Zebra Technologies DA402 User Manual

DA402

Stripe Series Direct Thermal Printer

®

User s

'

Guide

Customer order # 52005L

Manufacturer part # 52005LB

Rev. 2

Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and
use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used,
reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra
Technologies Corporation.

Product Improvements

Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are subject
to change without notice.

FCC Compliance Statement

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15
of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee
that the interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:

n

Reorient or relocate the receiving antenna.

n

Increase the separation between the equipment and the receiver.

n

Connect the equipment into an outlet on a circuit different than that to which the receiver is connected.

n

Consult the dealer or an experienced Radio/TV technician for help.

NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the unit to
insure compliance.

“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could
void the user’s authority to operate the equipment.”

Canadian DOC Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio
interference regulations of the Canadian Department of Communications.

Liability Disclaimer

Zebra Technologies Corporation takes steps to assure that its published Engineering specifications and Manuals are correct;
however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability
resulting therefrom.

No Liability for Consequential Damage

In no event shall Zebra Technologies Corporation or anyone else involved in the creation, production, or delivery of the
accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation,
damages for loss of business profits, business interruption, loss of business information, or other pecuniary loss) arising out of
the use of or the results of use of or inability to use such product, even if Zebra Technologies Corporation has been advised of
the possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or
incidental damages, the above limitation may not apply to you.

Copyrights

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

All products and brand names are trademarks of their respective companies. All rights reserved.
© 1999 Zebra Technologies Corporation

I have determined that the Zebra printers identified as the

Stripe Series

DA T

Zebra Technologies Corporation

333 Corporate Woods Parkway

Vernon Hills, Illinois 60061-3109 U.S.A.

have been shown to comply with the applicable technical standards of the FCC

®

402 and 402

manufactured by:

for Home, Office, Commercial, and Industrial use

if no unauthorized change is made in the equipment,

and if the equipment is properly maintained and operated.

Contents

Introduction

Hello! ..................................1

What’s in the Box ............................1

Unpacking and Inspection ........................2

Reporting Damage ..........................2

DC Power Supply ............................3

Printer Overview (illustration) .....................4

GettingReadytoPrint

LoadingtheMedia............................5

Tear-OffMode............................5

Peel-OffMode............................9

CutterMode.............................14

FanfoldMedia...........................17

AutoCalibration............................18

OperatorControls...........................19

PowerSwitch............................19

FeedButton.............................19

StatusLED.............................19

PrintingaTestLabel..........................20

HookingUpthePrinterandComputer.................20

Serial(RS-232)InterfaceRequirements..............20

ParallelInterfaceRequirements..................21

SerialandParallelCablingRequirements.............21

CommunicatingwiththePrinter....................22

ViatheSerialPort.........................22

ViatheParallelPort.........................22

UsingZPLII..............................23

AdjustingthePrintWidth.......................23

AdjustingthePrintDarkness......................23

AdjustingthePrintSpeed.......................23

i

Troubleshooting

WhattheStatusLEDisTellingYou..................25

PrintQualityProblems.........................26

ManualCalibration...........................28

TroubleshootingTests.........................29

PrintingaConfigurationLabel...................29

Recalibration............................29

ResettingtheFactoryDefaultValues................30

CommunicationsDiagnostics....................30

FeedButtonModes...........................31

Maintenance

Cleaning................................33

Lubrication...............................33

PartsList................................35

ReplacingthePrinthead........................36

RemovingthePrinthead......................36

InstallingthePrinthead.......................38

Specifications

Printing.................................41

Label/Tag................................42

Font/BarCode.............................43

Physical/Environmental/Electrical...................43

AgencyApprovals...........................44

Options.................................44

Serial(RS-232)ConnectorTechnicalInformation..........45

InterconnectingtoDTEDevices..................45

InterconnectingtoDCEDevices..................45

ParallelInterfaceTechnicalInformation................48

Index

ii

Introduction

Hello!

Thank you for choosing the ZebraDA402Printer. This rugged little
printer is certain to become a productive and efficient addition to your
workplace!

n

This user’s guide provides the information you will need to operate and
maintain the printer.

n

To create and print label formats, take a look at the ZPL II Programming
Guide. If one was not ordered with your printer, simply call your

distributororvisitourwebsiteatwww.zebra.com.

NOTE: Many printer settings may also be controlled by your
printer’s driver or label preparation software. Refer to the driver
or software documentation for more information.

What’s in the Box

Printer

Power

Supply

Quick

Product

Support Services

Brochure

Reference

Guide

User’s

Guide

CD-Rom

Registration

Card

Sample

Roll of Media

Test

Label

1

Unpacking and Inspection

Inspect the printer for possible shipping damage:

n

Check all exterior surfaces for damage.

n

Raisethetopcover(referto“LoadingtheMedia”onpage5)andinspect
the media compartment for damage.

In case shipping is required, save the carton and all packing material.

Reporting Damage

If you discover shipping damage:

n

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

Zebra Technologies Corporation is not responsible for any damage
incurred during shipment of the printer and will not cover the repair of
this damage under its warranty policy.

n

Keep the carton and all packing material for inspection.

n

Notify your authorized reseller.

