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PA400
PA400
PORTABLE PRINTERS
Users
Guide
'
Page 2
Manufacturer part
Customer order #52600L
#52600LB Rev. 1
User's
Guide
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Proprietary Statement
This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and
use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies
Corporation.
Product Improvements
Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are subject to
change without notice.
FCC Compliance Statement
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of
the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance
with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that the interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by
one or more of the following measures:
Reorient or relocate the receiving antenna.
•
Increase the separation between the equipment and the receiver.
•
Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
•
Consult the dealer or an experienced Radio/TV technician for help.
•
NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the unit to insure compliance.
“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could void
the user’s authority to operate the equipment.”
Canadian DOC Compliance Statement
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio
interference regulations of the Canadian Department of Communications.
Liability Disclaimer
Zebra Technologies Corporation takes steps to assure that its published Engineering Specifications and Manuals are correct;
however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability
resulting therefrom.
No Liability for Consequential Damage
In no event shall Zebra Technologies corporation or anyone else involved in the creation, production, or delivery of the accompanying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, damages for loss of business profits, business interruption, loss of business information, or other pecuniary loss) arising out of the
use of or the results of use of or inability to use such product, even if Zebra Technologies Corporation has been advised of the
possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.
Copyrights
This copyrighted manual and the label printer described herein are owned by Zebra Technologies Corporation. All rights are reserved. Unauthorized reproduction of this manual or the software in the label printer may result in imprisonment of up to one year
and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability.
All products and brand names are trademarks of their respective companies. All rights reserved.
© 1999 Zebra Technologies Corporation
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I have determined that the Zebra printers identified as the
Zebra Portable Line
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
®™
400 and 400
PA P T
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.
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Contents
Introduction
Hello!..................................1
Unpacking and Inspection ........................1
Reporting Damage ..........................1
Getting Ready to Print
Battery ..................................3
Installing the Battery .........................3
Charging the Battery .........................4
Loading the Media............................5
Tear-Off Mode ............................5
Peel-Off Mode ...........................10
Fanfold Media ...........................13
Loading the Ribbon ..........................16
Operator Controls ...........................18
Power Button ............................18
Feed Button .............................18
Indicator LEDs .............................19
Power LED .............................19
Error LED..............................19
Battery Charging LED .......................19
Printing a Test Label ..........................20
Connecting the Printer and Computer .................20
Communicating with the Printer ....................22
Setting the Communication Parameters ..............22
Setting Up the Software ........................22
Adjusting the Print Width .......................22
Adjusting the Print Darkness......................22
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Adjusting the Printhead Pressure....................23
Adjusting the Strap ...........................24
Hand/Shoulder Strap ........................24
Adjustable Shoulder Strap .....................26
Calibration
Auto Calibration ............................27
Manual Calibration...........................28
Preventive Maintenance
Cleaning ................................29
Lubrication ...............................30
Extending Battery Life .........................30
Battery Disposal ..........................31
Troubleshooting
Help! The LEDs are On/Off/Flashing! ................33
Print Quality Problems .........................35
Troubleshooting Tests .........................37
Printing a Configuration Label ...................37
Recalibration ............................37
Resetting the Factory Default Values................37
Communications Diagnostics....................37
Feed Button Modes .........................39
Specifications
Printing .................................41
Ribbon Cartridge ............................41
Label ..................................42
Memory/Communications .......................42
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Font/Bar Code .............................43
Physical/Environmental/Electrical ...................43
Agency Approvals ...........................44
Options .................................44
Adapter Cable Pinouts .........................45
RJ45 Connector Pin Identification ...................45
Null Modem Cable Pinouts ......................46
Index
iii
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iv
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Introduction
Hello!
Thank you for choosing our Zebra Portable Printer. Don’t let its size fool
you - this rugged little printer is sure to become a productive and efficient
addition to your workplace. And it’s no wonder, because it’s made by
Zebra Technologies Corporation - your number one source for bar code
printers, software, and supplies!
This user’s guide gives you all the information you’ll need to operate the
•
printer.
To create and print label formats, take a look at the ZPL II Programming
•
Guide (part #46530L) for information about Zebra’s label design
programming language, better known as “ZPL II.” If one was not
ordered with your printer, simply call your reseller or Zebra
TechnologiesCorporationorvisittheZebrawebsite.Ifyou’dliketo
use a different label preparation software, contact your reseller or Zebra
for advice and information.
