DSR/DTR, RTS/CTS, APL-I

Default Value: XON/XOFF

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Control Panel LCD Display

Table 11 • Printer Parameters, Level 3 (Page 4 of 9)

Parameter Explanation

CONTROL CHAR

(ZPL mode only)

COMMAND CHAR

(ZPL mode only)

Set Control Character

The printer looks for this two-digit hexadecimal character to indicate the start of a ZPL/ZPL II control instruction.

Note • Do not use the same hexadecimal value for the control,

command, and delimiter character. The printer must see different characters to work properly.

Range: 00 to FF

Default Value: 7E (tilde—displayed as an arrow)

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Set Command Character

The command prefix is a two-digit hexadecimal value used as a parameter place marker in ZPL/ZPL II format instructions. The printer looks for this two-digit hexadecimal character to indicate the start of a ZPL/ZPL II format instruction. See the ZPL II Programming Guide Volume I for more information.

Note • Do not use the same hexadecimal value for the control,

command, and delimiter character. The printer must see different characters to work properly.

Range: 00 to FF

Default Value: 5E (caret)

DELIM. CHAR

(ZPL mode only)

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Set Delimiter Character

The delimiter character is a two-digit hexadecimal value used as a parameter place marker in ZPL/ZPL II format instructions. See the ZPL II Programming Guide Volume I for more information.

Note • Do not use the same hexadecimal value for the control,

command, and delimiter character. The printer must see different characters to work properly.

Range: 00 to FF

Default Value: 2C (comma)

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

13290L-001 Rev. A S4M User Guide 10/21/05

Table 11 • Printer Parameters, Level 3 (Page 5 of 9)

Parameter Explanation

Configuration

Control Panel LCD Display

HEXDUMP

(ZPL, EPL, APL-D modes)

CHANGE RTC DATE

Hex Dump

The hexadecimal dump mode is a troubleshooting tool for checking the interconnection between the printer and the host computer. When

YES is

selected, all data sent from the host computer to the printer prints as straight ASCII characters, with the hexadecimal value below the ASCII text. The printer prints all characters received, including control codes, such as

CR (carriage return). A sample printout is shown in

Communications Diagnostics Test on page 103.

Selections: NO, YES Default Value: NO

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Set RTC (Real-time clock) Date

If RTC is installed, this parameter allows you to set the RTC date.

Note • The printer saves the RTC date immediately.

To modify this parameter:

1. Press ENTER.

The printer displays the current RTC date.

2. Modify the values as follows:

• Press the right arrow to move to the next digit position.

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

3. Press ENTER to accept the value shown.

CHANGE RTC TIME

Set RTC (Real-time clock) Time

If RTC is installed, this parameter allows you to set the RTC time.

Note • The printer saves the RTC time immediately.

To modify this parameter:

1. Press ENTER.

The printer displays the current RTC time.

2. Modify the values as follows:

• Press the right arrow to move to the next digit position.

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

3. Press ENTER to accept the value shown.

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Control Panel LCD Display

Table 11 • Printer Parameters, Level 3 (Page 6 of 9)

Parameter Explanation

LOAD DEFAULTS

INIT FLASH MEM

Load Factory Defaults

Sets all parameters back to factory defaults.

Important • Use care when using this command. All printer

parameters are reset to factory values with this command. If possible, print a configuration label to have as a record of the printer’s settings before loading defaults.

How to select this parameter:

1. Press ENTER.

The printer asks

2. To load factory defaults, press ENTER to select YES. To cancel, press

ARE YOU SURE?

any other key.

Initialize Flash Memory

This parameter allows you to erase the printer’s Flash memory.

Important • The internal Flash memory is entirely erased with this

command.

To select this parameter:

1. Press ENTER to select YES.

The printer asks

2. To initialize Flash memory, press ENTER. To cancel, press any other

ARE YOU SURE?

key.

RIBBON

Set Ribbon Use

Note • This parameter appears only for printers that have the

Thermal Transfer option installed.

The printer can automatically detect if you are using ribbon. However, you may use this parameter to tell the printer the method of printing that you wish to use each time: direct thermal (no ribbon) or thermal transfer (using ribbon).