2

WARNING: NEVER OPERATE THE PRINTER AND POWER
SUPPLY IN AN AREA WHERE THEY CAN GET WET.
SERIOUS PERSONAL INJURY COULD RESULT!

DC Power Supply

Refer to Figure 1.

1. The DC power supply has a barrel connector on one end that must be
inserted into the power supply receptacle on the back of the printer.

2. Insert the separate AC power cord into the power supply.

3. Plug the other end of the cord into an appropriate AC electrical outlet.

Plug

Varies by

Country

Power

Switch

Power

Supply

Receptacle

Barrel

Connector

Figure 1

AC

Power

Cord

Power

Supply

3

Printer Overview

Tear Bar

Printhead

Release

Lever

Feed

Button

Status

LED

Release

Lever

Lock-down Screw

Media Guide Adjuster

4

Media

Hangers

Peel-Off Option

Platen Roller

Media Guides

Cutter Option

Peel

Bar

Peel Roller Cutter Unit

Figure 2

Getting Ready to Print

Loading the Media

You can operate this printer in three different modes: tear-off, peel-off, or
with a cutter.

n

Tear-off mode allows you to tear off each label (or a strip of labels) after
it is printed.

n

In peel-off mode, the backing material is peeled away from the label as it
is printed. After this label is removed, the next one is printed.

n

In cutter mode, the printer automatically cuts the label after it is printed.

Tear-Off Mode

1. Unlatch the top cover by pulling the two green release levers toward
you (refer to Figure 3). Then, lift the top cover to expose the media
compartment.

Release

Lever

Release

Lever

Figure 3

5

2. Separate and hold open the media hangers (refer to Figure 4).

3. Place the media roll onto the media hangers, ensuring that it is tightly
wound(refertoFigure5).

NOTE:RefertoFigure6.Ifyouareusinglabels,makesurethe
media unwinds from the top of the roll. Tags unwind from the
bottom of the roll.

Media

Hanger

Media

Hanger

Figure 4

6

Labels

Figure 5

Tags

Figure 6

7

4. Refer to Figure 7. Thread the media through the media guides.

NOTE: If the media guides must be changed to accommodate the
width of the media, turn the green media guide adjuster (refer to
Figure 7). The media guides should just touch, but not restrict, the
edges of the media.

5. Close the top cover and turn on the printer or press the feed button if
theprinterisalreadyon(see“AutoCalibration”onpage18formore
information).

Media

Guides

Media Guide Adjuster

Figure 7

8

Wide Media

Narrow Media

Peel-Off Mode (optional)

1. Unlatch the top cover by pulling the two green release levers toward

you (refer to Figure 8). Then, lift the top cover to expose the media
compartment.

Release

Lever

Release

Lever

Figure 8

9

2. Separate and hold open the media hangers (refer to Figure 9).

3. Place the media roll onto the media hangers, making sure it is tightly
wound(refertoFigure10).

4. Open the peel-off unit by pulling down on its textured top surface (refer
toFigure11).

5. Activate the peel-off unit by moving the peel-off switch to the left
(refertoFigure11inset).

NOTE: When not operating the printer in peel-off mode, always
deactivate the peel-off unit by moving the peel-off switch to the
right.

6. Remove approximately 6” (152 mm) of labels from the label backing.

10

Media

Hanger

Media

Hanger

Figure 9

Figure 10

Figure 11

Peel-off Switch

ON OFF

11

7. Refer to Figure 12. Thread the label backing through the media guides
and over the peel bar.

NOTE: If the media guides must be changed to accommodate the
width of the media, turn the green media guide adjuster (refer to
Figure 12). The media guides should just touch, but not restrict,
the edges of the media.

12

Media

Guides

Peel Bar

Media Guide Adjuster

Wide Media

Narrow Media

Figure 12

8. Thread the label backing between the black platen roller and white peel

roller until it comes out of the slot beneath the peel-off unit (refer to
Figure 13).

9. Close the peel-off unit by pushing in on its smooth side surface.

10. To remove any slack, rewind media onto the roll.

11. Close the top cover and turn on the printer or press the feed button if

theprinterisalreadyon(see“AutoCalibration”onpage18formore
information).

Slot

Platen
Roller

Peel Bar

Peel

Roller

Figure 13

13

Cutter Mode (optional)

NOTE: The cutter is designed to cut through paper labels or the
backing between labels, not the adhesive backing of the label.
Adhesive build-up on the cutter blade may cause thecutter to jam.

1. Unlatch the top cover by pulling the two green release levers toward
you (refer to Figure 14). Then, lift the top cover to expose the media
compartment.

2.Separateandholdopenthemediahangers(refertoFigure15).

3. Place the media roll onto the media hangers, ensuring that it is tightly
wound(refertoFigure16).

Release

Lever

14

Release

Lever

Figure 14

Media

Hanger

Media

Hanger

Figure 15

Figure 16

15

4. Refer to Figure 17. Thread the media through the media guides.

NOTE: If the media guides must be changed to accommodate the
width of the media, turn the green media guide adjuster (refer to
Figure 17). The media guides should just touch, but not restrict,
the edges of the media.