• The PA400/PT400 Maintenance Manual (part #505142L) contains all
the information you’ll need to properly maintain the printer.
Unpacking and Inspection
Inspect the printer for possible shipping damage:
•
Check all exterior surfaces for damage.
•
Raise the media access door (refer to “Loading the Media” in Getting
Ready to Print) and inspect the media compartment for damage.
In case shipping is required, save the carton and all packing material.
Reporting Damage
If you discover shipping damage:
•
Immediately notify and file a damage report with the shipping company.
Zebra Technologies Corporation is not responsible for any damage
incurred during shipment of the printer and will not cover the repair of
this damage under its warranty policy.
•
Keep the carton and all packing material for inspection.
•
Notify your authorized Zebra reseller.
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15
1
2
3
14
13
Top Cover
1
2
Error LED
2
3
Power LED
3
4
Printhead Pressure Adjuster
4
5
Power Button
5
6
Feed Button
6
7
7
Ribbon Cartridge
Printhead
7
8
Platen Roller
8
9
Media Guides
9
10
Media Hangers
10
11
11
Media Access Door
12
12
Battery Compartment
13
13
Media Compartment
14
14
Strap
15
15
Communications Port
16
16
Battery Charging Receptacle
17
17
Battery Charging LED
18
18
Charging Station Connector
19
19
Peel Bar
20
20
6
8
9
10
11
5
12
4
7
16
17
18
19
Figure 1
2
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Getting Ready to Print
Battery
Installing the Battery
NOTE: Batteries are shipped uncharged.
1. Slide up the battery compartment door.
2. Insert the battery into the printer as shown in Figure 2, with the
silver-colored battery contacts facing up.
3. After the battery is completely inserted, slide down the battery
compartment door.
When the battery is first installed, the Power and Error LEDs will light for
approximately two seconds and then go off. If these lights do not go on, the
batteryisnotfullycharged(see“ChargingtheBattery”).
Battery
Compartment
Door
Silver-colored
Battery
Contacts
Battery
Figure 2
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Charging the Battery
Refer to Figure 3 (your battery charger may look slightly different than the
ones illustrated).
If you are using a 120 VAC battery charger:
1. With the battery installed in the printer, insert the connector of the
battery charger into the receptacle on the side of the printer.
2. Plug the battery charger into an appropriate 120 VAC electrical outlet.
3. The battery charging LED will briefly flash and then stay on. When
the battery is fully charged (approximately one hour for the standard
battery; two hours for the extended life battery), the light will go off.
4. You may either remove the battery charger from the printer or leave it
connected for a continuous maintenance charge.
If you are using a universal battery charger:
1. With the battery installed in the printer, insert the connector of the
battery charger into the receptacle on the side of the printer.
2. Make sure the supplied power cord is inserted in the battery charger.
3. Plug the other end of the cord into an appropriate AC electrical outlet.
Power
120 VAC
Charger
Universal
Charger
Figure 3
4
Cord Plug
Varies by
Country
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4. The battery charging LED will briefly flash and then stay on. When
the battery is fully charged (approximately one hour for the standard
battery; two hours for the extended life battery), the light will go off.
5. You may either remove the battery charger from the printer or leave it
connected for a continuous maintenance charge.
Loading the Media
You can operate this printer in one of two different modes: Tear-Off or
Peel-Off. Tear-Off mode allows you to tear off each label (or a strip of
labels) after it is printed. In Peel-Off mode, the backing material is peeled
away from the label as it is printed. After you remove this label, the next
one is printed.
Tear-Off Mode
NOTE: If ribbon is loaded (PT400 only), remove the ribbon
cartridge before loading the media.
1. Refer to Figure 4. Raise the media access door by lifting at the notch
until it unhooks from the top cover.
Top Cover
Media
Access
Door
Notch
Figure 4
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2. Refer to Figure 5. Swing the media access door open to expose the
media compartment.
3. Pivot the top cover to reveal the printhead.
4. Lift the printhead until you feel it “lock” into place. Be careful not to
force the printhead past this position!
WARNING: NEVER touch the thermal print elements on the
underside of the printhead. Under certain conditions, they
can be very hot! Also, dirt or moisture from your hands can
damage the printhead!