Selections:

• AUTO (the printer detects if ribbon is present)

• NO (direct thermal mode, no ribbon)

• YES (thermal transfer mode, with ribbon)

Default Value: AUTO

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

13290L-001 Rev. A S4M User Guide 10/21/05

Table 11 • Printer Parameters, Level 3 (Page 7 of 9)

Parameter Explanation

Configuration

Control Panel LCD Display

ZPL OVERRIDE

(ZPL mode only)

EPL OVERRIDE

(EPL mode only)

Override Certain ZPL Commands

Prevents the printer from accepting the following ZPL commands:

^MM (media mode)

•

^MT (media type direct thermal or thermal transfer)

•

^MN (media non-continuous or continuous)

Selections:

• NO—allows the printer to accept the listed ZPL commands.

• YES—tells the printer to ignore the listed ZPL commands.

Default Value: NO

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Override Certain EPL Commands

Prevents the printer from accepting certain EPL commands.

Selections:

• DISABLED—allows the printer to accept the listed EPL commands.

• ENABLED—tells the printer to ignore the listed EPL commands.

Default Value: DISABLED

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

SENSOR PROFILE

Print Sensor Profile

Use the sensor profile (Figure 26) to troubleshoot registration problems that may occur if the media sensor detects preprinted areas on the media or if it experiences difficulty in determining web location. To adjust the sensitivity of the media and/or ribbon sensors, use Calibrate Media and

Ribbon Sensors on page 72.

Note • The ribbon portion of the label appears only for printers

that have the Thermal Transfer option installed.

Figure 26 • Sensor Profile

To select this parameter:

1. Press ENTER to start this standard calibration procedure and print a

media sensor profile.

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Control Panel LCD Display

Table 11 • Printer Parameters, Level 3 (Page 8 of 9)

Parameter Explanation

MEDIA/RIBBON CALIBRATE

(Thermal Transfer only)

MEDIA CALIBRATE

(Direct Thermal only)

Calibrate Media and Ribbon Sensors

Use this procedure to adjust the sensitivity of the printer’s sensors. In a printer that has the Thermal Transfer option installed, both media and ribbon sensors are adjusted. In a Direct Thermal printer (no Thermal Transfer option installed), only media sensors are adjusted, and the LCD displays for ribbon do not appear in this procedure.

Important • This procedure must be followed exactly as presented.

All of the steps must be performed even if only one of the sensors requires adjustment. You may press the left arrow at any step in this procedure to cancel the procedure.

How to select this parameter:

1. Press ENTER to start the calibration procedure.

The

LOAD BACKING/REMOVE RIBBON prompt displays.

2. Open the printhead.

3. Remove approximately 8 in. (203 mm) of labels from the backing,

and pull the media into the printer so that only the backing is between the media sensors.

4. Remove the ribbon (if used).

5. Press the right arrow to continue.

The message

CALIBRATING PLEASE WAIT displays.

The printer adjusts the scale (gain) of the signals that it receives from the media and ribbon sensors. On the sensor profile, this essentially corresponds to moving the peak of the graph up or down to optimize the readings for your application.

RELOAD ALL displays.

6. Reload the media and ribbon (if used).

7. Close the printhead.

8. Press the right arrow to continue.

The message The printer does a calibration; during this process, the printer

determines the label length. To see the new readings on the new scale, print a sensor profile.

CALIBRATING PLEASE WAIT displays.

13290L-001 Rev. A S4M User Guide 10/21/05

Table 11 • Printer Parameters, Level 3 (Page 9 of 9)

Parameter Explanation

Configuration

Control Panel LCD Display

LANGUAGE

Select the Display Language

This parameter allows you to display the control panel in the language of your choice. As soon as you select a language, all parameters are displayed in that language. Save changes as you exit Setup mode to save the language setting.

Selections: English (

FRANCAIS), German (Deutsch), Italian (ITALIANO), Norwegian

(

NORSK), Portuguese (PORTUGUES), Swedish (SVENSKA), Danish

( (

DANSK), Spanish2 (ESPANOL2), Dutch (NEDERLANDS), Finnish SUOMI), and Japanese.

( Default Value: ENGLISH

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

ENGLISH), Spanish (ESPANOL), French

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Control Panel LCD Display

ZebraNet®Wired and Wireless Print Server LCD Displays

The menu options shown in Table 1 2 display only if you have the ZebraNet PrintServer II, or 10/100 PrintServer, or Wireless Print Server installed and are operating in ZPL or EPL mode. These parameters are considered part of Level 3.