5. Refer to Figure 17. Thread the media through the cutter unit.

6. Close the top cover and turn on the printer or press the feed button if
theprinterisalreadyon(see“AutoCalibration”onpage18formore
information).

16

Media

Guides

Wide Media

Narrow Media

Media Guide Adjuster

Figure 17

Fanfold Media

Fanfold media loads from the outside of the printer. Refer to Figure 18.

1. Thread the media through the access slot in the back of the printer.

2. Separate and hold open the media hangers.

3. Lock the media hangers in position by tightening the screw located on

the right media hanger.

CAUTION: Do not overtighten the screw! Overtightening
could pierce the case and damage the printer’s electronics!

4. Thread the media through the media guides.

NOTE: If the media guides must be changed to accommodate the
width of the media, turn the green media guide adjuster. Media
guides should just touch, but not restrict, the edges of the media.

5. Close the top cover and turn on the printer or press the feed button if

theprinterisalreadyon(see“AutoCalibration”onpage18formore
information).

Media

Hangers

Access

Slot

Lock-down

Screw

Media
Guide

Adjuster

Media

Guides

Figure 18

17

Auto Calibration

NOTE: If you are using pre-printed labels, pre-printed label
backing,orcontinuousmedia,see“ManualCalibration”on
page 28.

Anautocalibrationisperformedwhentheprinteristurnedon(ifmediais
loaded) or after a media error is cleared. When it is auto calibrating, the
printer sets the sensor levels for, and determines the length of, the label you
are using.

IfthestatusLEDflashesred,referto“ManualCalibration”onpage28.

18

Operator Controls

Refer to Figure 19.

Power Switch

n

Press to turn on and turn off the printer.

CAUTION: The power should be turned off before connecting
or disconnecting the communications and power cables.

Feed Button

n

Forces the printer to feed one blank label.

n

Takes the printer out of a “pause” condition. (The printer is put into
“pause”byeitheraZPLIIcommandoranerrorcondition.)See“What

theStatusLEDisTellingYou”onpage25.

n

Usedforprintersetupandstatus(see“FeedButtonModes”onpage31).

Status LED

n

Functionsasaprinteroperationalindicator(see“WhattheStatusLEDis

TellingYou”onpage25).

Feed

Button

Status

LED

Figure 19

Power

Switch

19

Printing a Test Label

Before you connect the printer to your computer, make sure that the printer
is in proper working order. You can do this by printing a configuration
label:

1. Make sure the media is properly loaded and the top cover of the printer
is closed. Then, turn the printer power on if you have not already done
so.

2. When the status LED is solid green, press and hold the feed button until
the status LED flashes once.

3. Release the feed button. A configuration label will print.

Ifyoucannotgetthislabeltoprint,refertoTroubleshooting.

Hooking Up the Printer and Computer

CAUTION: The power supply barrel connector must be
inserted into the power supply receptacle on the back of the
printer before connecting or disconnecting the
communicationscables.(Ifnecessary,refertoFigure1.)

This printer comes with both a nine-pin Electronics Industries Association
(EIA) RS-232 serial data interface and an IEEE 1284-compliant
bidirectional parallel data interface. In either case, you must supply the
required interface cable for your application.

CAUTION: This printer complies with FCC “Rules and
Regulations,” Part 15, for Class B Equipment, using fully
shielded six-foot data cables. Use of longer cables or
unshielded cables may increase radiated emissions above the
Class B limits.

Serial (RS-232) Interface Requirements

The required cable must have a nine-pin “D” type (DB-9P) male connector
on one end, which is plugged into the mating (DB-9S) serial port located on
the back of the printer (refer to Figure 20). The other end of this signal
interface cable connects to a serial port at the host computer. Depending on
the specific interface requirements, this will most likely be a null modem
cable.

Fortechnicalandpinoutinformation,refertopage45.

20

ParallelInterfaceRequirements

Therequiredcable(IEEE1284-compliantisrecommended)musthavea
standard36-pinparallelconnectorononeend,whichispluggedintothe
parallelportlocatedonthebackoftheprinter(refertoFigure20).The
otherendoftheparallelinterfacecableconnectstotheprinterconnectorat
thehostcomputer.

Forpinoutinformation,refertopage48.

SerialandParallelCablingRequirements

Datacablesmustbeoffullyshieldedconstructionandfittedwithmetalor
metalizedconnectorshells.Shieldedcablesandconnectorsarerequiredto
preventradiationandreceptionofelectricalnoise.

Tominimizeelectricalnoisepickupinthecable:

n

Keepdatacablesasshortaspossible(6’[1.83m]recommended).

n

Donottightlybundlethedatacableswithpowercords.

n

Donottiethedatacablestopowerwireconduits.

Parallel

Port

Figure20

Serial

Port

Connectsto

SerialPorton

HostComputer

Connectsto

ParallelPorton

HostComputer

21

Communicating with the Printer

Via the Serial Port

Serial communications between the printer and the host computer can be set
by either autobaud synchronization or the ^SC command.