Media
Compartment
Printhead
Media
Guides
Media
Hangers
Figure 5
6
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5. Refer to Figures 5 and 6. Thread the media into the printer until it
extends approximately 1” (25.4 mm) past the printhead.
6. Separate and hold open the media hangers.
7. Place the media roll onto the media hangers, making sure it is tightly
wound.
8. Release the media hangers so the media locks into the correct position.
Make sure the media is threaded under both media guides.
Media
Guides
Media
Roll
1“ Past Printhead
Media
Hangers
Unwind this direction
Figure 6
7
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9. Refer to Figure 7. If it’s not already in place, install the tear bar in the
media access door. Gently lift the tab on the bar to move it over the
protrusion on the door. Make sure the lip of the bar (inset, Figure 7)
faces out of the printer.
If you’re using direct thermal media, continue on with step 10.
However, if you’re using thermal transfer media, you must also install
a ribbon cartridge. Proceed to “Loading the Ribbon” in this chapter.
10. Close the printhead and the top cover.
Ta b
Protrusion
Lip
Figure 7
8
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11. Swing up the media access door, ensuring that the media extends over
the tear bar (refer to Figure 8).
12. Lift to hook the top of the media access door over the top cover.
13. Push in the bottom of the media access door to close.
14. Turn on the printer or press the Feed button if the printer is already on.
Figure 8
Tear Bar
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Peel-Off Mode
NOTES: Your authorized Zebra reseller can recommend the
correct ribbon and peel-off media for your application.
If ribbon is loaded (PT400 only), remove the ribbon cartridge
before loading the media.
1.RefertoFigure4.Raisethemediaaccessdoorbyliftingatthenotch
until it unhooks from the top cover.
2.RefertoFigure5.Swingthemediaaccessdooropentoexposethe
media compartment.
3. Pivot the top cover to reveal the printhead.
4. Lift the printhead until you feel it “lock” into place. Use caution not to
force the printhead past this position!
WARNING: NEVER touch the thermal print elements on the
underside of the printhead. Under certain conditions, they
can be very hot! Also, dirt or moisture from your hands can
damage the printhead!
5.RefertoFigures5and6.Removeapproximately6”(152.4mm)of
labels from the media roll. Then, thread the media into the printer until
it extends approximately 1” (25.4 mm) past the printhead.
6. Separate and hold open the media hangers.
7. Place the media roll onto the media hangers, making sure it is tightly
wound.
8. Release the media hangers to lock the media into the correct position.
Ensure that the media is threaded under both media guides.
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9. The tear bar should not be installed in the printer. If it is, gently lift the
tab on the bar to get it over the protrusion on the door (reverse the
procedureshowninFigure7).Then,pullthebaroutoftheprinter.
NOTE:Whennotinuse,thetearbarmaybestoredontheinside
ofthemediaaccessdoor.RefertoFigure9.Withthelipofthebar
facingtheinsideofthedoor,simplyalignthenotchesofthebar
withthetabsonthedoor.Pressandslidethebartowardthe
door’shingedend.
If you’re using direct thermal media, continue on with step 10.
However, if you’re using thermal transfer media, you must also install
aribboncartridge.Proceedto“LoadingtheRibbon”inthischapter.
Door
Door
Ta b
Ta b
Tear Bar
Notch
Figure 9
Tear Bar
Notch
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10. Close the printhead and the top cover.
11. Swing up the media access door, ensuring that the media liner is
threaded through the wide slot in the media access door (refer to
Figure 10).
12. Lift to hook the top of the media access door over the top cover.
13. Push in the bottom of the media access door to close.
14. Turn on the printer or press the Feed button if the printer is already on.
NOTES: To ensure optimal print quality, make sure that the
backing material is flush against the peel bar (as shown in
Figure 10). If it starts to “loop” away from the peel bar, gently
pull down on the backing material.
With certain types of media, it may be necessary to reduce the
print speed to 1.5” (38.1 mm) per second to produce consistent
peel operation. Consult your authorized Zebra reseller for advice
and information.
12
Label
Backing
Material
Wide Slot
Figure 10
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Fanfold Media (optional vibration mount required)
NOTE: If ribbon is loaded (PT400 only), remove the ribbon
cartridge before loading the media.