Table 12 • Print Server LCD Displays (Page 1 of 2)

Parameter Explanation

OBTAIN IP ADDRESS

CHANGE IP ADDRESS

CHANGE SUBNET

Obtain an IP Address

Selects the method by which an IP address will be assigned to the printer.

Selections: AUTO SELECT (dynamic), PERMANENT (user-specified) Default Value: AUTO SELECT

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

Change the Printer’s IP Address

This parameter can be modified only when PERMANENT is selected for

OBTAIN IP ADDRESS.

Selections: 0 to 255 for each field Default Value: 0.0.0.0

Note • Leading zeroes are not shown in the address. If an IP

address contains more digits than can be displayed at one time, use the left or right arrows to scroll through the digits.

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Change the Subnet

This parameter can be modified only when PERMANENT is selected for

OBTAIN IP ADDRESS.

Selections: 0 to 255 for each field Default Value: 0.0.0.0

Note • Leading zeroes are not shown in the address. If an IP

address contains more digits than can be displayed at one time, use the left or right arrows to scroll through the digits.

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

13290L-001 Rev. A S4M User Guide 10/21/05

Table 12 • Print Server LCD Displays (Page 2 of 2)

Parameter Explanation

Configuration

Control Panel LCD Display

CHANGE GATEWAY

CHANGE IP PROTOCOL

Change the Gateway

This parameter can be modified only when PERMANENT is selected for

OBTAIN IP ADDRESS.

Selections: 0 to 255 for each field Default Value: 0.0.0.0

Note • Leading zeroes are not shown in the address. If an IP

address contains more digits than can be displayed at one time, use the left or right arrows to scroll through the digits.

To modify this parameter:

• To increase the value, press the up arrow.

• To decrease the value, press the down arrow.

Change the IP Protocol

Determines the method(s) by which the print server (wired or wireless) receives the IP address from the server.

This parameter can be modified only when

OBTAIN IP ADDRESS.

for

Selections: ALL, GLEANING ONLY, RARP, BOOTP, DHCP, DHCP AND BOOT

Default Value: ALL

To modify this parameter:

• Press the up or down arrow to scroll through the selections.

AUTO SELECT is selected

10/21/05 S4M User Guide 13290L-001 Rev. A

Configuration

Control Panel LCD Display

Notes • ___________________________________________________________________

__________________________________________________________________________

13290L-001 Rev. A S4M User Guide 10/21/05

Routine Maintenance

This section provides routine cleaning and maintenance procedures.

Contents

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Clean the Media Compartment and Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Clean the Peel-Off Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

10/21/05 S4M User Guide 13290L-001 Rev. A

Routine Maintenance

Lubrication

No lubrication is needed for this printer.

Caution • Some commercially available lubricants will damage the finish and the

mechanical parts if used on this printer.

Cleaning Procedures

Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this

printer.

Specific cleaning procedures are provided on the following pages. Table 13 shows the recommended cleaning schedule.

Table 13 • Recommended Cleaning Schedule

Area Method Interval

Printhead Solvent* Direct Thermal Mode: After every roll of

Platen roller Solvent*

Media sensors Air blow

Ribbon sensor Air blow

Media path Solvent*

Ribbon path Solvent*

media (or 500 feet of fanfold media).

Thermal Transfer Mode: After every roll of ribbon or three rolls of media.

These intervals are intended as guidelines only. You may have to clean more often, depending upon your application and media.

Pinch roller. (part of Peel-Off option) Solvent*

Tear-off/peel-off bar Solvent* Once a month.

Take label sensor Air blow Once every six months.

* Zebra recommends using Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl and

10% deionized water)

Clean the Exterior

You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

13290L-001 Rev. A S4M User Guide 10/21/05

Clean the Printhead and Platen Roller

You can minimize printhead wear and maintain print quality with regular preventive measures. Over time, the movement of media or ribbon across the printhead wears through the protective ceramic coating, exposing and eventually damaging the print elements (dots). To avoid abrasion:

• Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with backings optimized to reduce friction.

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

• Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent exposing the elements to the more abrasive label material.

For best results, clean the printhead after changing every roll of ribbon. Inconsistent print quality, such as voids in the bar code or graphics, may indicate a dirty printhead.