Autobaud

Autobaud synchronization allows the printer to automatically match the
communication parameters of the host computer. To autobaud:

1. Press and hold the feed button until the green status LED flashes once,
twice, and then three times.

2. While the status LED flashes, send a ZPL II format to the printer.

3. When the printer and host are synchronized, the LED changes to solid
green. (No labels will print during autobaud synchronization.)

^SC Command

Use the Set Communications (^SC) command to change the
communications settings on the printer.

1. With the host computer set at the same communications settings as the
printer, send the ^SC command to change the printer to the desired
settings.

2. Change the host computer settings to match the new printer settings.

Refer to the ZPL II Programming Guide for more information about this
command.

Setting the Communications Parameters

To reset the communications parameters on the printer to the factory
defaults (9600 baud, 8 bit word length, no parity, 1 stop bit, and
XON/XOFF), do the following:

1. Press and hold the feed button until the green status LED flashes once,
twice, and then three times.

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

Via the Parallel Port

Typically, no setup is required once the cable is plugged in. If you should
encounter any problems, consult the user’s guide that came with your
computer.

22

Using ZPL II

For detailed information about creating labels using ZPL II, refer to the
ZPLIIProgrammingGuideorvisitourwebsiteatwww.zebra.com.

Adjusting the Print Width

Print width must be calibrated when:

n

You are using the printer for the first time.

n

There is a change in the width of the media.

Printwidthmaybesetbywayofthefive-flashsequencein“FeedButton

Modes”(seepage31)orrefertothePrintWidth(^PW)command(consult

your ZPL II Programming Guide).

Adjusting the Print Darkness

The relative darkness setting is controlled by either the six-flash sequence in

“FeedButtonModes”(seepage31)ortheSetDarkness(~SD)ZPLII

command (follow the instructions in the ZPL II Programming Guide).

Adjusting the Print Speed

Printqualityisaffectedbyprintspeedandthemediayouareusing.Only
by experimenting will you find the optimal mix for your application.

If you find that the print speed needs to be adjusted, refer to the Print Rate
(^PR) command in the ZPL II Programming Guide.

23

24

Troubleshooting

What the Status LED is Telling You

Status LED

Condition and Color

Off Off 1

Solid Green On 2

Flashing Yellow Stopped 3

Flashing Green Normal Operation 4

Flashing Red Stopped 5

Double Flashing Green Paused 6

Solid Yellow Various 7

Alternately Flashing Green and Red Needs Service 8

Printer
Status

For a Resolution,

Refer to:

RESOLUTIONS:

1. The printer is not receiving power.

n

Have you turned on the printer power?

n

Check power connections from the wall outlet to the power supply,
and from the power supply to the printer.

2. The printer is on and in an idle state.

3. The printer has failed its power on self test (POST).

n

If this error occurs right after you turn on the printer, contact an
authorized reseller for assistance.

There is a shortage of memory.

n

If this error occurs after you have been printing, turn the printer
power off and on. Then, resume printing.

4. The printer is receiving data.

n

As soon as all of the data has been received, the status LED will
turn green; then, the printer will automatically resume operation.

25

5. The media is out.

n

Loadarollofmedia,followingtheinstructionsin“Loadingthe

Media”onpage5.Then,pressthefeedbuttontoresumeprinting.

The printhead is open.

n

Close the top cover. Then, press the feed button to resume printing.

The cutter is jammed.

n

Turn off the printer and remove any jammed labels from the cutter
unit. Then, turn on the printer to resume printing.

6. The printer is paused.

n

Press the feed button to resume printing.

7. The printhead is under temperature.

n

Continue printing while the printhead reaches the correct operating
temperature.

The printhead is over temperature.

n

Printing will stop until the printhead cools to an acceptable printing
temperature. When it does, the printer will automatically resume
operation.

8. FLASH memory is not programmed.

n

Return the printer to an authorized reseller.

Print Quality Problems

No print on the label.

n

Make sure the correct media (direct thermal) is loaded. Try this:
Quickly rub your nail or a blunt object over the label surface. If it does
not produce dark marks, the wrong media (thermal transfer) is loaded.

n

Isthemedialoadedcorrectly?Followtheinstructionsin“Loadingthe

Media”onpage5.

The printed image does not look right.

n

Theprintheadisdirty.Cleantheprintheadaccordingtotheinstructions
on page 33.

n

The printhead is under temperature.

26

n

Adjust the print darkness and/or print speed. Refer to the six-flash
sequencein“FeedButtonModes”onpage31,orthe^PRand~SD
commands in the ZPL II Programming Guide.

n

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

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

n

Theprintheadisdirty.Cleantheprintheadaccordingtotheinstructions
on page 33.

n

The printhead elements are damaged. Replace the printhead (see

“ReplacingthePrinthead”onpage36).

The printing does not start at the top of the label, or
misprinting of one to three labels.

n

The media may not be threaded under the media guides. Refer to

“LoadingtheMedia”onpage5.

n

Theprinterneedstobecalibrated.Referto“AutoCalibration”on

page 18.

n

The correct media sensor may not be activated. Manual calibration
selects the media sensing method for the labels being used (refer to the
^MN command in the ZPL II Programming Guide).

n

Verify that the Label Top (^LT) command is correctly set for your
application (consult the ZPL II Programming Guide).

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

n

Is the printer in pause mode? If so, press the feed button.

n

IfthestatusLEDisonorflashing,referto“WhattheStatusLEDis

TellingYou”onpage25.

n

Make sure the data cable is correctly installed.

n

A communications problem has occurred. First, make sure that the
correct communications port on the computer is selected. Next, verify
that the same handshaking is in use by both the printer and the computer.
Then, ensure that the baud rates of the printer and the computer match.
Referto“CommunicatingwiththePrinter”onpage22.

27

Manual Calibration

Manual calibration is recommended whenever you are using pre-printed
labels (or label backing) or if the printer will not correctly auto calibrate.

1. Turn on the printer power.

2. Remove approximately 4” (102 mm) of labels from a section of
backing material. Load the media so that only the backing material is
threaded through the printer and under the printhead.

3. Press and hold the feed button until the green status LED flashes once,
then twice. Release the feed button.

4. The printer will set the media sensor for the label backing being used.
After it is done making this adjustment, the roll will automatically feed
until a label is positioned at the printhead.

5. A profile of the media sensor settings (similar to the example in
Figure 21) will print. Upon completion, the printer will save the new
settings in memory and the printer is ready for normal operation.

6. Press the feed button. One entire blank label will feed. If this does not
happen,trydefaulting(refertothefour-flashsequencein“FeedButton

Modes”onpage31)andrecalibratingtheprinter.

NOTE: Performing a manual calibration disables the auto
calibration function. To return to auto calibration, default the
printer(seethefour-flashsequencein“FeedButtonModes”on
page 31).

28

Figure 21

Troubleshooting Tests

Printing a Configuration Label

To print out a listing of the printer’s current configuration (an example is
showninFigure22),refertotheone-flashsequencein“FeedButton

Modes”onpage31.

Recalibration

Recalibrate the printer if it starts to display unusual symptoms, such as
skippinglabels.See“AutoCalibration”onpage18.

Figure 22

29

Resetting the Factory Default Values

Sometimes, resetting the printer to the factory defaults solves some of the
problems.Followthefour-flashsequenceinstructionsin“FeedButton

Modes”onpage31.

Communications Diagnostics

If there is a problem transferring data between the computer and printer, try
putting the printer in the communications diagnostics mode. The printer
will print the ASCII characters and their respective hexadecimal values (a
sample is shown in Figure 23) for any data received from the host
computer.Tofindouthow,refertothepoweroffmodeprocedurein“Feed

ButtonModes”onpage31.

30

Figure 23

Feed Button Modes

Power Off Mode (Communications Diagnostics Mode)

With the printer power off, press and hold the feed button while you turn on the
power.Theprinterprintsoutalistingofitscurrentconfiguration(seeFigure22).
After printing the label, the printer will automatically enter a diagnostic mode in
whichtheprinterprintsoutaliteralrepresentation(seeFigure23)ofalldata
subsequently received. To exit the diagnostic mode and resume printing, turn off
and then turn on the printer.

Power On Modes

With the printer power on and top cover closed, press and hold the feed button for
several seconds. The green status LED will flash a number of times in sequence.
The explanation at the right (Action) shows what happens when you release the key
after the specific number of flashes.

Flash

Sequence Action

* A configuration label prints.

*
**

*
**
***

*
**
***
****

*
**
***
****
*****

*
**
***
****
*****
******

If the feed button remains pressed after a 7-flash sequence, the printer will ignore
the button when it is released.

The media sensor calibrates and a media sensor profile prints (see

“ManualCalibration”onpage28).

To reset the communication parameters: Press and release the feed
button while the LED rapidly flashes yellow and green. The serial
communication parameters reset to 9600 baud, 8 bits per character,
no parity, 1 stop bit, and XON/XOFF.

For autobaud synchronization: Send a ZPL II format to the printer
while the LED rapidly flashes yellow and green. When the printer and
host are synchronized, the LED changes to solid green. NOTE: No

labels will print during autobaud synchronization.

Resets the factory defaults, auto calibrates, and saves settings into
memory.

The print width calibrates. While the status LED alternately flashes
green and yellow, a series of stacking rectangles print on the label.
When the rectangle prints to the outer edges of the label, press and
release the feed button. The label width and current communication
parameters will be saved into memory.

The print darkness calibrates. A series of nine samples print, starting
with the lightest and ending with the darkest image. When the desired
print darkness is achieved, press and release the feed button. The
print darkness will be saved into memory.

31

32

Maintenance

Cleaning

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

Ifnecessary,refertoFigure2forpartlocations.

Area Method Interval

After allowing the printhead to cool for approximately one
minute, use 70% isopropyl alcohol on a cotton swab to
clean the print elements from end to end (the print
elements are located in the thin gray line on the printhead).