Note • The printer can remain on while you are cleaning the printhead. In this way, all label

formats, images, and all temporary parameter settings stored in the printer’s internal memory are saved. In addition, keep the peel engaged while cleaning the platen roller (media must be unloaded to do this) to reduce the risk of bending the tear-off/peel-off bar.

Routine Maintenance

Cleaning Procedures

Figure 27 • Cleaning the Printhead and Platen Roller

Printhead assembly

Platen roller

Caution • Observe proper electrostatic safety precautions when handling any

static-sensitive components such as circuit boards and printheads.

10/21/05 S4M User Guide 13290L-001 Rev. A

Routine Maintenance

Cleaning Procedures

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to

cool.

To clean the printhead and platen roller, complete these steps:

1. Open the printhead assembly.

2. Remove the media and ribbon.

3. Using the swab from the Preventive Maintenance Kit (part number 47362) or a solution of

90% Isopropyl alcohol and 10% deionized water and a cotton swab, wipe along the brown strip on the printhead assembly from end to end. Allow the solvent to evaporate.

4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the

solvent to evaporate.

5. Reload media and ribbon, and close the printhead assembly.

Note • If performing this procedure does not improve print quality, try cleaning the

printhead with Save-A-Printhead cleaning film. This specially coated material removes contamination buildup without damaging the printhead. Call your authorized Zebra reseller for more information.

13290L-001 Rev. A S4M User Guide 10/21/05

Clean the Media Compartment and Sensors

To clean the media compartment and sensors, complete these steps:

1. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon

paths.

2. Brush or vacuum any paper lint and dust away from the sensors (see Figure 28).

Figure 28 • Cleaning the Sensors

Routine Maintenance

Cleaning Procedures

Take-label sensor

Ribbon sensor

Transmissive sensor

Reflective sensor

10/21/05 S4M User Guide 13290L-001 Rev. A

Routine Maintenance

Cleaning Procedures

Clean the Peel-Off Assembly

The Peel-Off option is required.

Caution • Observe proper electrostatic safety precautions when handling any

static-sensitive components such as circuit boards and printheads.

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to

cool.

If adhesive buildup affects peel-off performance, complete these steps:

1. Press the printhead release latch to open the printhead assembly.

2. Lift the printhead until it latches open.

3. Open the peel assembly by pivoting the module toward you.

4. Remove any media backing to expose the pinch roller.

5. While manually rotating the pinch roller, clean it thoroughly with the swab from the

Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl alcohol and 10% deionized water and a cotton swab. Allow the solvent to evaporate.

13290L-001 Rev. A S4M User Guide 10/21/05

Routine Maintenance

Cleaning Procedures

6. Use the swab to remove excess adhesive from the tear-off/peel-off bar. Allow the solvent

to evaporate.

Important • Apply minimum force when cleaning the tear-off/peel-off bar. Excessive

force can cause the tear-off/peel-off bar to bend, which could have a negative effect on peel performance.

7. Close the printhead assembly and the media door.

The printer is ready to operate.

10/21/05 S4M User Guide 13290L-001 Rev. A

Routine Maintenance

Cleaning Procedures

Notes • ___________________________________________________________________

__________________________________________________________________________

13290L-001 Rev. A S4M User Guide 10/21/05

Troubleshooting

This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included.

Contents

Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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

Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

10/21/05 S4M User Guide 13290L-001 Rev. A

Troubleshooting

Troubleshooting Checklists

If an error condition exists with the printer, review this checklist:

 Is there an error message on the LCD? If yes, see LCD Error Messages on page 87.

 Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media

and Ribbon Sensors on page 72.

 Is the

CHECK RIBBON light on when ribbon is loaded properly, or are noncontinuous

labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensors

on page 72.

 Are you experiencing problems with print quality? If yes, see Print Quality Problems

on page 90.

 Are you experiencing communications problems? If yes, see Communications Problems

on page 94.

If the labels are not printing or advancing correctly, review this checklist:

 Are you using the correct type of labels? Review the types of label in Types of Media

on page 25.

 Does the printhead need to be adjusted? See Adjust Printhead Pressure on page 49 for

more information.

 Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensors

on page 72 for more information.

If none of the above suggestions correct the problem, review this checklist:

 Perform one or more of the self-tests given in Printer Diagnostics on page 97. Use the

results to help identify the problem.

 If you are still having problems, see Contacts on page 3 for customer support information.

13290L-001 Rev. A S4M User Guide 10/21/05

LCD Error Messages

The LCD displays messages when there is an error. See Table 14 for LCD errors, the possible causes, and the recommended solutions.

Table 14 • LCD Error Messages

Troubleshooting

LCD Error Messages

LCD Display/ Printer Condition

WARNING

RIBBON IN

The ALERT light flashes.

ALERT

PAPER OUT

The printer stops and the ALERT light flashes.

ALERT

HEAD OPEN

The printer stops and the ALERT light flashes.

WARNING

HEAD TOO HOT

The printer stops and the ALERT light flashes.

Possible Cause Recommended Solution

Ribbon is loaded, but the printer is set for direct thermal mode.

Media is not loaded or is loaded incorrectly.

Misaligned media sensor. Check position of the media sensor.

The printer is set for noncontinuous media, but continuous media is loaded.

The printhead is not fully closed. Close printhead completely.

The head open sensor is not working properly.

Caution • The printhead may be hot enough to cause severe

burns. Allow the printhead to cool.

Caution • Observe proper electrostatic safety precautions when

handling any static-sensitive components such as circuit boards and printheads.

Ribbon is not required with direct thermal media. Remove ribbon unless you are using it to protect the printhead. This error message will not affect printing.

Load media correctly.

Install proper media type, or reset printer for current media type and perform calibration.

Call a service technician.

The printhead is over temperature. Allow the printer to cool. Printing

automatically resumes when the printhead elements cool to an acceptable operating temperature.

10/21/05 S4M User Guide 13290L-001 Rev. A

Troubleshooting

LCD Error Messages

Table 14 • LCD Error Messages (Continued)

LCD Display/ Printer Condition

WARNING

HEAD COLD

The printer stops and the ALERT light flashes.

Possible Cause Recommended Solution

Caution • An improperly connected printhead data or power cable

can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool.

Caution • Observe proper electrostatic safety precautions when

handling any static-sensitive components such as circuit boards and printheads.

The printhead is under temperature.

Continue printing while the printhead reaches the correct operating temperature. If the error remains, the environment may be too cold for proper printing. Relocate the printer to a warmer area.

The printhead data cable is not properly connected.

Caution • Turn off (O) the

printer before performing this procedure. Failure to do so can damage the printhead.

1. Turn Off (O) the printer.

2. Disconnect and reconnect the data cable to the printhead.

3. Ensure that the cable connector is fully inserted into the printhead connector.

4. Turn on (

I) the printer.

HEAD ELE. BAD

The printer stops.

The print head is not installed.

The printhead data cable is not connected.

The printhead is bad.

Caution • The printhead may be hot enough to cause severe

burns. Allow the printhead to cool.

Caution • Observe proper electrostatic safety precautions when

handling any static-sensitive components such as circuit boards and printheads.

Caution • Turn off (O) the

printer before performing this procedure. Failure to do so can damage the printhead.

1. Turn Off (O) the printer.

2. Disconnect and reconnect the data cable to the printhead.

3. Ensure that the cable connector is fully inserted into the printhead connector.

4. Turn on (

I) the printer.

5. If the problem persists, replace the printhead.

13290L-001 Rev. A S4M User Guide 10/21/05

Memory Errors

The memory errors in Table 15 indicate that the printer does not have enough memory to perform the function shown on the second line of the LCD.

Table 15 • Memory Errors

Problem/LCD Display Possible Cause Recommended Solution

Troubleshooting

Memory Errors

OUT OF MEMORY

CREATING BITMAP

OUT OF MEMORY

STORING BITMAP

OUT OF MEMORY

BUILDING FORMAT

OUT OF MEMORY

STORING FORMAT

OUT OF MEMORY

STORING GRAPHIC

OUT OF MEMORY

STORING FONT

Creating Bitmap

The bitmap size (label length/width) does not fit in available memory.

Storing Bitmap

Not enough memory is available to store the bitmap created.

Building Format

Label is too complex.

Storing Format

Format is too large to fit in available memory.

Storing Graphic

The graphic image is too large to fit in available memory.

Storing Font

Not enough memory available to store the font.

You may do any of the following:

• Press PAUSE. Send a ~HM ZPL command to the printer to display the amount of free memory. Then redesign the graphic/format to fit available memory, or remove items from memory to create more space.