NOTE: You do not have to turn off the printer to do this.

Printhead

Platen roller

Peel bar

Tear bar

Cutter

Exterior Water-dampened cloth

Interior Brush/air blow

If print quality has not improved after performing this
procedure, try cleaning the printhead with
Save-a-Printhead cleaning film. This specially coated
material removes contamination buildup without
damaging the printhead. Call your authorized reseller for
more information.

Manually rotate the platen roller. Clean it thoroughly with
70% isopropyl alcohol and a cotton swab or lint-free cloth.

Clean it thoroughly with 70% isopropyl alcohol and a
cotton swab.

Clean it thoroughly with 70% isopropyl alcohol and a
cotton swab.

Turn off the printer power. Use tweezers to remove the
media.

After
every five
rolls of
media

As
needed

As
needed

As
needed

As
needed

As
needed

Lubrication

CAUTION! No lubricating agents of any kind should be used
on this printer! Some commercially available lubricants, if
used, will damage the finish and the mechanical parts inside
the printer.

33

1

2

3

4

5

6

9

34

7

8

Figure 24

Parts List

RefertoFigure24.

Item

Number Description

Feed Switch Assembly (set of 3)

1

Printhead and Latch Assembly

2

Printhead Assembly

3

Media Sensor PCB Assembly (set of 3)

4

Platen Roller Kit, Standard (set of 3)

5

Platen Roller Kit, Linerless

Front Bezel, Standard (set of 10)

Front Bezel, Peel-Off (set of 5)

6

Peel-Off Sensor PCB Assembly (set of 3)

Base Housing (set of 3)

7

Rubber Foot Kit (set of 24)

8

Main Logic Board Kit, Maintenance

9

Stepper Motor, (set of two)

Power Supply Assembly (90-264 VAC, 47-63 Hz)

Power Cord, 110V (set of 5)

Power Cord, 230V European (set of 5)

Power Cord, 230V UK (set of 5)

Power Cord, 230V Australian (set of 5)

Not

shown:

Cutter

4M FLASH Memory Option Assembly

8M FLASH Memory Option Assembly

4M FLASH Memory w/Real Time Clock Option Assembly

8M FLASH Memory w/Real Time Clock Option Assembly

User’s Guide

Quick Reference Guide

Part

Number

105910-004

105910-003

105910-010

105910-011

105910-001

105910-002

105910-005

105910-012

105910-013

105910-006

105910-007

52050M

105910-009

105903-040

105950-014

105950-015

105950-030

105950-029

105910-028

52051

52052

52053

52054

52005L

52006L

35

Replacing the Printhead

Removing the Printhead

1. Turn printer power off and unplug the printer.

2. Refer to Figure 25. Remove the four screws that secure the printhead
and latch assembly to the top cover.

3.RefertoFigure26.Slidethetensionbarallthewaytotherightinits
mounting bracket (1). Then, while gently pressing on the opposite
mounting bracket (2), lift and remove the tension bar (3).

4.RefertoFigure27.Removebothprintheadwireharnessconnectors
from their receptacles.

5.RefertoFigure27.Removethetwoscrewsandwashersthatsecure
the printhead to the printhead bracket. Then, lift the lip on the front of
the printhead bracket to remove the printhead.

Printhead and Latch Assembly

Top Cover

36

Screws (4)

Figure 25

Tension Bar

Tension Bar

Mounting

Bracket

2

Screw

and

Washer

Connector

3

Tension Bar

Mounting

Bracket

1

Figure 26

Screw

and

Washer

Connector

Receptacle

(shown hidden)

Printhead

Bracket Lip

Receptacle

(shown hidden)

Printhead

Figure 27

37

Installing the Printhead

1. Ensure that the printer is turned off and unplugged.

2. Refer to Figure 28. Route the two printhead wire harness connectors as
shown. Then, insert the connectors into their receptacles.

3. Insert the printhead into the printhead bracket.

4.RefertoFigure29.Reinstallthetwoscrewsandwashersthatsecure
the printhead to the printhead bracket.

NOTE: The green grounding cable, which attaches to the feed
switch assembly PC board, must also be secured by one of the
screws.

5.RefertoFigure30.Insertoneendofthetensionbarintoitsmounting
bracket (1). Then, gently push down on the opposite end of the tension
bar until it locks into place (2).

NOTE: Make sure the “V” of the tension bar fits into the notch in
the printhead bracket.

6. Insure that all cables are properly dressed between the printhead and
latch assembly and the top cover.

7. Reinstall the four screws that secure the printhead and latch assembly
to the top cover. Then, plug in the printer and turn on the power.

Connector

Receptacle

(shown hidden)

38

Connector

Receptacle

(shown hidden)

Printhead

Figure 28

Screw

and

Washer

Green

Grounding

Cable

Screw

and

Washer

Printhead

Printhead

Bracket

Figure 29

Tension Bar

2

Printhead

Bracket

Notch

1

“V” of Tension Bar

Figure 30

39

40

Specifications

NOTE: Printer specifications are subject to change without
notice.