• Press

• Turn the printer Off (O) and then On (

PAUSE to skip the formatting step

in process and proceed to the next step. With the printer paused, press The printer skips the current label formatting process and goes to the next label.

to clear the printer’s memory.

CANCEL.

10/21/05 S4M User Guide 13290L-001 Rev. A

Troubleshooting

Print Quality Problems

Table 16 identifies problems with print quality, the possible causes, and the recommended

solutions.

Table 16 • Print Quality Problems

Problem Possible Cause Recommended Solution

General print quality issues

The printer is set at the incorrect print speed.

For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software. See

Adjust Print Speed on page 63. You may wish to

perform the FEED Self Test on page 100.

You are using an incorrect combination of labels and

Consult your authorized Zebra reseller or distributor for information and advice.

ribbon for your application.

The printer is set at an incorrect darkness level.

For optimal print quality, set the darkness to the lowest possible setting for your application via the control panel, the driver, or the software. See

Adjust Print Darkness on page 60. You may wish

to perform the FEED Self Test on page 100 to determine the ideal darkness setting.

The printhead is dirty. Clean the printhead according to the instructions

in Clean the Printhead and Platen Roller

on page 79.

Caution • The printhead may be hot

enough to cause severe burns. Allow the printhead to cool.

Caution • Observe proper electrostatic

safety precautions when handling any static-sensitive components such as circuit boards and printheads.

13290L-001 Rev. A S4M User Guide 10/21/05

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Troubleshooting

Print Quality Problems

Wrinkled ribbon Ribbon fed through the

machine incorrectly.

Incorrect burn temperature. Set the darkness to the lowest possible setting for

Incorrect or uneven pressure. Set the pressure to the minimum needed for good

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

The strip plate needs adjusting. Call a service technician.

The printhead needs vertical adjustment.

The printhead and platen roller need to be realigned.

Long tracks of

Print element damaged. Call a service technician.

missing print on several labels

Wrinkled ribbon. See wrinkled ribbon causes and solutions in this

See Load Ribbon on page 41.

good print quality. See Adjust Print Darkness

on page 60.

print quality.

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

Call a service technician.

table.

Fine, angular gray lines on blank labels

Printing too light or too dark over the entire label

Smudge marks on labels

Misregistration/skips labels

Misregistration and misprint of one to three labels

Wrinkled ribbon. See wrinkled ribbon causes and solutions in this

table.

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

Incorrect or uneven printhead pressure.

Media or ribbon not designed for high-speed operation.

Media sensor not positioned

Replace supplies with those recommended for high-speed operation.

Set the pressure to the minimum needed. See

Adjust Printhead Pressure on page 49.

Replace supplies with those recommended for high-speed operation.

Perform media sensor position adjustment.

correctly.

The printer is not calibrated. Recalibrate the printer.

Improper label format. Use correct label format.

Media sensor is not positioned

Place media sensor in proper position.

correctly.

The platen roller is dirty. See Clean the Printhead and Platen Roller

on page 79.

Media does not meet

Use media that meets specifications.

specifications.

10/21/05 S4M User Guide 13290L-001 Rev. A

Troubleshooting

Print Quality Problems

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Vertical drift in top-of-form position

Vertical image or label drift

A plus or minus 4 to 6 dot row (approximately 0.5 mm) vertical drift is acceptable due

1. Calibrate the printer.

2. Adjust the label top position setting. See

Adjust Label Top Position on page 61.

to different tolerances of mechanical parts and printer modes.

The printer is out of calibration. Recalibrate the printer.

The platen roller is dirty. See Clean the Printhead and Platen Roller

on page 79.

The printer is using noncontinuous labels but is

Configure the printer for non-continuous and run calibration routine, if necessary.

configured in continuous mode.

Incorrectly positioned media sensor.

Improperly calibrated media sensor.

Ensure the media sensor is properly positioned to read a single/consistent interlabel gap.

See Calibrate Media and Ribbon Sensors

on page 72.

The platen roller is dirty. Clean the platen roller. See Clean the Printhead

and Platen Roller on page 79.

Improper printhead pressure settings (toggles).

Adjust the printhead pressure to ensure proper functionality.

The bar code printed on a label does not scan.

Improperly loaded ribbon or

Verify that the printer is loaded properly.

media.

Incompatible media. Ensure that the interlabel gaps or notches are 2 to

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

The bar code is not within specifications because the print

Perform the FEED Self Test on page 100. Adjust the darkness or print speed settings as necessary.

is too light or too dark.

Not enough blank space around the bar code.

Leave at least 1/8 in. (3.2 mm) between the bar code and other printed areas on the label and between the bar code and the edge of the label.

13290L-001 Rev. A S4M User Guide 10/21/05

Calibration Problems

Table 17 identifies problems with calibration, the possible causes, and the recommended

solutions.

Table 17 • Calibration Problems and Solutions

Problem Recommended Solution

Troubleshooting

Calibration Problems

Loss of printing registration on labels.Excessive vertical drift in top-of-form registration.

Auto Calibrate failed. Ensure that media and ribbon are loaded correctly.

Ensure that the media guides are properly positioned.

Set the printer for the correct media type (non-continuous or continuous). See Set Media Type on page 62 .

Clean the platen roller according to the instructions in Clean

the Printhead and Platen Roller on page 79.

Ensure that the sensors are clean and properly positioned.

10/21/05 S4M User Guide 13290L-001 Rev. A

Troubleshooting

Communications Problems

Table 18 identifies problems with communications, the possible causes, and the recommended

solutions.

Table 18 • Communications Problems

Problem Possible Cause Recommended Solution

A label format was sent to the printer but was not recognized.

A label format was sent to the printer. Several labels print, then the printer skips, misplaces, misses, or distorts the image on the label.

A label format was sent to the printer but was not recognized. No printing occurs.

The communication parameters are incorrect.

The serial communication settings are incorrect.

The prefix and delimiter characters set in the printer do not match the ones in the label format.

Incorrect data is being sent to the printer.

Check the printer driver or software communications settings (if applicable).

Make sure you are using the correct communication cable. See Data Cable

Requirements on page 24 for the requirements.

If a driver is used, check the driver communication settings for your connection.

Ensure that the flow control settings match.

Check the communication cable length. See

Data Cable Requirements on page 24 for

requirements.

Check the printer driver or software communications settings (if applicable).

Verify the prefix and delimiter characters. See

Set Command Character on page 68 and Set Delimiter Character on page 68 for the

requirements.

Ensure that the label format being used matches the operating language of the printer. See Printer Language Modes on page 14.

Check the communication settings on the computer. Ensure that they match the printer settings.

If the problem continues, check the label format.

13290L-001 Rev. A S4M User Guide 10/21/05

Zebra S4M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

About This Document

Who Should Use This Document

How This Document Is Organized

Contacts

Web Site

The Americas

Europe, Africa, Middle East, and India

Asia Pacific

Document Conventions

Introduction

External View

Control Panel

Control Panel LCD

Control Panel Buttons

Control Panel Lights

Printer Media Compartment

Printer Language Modes

Firmware Downloads

New or Modified Commands

Additional Printer Language Information

Printer Setup

Before You Begin

Unpack and Inspect the Printer

Inspect the Printer

Report Shipping Damage

Store the Printer

Shipping

Select a Site for the Printer

Select a Surface

Provide Proper Operating Conditions

Allow Proper Space

Provide a Data Source

Provide a Power Source

Connect the Printer to a Power Source

Power Cord Specifications

Select a Communication Interface

Connector Locations

Types of Connections

Data Cable Requirements

Types of Media

Ribbon Overview

When to Use Ribbon

Coated Side of Ribbon

Operations

Media Loading Overview

Print Modes

Starting a Roll of Media

Inserting Media into the Printer

Load Media in Tear-Off Mode

Load Media in Peel-Off Mode

Load Ribbon

Remove the Ribbon

Calibrate the Printer

Auto Calibration

Manual Calibration

Position the Media Sensors

Select the Transmissive Sensor

Adjust the Reflective Sensor

Adjust Printhead Pressure

Configuration

Setup Mode

Enter Setup Mode

Leave Setup Mode

Password Protection of Parameters

Printing Configuration Labels

Select a Display Language

Control Panel LCD Display

Password Level 1 and 2 Parameters

Password Level 3 Parameters

Routine Maintenance

Lubrication

Cleaning Procedures

Clean the Exterior

Clean the Printhead and Platen Roller

Clean the Media Compartment and Sensors