Printing Specifications

Print Density 203 dots/inch (8 dots/mm)

Print Speed 1.5” (38 mm), 2” (51 mm), and 2.5” (64 mm) per second

Print Width

Print Length .005” to 22” (.125 mm to 559 mm) with standard memory

Registration
Tolerance

FLASH Memory
(User Available)

DRAM Memory
(User Available)

1” to 4.09” (25.4 mm to 104 mm)
1” to 2.25” (25.4 mm to 57 mm) for tag stock

Horizontal: +/- 0.0591” (1.5 mm)
Vertical: +/- 0.0393” (1 mm)

1MB

1MB

41

Label/Tag Specifications

Label/Tag Width

Label/Tag Length 0.5” to 22” (13 mm to 559 mm) with standard memory

Interlabel Gap

Label/Tag Thickness

Label
Roll
Size

Media
Requirements

Max. Outer
Diameter

Inner Core

1” to 4.25” (25.4 mm to 108 mm)
1” to 2.25” (25.4 mm to 57 mm) for tag stock

0.08” to 0.16” (2 mm to 4 mm)

0.118” (3 mm) recommended

.003” to .007” (.08 mm to .18 mm)
.003” to .0053” (.08 mm to .135 mm) for cutter option

5” (127 mm)

1” (25.4 mm) or 1.5” (38 mm)

Use Zebra-brand direct thermal media that is outside

ü

wound. Media may be reflective (black mark) sensing
or transmissive sensing, die-cut, notched, or
continuous.

ü For die-cut labels, use only full auto dies.

ü Notched media must have a 0.5” (13 mm) wide x

0.094” (2.4 mm) long cutout located in the center of the
roll. The reflective media black marks must be located
in the center of the roll.

Minimum Black Mark Dimensions:

ü

Mark width: 0.5” (13 mm) centered and perpendicular
to the edge of the media.

ü

Mark length: 0.094” (2.4 mm) parallel to the bottom
edge of the media.

42

Font/Bar Code Specifications

CG Triumvirate Bold Condensed scalable smooth (0)

ü

Zebra fonts A-H, GS, P-V

Fonts Available

Bar Codes
Available (1D)

Bar Codes
Available (2D)

Rotation Angles 0°,90°, 180°, and 270°

ü

IBM Code Page 850 International Symbols

ü

Codabar (supports ratios

ü

of 2:1 to 3:1)

Code 11

ü

Code 128/USD 8 (supports

ü

serialization in all subsets
and UCC Case Codes)

Code 39 (supports ratios

ü

of 2:1 to 3:1)

Code 93

ü

EAN 8/JAN 8

ü

EAN 13/JAN 13

ü

EAN 14/UPC-A

ü

ü Codablock

ü Code 49

ü Data Matrix

ü MaxiCode

Industrial 2 of 5

ü

Standard 2 of 5

ü

Interleaved 2 of 5

ü

(supports ratios of 2:1 to
3:1, Modulus 10 Check
Digit)

LOGMARS

ü

MSI

ü

Plessey

ü

POSTNET

ü

UPC-E

ü

ü UPC/EAN Extensions

ü MicroPDF417

ü PDF 417

ü QRcode

Physical/Environmental/Electrical
Specifications

Physical Size (LxWxH) 8.5” x 7.6” x 6.6” 216 mm x 193 mm x 167 mm

Weight

Temperature
Range

Relative
Humidity

Electrical

Printer

Shipping

Operating

Storage

Operating

Storage

3 lbs. 1.4 kg.

9 lbs. 4.1 kg.

40° to 105° F5°to 41° C

-40° to 140° F -40° to 60°C

10% to 90% (non-condensing)

5% to 95% (non-condensing)

External 90-264 VAC, 47-63 Hz universal power
supply. Regional line cords are available.

43

Agency Approvals

n

UL 544 Medical Equipment Standard Part 42.5

n

CSA 22.2 No. 950-95 Canadian Safety Standard

n

IEC 950/EN 60950 International Safety Standard

n

FCC Class B

n

UL 1950 Domestic Safety Standard, 3rd Ed.

n

Canadian DOC Class A

n

EN50082-1:1997 International Immunity Standard

n

EN55022 Class B European Electromagnetic Radiation Standard

n

EN61000-3-2, 3 Powerline Disturbance

n

AS/NZS 3548 Australia EMC

n

CE Compliant

n

EMC Taiwan

n

CB Scheme Documents

Options

n

Peel-off

n

Cutter

n

Linerless

n

4 MB FLASH memory

n

8 MB FLASH memory

n

Real time clock with 4 MB FLASH

n

Real time clock with 8 MB FLASH

n

Power rewinder, 110 VAC

n

Power rewinder, 230 VAC

For details, call your authorized reseller.

44

Serial (RS-232) Connector Technical
Information

Pin No. Description

1

2

3

4

5

6

7

8

9

Not used

RXD (receive data) input to the printer

TXD (transmit data) output from the printer

DTR (data terminal ready) output from the printer -- controls when
the host may send data

Chassis ground

DSR (data set ready) input to the printer

RTS (request to send) output from the printer -- always in the
ACTIVE condition when the printer is turned on

Not used

+5 V @ 0.75 A fused

NOTES: The maximum current available through the serial
and/or parallel port is not to exceed a total of 0.75 Amps.

When XON/XOFF handshaking is selected, data flow is controlled
by the ASCII control codes DC1 (XON) and DC3 (XOFF). The
DTR control lead will have no effect.

Interconnecting to DTE Devices

The printer is configured as data terminal equipment (DTE). To connect the
printer to other DTE devices (such as the serial port of a personal
computer), use an RS-232 null modem (crossover) cable.

Figure31showstherequiredcableconnections.

Interconnecting to DCE Devices

When the printer is connected via its RS-232 interface to data
communication equipment (DCE) such as a modem, a STANDARD
RS-232(straight-through)interfacecablemustbeused.Figure32shows
the connections required for this cable.

45

Connecting the Printer to a DTE Device

DB-25S

Connector

to DTE Device (PC)

TXD

2

RXD RXD

3

RTS

4

CTS

5

DSR

6

GND

7

DCD

8

DTR

20
22

DB-9S

Connector

to DTE Device (PC)

DCD

1
2
3
4
5
6

RTS

7

CTS

8
9

DB-9P

Connector

to Printer

DCD

1
2

TXD

3

DTR

4

GND

5

DSR

6

RTS

7

CTS

8
9

DB-9P

Connector

to Printer

DCD

1

RXDRXD

2

TXDTXD

3

DTRDTR

4

GNDGND

5

DSRDSR

6

RTS

7

CTS

8
9

46

Figure 31

Connecting the Printer to a DCE Device

DB-25S

Connector

to DCE Device

RXD

2

TXD

3

CTS

4

RTS

5

DTR

6

GND

7

DCD

8

DSR

20
22

DB-9S

Connector

to DCE Device

DCD

1

TXD

2

RXD

3

DSR

4
5

DTR

6

CTS

7

RTS

8
9

DB-9P

Connector

to Printer

DCD

1

RXD

2

TXD

3

DTR

4

GND

5

DSR

6

RTS

7

CTS

8
9

DB-9P

Connector

to Printer

DCD

1

RXD

2

TXD

3

DTR

4

GNDGND

5

DSR

6

RTS

7

CTS

8
9

Figure 32

47

Parallel Interface Technical Information

Pin No. Description

1

2-9

10

11

12

13

14

15

16 & 17

18

19-30

31

32

33 & 34

35

36

nStrobe/Host Clk

Data Bits 1-8

nACK/PtrClk

Busy/Per Busy

PError/ACK Data Req.

Select/Xflag

nAuto Fd/Host Busy

Not Used

Ground

+5 V @ 0.75 A Fused

Ground

nInit

nFault/nData Avail.

Not Used

+5V through 1.8 KΩ Resistor

nSelectin/1284 active

48

NOTE: The maximum current available through the serial and/or
parallel port is not to exceed a total of 0.75 Amps.

Index

A

Adjustments

Printdarkness........23

Printspeed.........23

Printwidth.........23

Agencyapprovals........44

Autocalibration.........18

Autobaud............22

C

Calibration

Auto.............18

Manual...........28

Cleaning

Cutter............33

Exterior...........33

Interior...........33

Peelbar...........33

Platenroller.........33

Printhead..........33

Tearbar...........33

Communicationsparameters,

setting............22

Communicationsdiagnostics..30

Configurationlabel.......29

Cuttermode...........14

D

Damage,shipping........2

Darkness,adjusting.......23

DCEdevices,

interconnecting........45

Defaultingtheprinter......30

DTEdevices,

interconnecting........45

F

Factorydefaults,

resetting..........30,31

Fanfoldmedia..........17

Feedbutton...........19

Feedbuttonmodes.......31

I

Inspection............2

L

Loading the media

Cuttermode.........14

Fanfold...........17

Peel-offmode.........9

Tear-offmode........5

Lubrication...........33

49

M

Maintenanceparts........35

Manualcalibration.......28

Medialoading

Cuttermode.........14

Fanfold...........17

Peel-offmode.........9

Tear-offmode........5

O

Operatorcontrols........19

Options.............44

P

Parallelconnectorpinouts...48

Partslist.............35

Peel-offmode..........9

Pinouts

Parallel...........48

Serial............45

Powerswitch..........19

Printdarkness,adjusting..23,31

Printspeed,adjusting......23

Printwidth,adjusting....23,31

Printhead,replacing.......36

S

Serialconnectorpinouts....45

Setcommunications(^SC)...22

Specifications

Font/barcode........43

Label/tag..........42

Physical/environmental/

electrical..........43

Printing...........41

StatusLED.........19,25

T

Tear-offmode..........5

Troubleshooting.........25

Troubleshootingtests......29

U

Unpacking............2

Z

ZPLII..............23

ZPLIIProgramming

Guide............1,23

R

Recalibratingtheprinter....29

Repairparts...........35

Replacingtheprinthead.....36

Reportingdamage,shipping...2
Resettingthefactory

defaults..........30,31

50