1. Raise the media access door by lifting at the notch until it unhooks
fromthetopcover(refertoFigure4).
2.Swingthemediaaccessdooropentoexposethemediacompartment
(refertoFigure5).
3. Pivot the top cover to reveal the printhead.
4. Lift the printhead until you feel it “lock” into place. Be careful not to
force the printhead past this position!
WARNING: NEVER touch the thermal print elements on the
underside of the printhead. Under certain conditions, they
can be very hot! Also, dirt or moisture from your hands can
damage the printhead!
5. Separate and hold open the media hangers (refer to Figure 11).
6. Place the plastic media core (refer to Figure 11) onto the media
hangers.
Media
Guides
Figure 11
Media
Hangers
Plastic
Media
Core
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NOTE: The plastic media core can be obtained from an
authorized Zebra supplies reseller.
7. Release the media hangers so the plastic media core locks into the
correct position.
8. Place the fanfold media in the fanfold media tray.
9. Swing up the media access door. Thread the fanfold media through the
slotbeneaththenotchonthemediaaccessdoor(refertoFigure12).
10. Swing open the media access door. Continue to insert the media into
the printer and under the plastic media core until it appears beneath the
printhead. Make sure the media is threaded under both media guides.
If you’re using direct thermal media, continue on with step 11.
However, if you’re using thermal transfer media, you must also install
aribboncartridge.Proceedto“LoadingtheRibbon”inthischapter.
11. Swing up the media access door, ensuring that the media extends over
thetearbar(refertoFigure13).
12. Lift to hook the top of the media access door over the top cover.
13. Push in the bottom of the media access door to close.
14. Turn on the printer or press the Feed button if the printer is already on.
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Slot
Notch
Fanfold
Media
Figure 12
Media
Figure 13
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Loading the Ribbon (PT400 only)
1. If the printhead is not already open, lift it until you feel it “lock” into
place.
WARNING: NEVER touch the thermal print elements on the
underside of the printhead. Under certain conditions, they
can be very hot! Also, dirt or moisture from your hands can
damage the printhead!
2. Hold the ribbon cartridge as shown in Figure 14. The placement
arrows should be visible and pointing toward the back of the printer.
3. Align the lower protrusions on both sides of the ribbon cartridge with
the channels in the left and right frames (refer to Figure 14).
4.Slidetheribboncartridgepasttheprinthead(refertoFigure15).Itwill
automatically move into the correct operating position.
5.Closetheprinthead(refertoFigure16)andthetopcover.Swingup
the media access door, ensuring that the media is properly extending
outoftheprinter(seeFigure8forTear-Off,orFigure10forPeel-Off).
6. Lift to hook the top of the media access door over the top cover. Push
in the bottom of the media access door to close.
7. Turn on the printer or press the Feed button if the printer is already on.
Channel
16
Printhead
Lower
Protrusion
Arrows
Ribbon
Cartridge
Figure 14
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To remove the ribbon cartridge, simply lift the printhead and pull the ribbon
cartridge from the printer.
Printhead
Ribbon
Cartridge
Figure 15
Close
Printhead
Ribbon
Figure 16
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Operator Controls
Refer to Figure 17.
Power Button
Press to turn on the printer.
•
To turn off the printer, press and hold until the Power LED flashes once.
•
(Holding the button for approximately two seconds acts as a safeguard.
That way, no data will be lost if the button is accidentally pressed or
bumped.)
CAUTION: The power should be turned off before connecting
or disconnecting the communications cable.
Feed Button
• Forces the printer to feed one blank label.
Takes the printer out of a “pause” condition. (The printer is put into
•
“pause” by either a software command or an error condition.) See
Troubleshooting.
•Usedforprintersetupandstatus(see“FeedButtonModes”in
Troubleshooting).
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Feed
Button
Error
LED
Power
LED
Figure 17
Power
Button
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Indicator LEDs
RefertoFigures17and18.
Power LED (Green)
“On” during normal printer operation.
•
Functionsasaprinteroperational/batterystatusindicator(see“Help!
•
TheLEDsareOn/Off/Flashing!”inTroubleshooting).
Error LED (Orange)
“Off” during normal printer operation.
•
Functionsasaprinteroperationalstatusindicator(see“Help!TheLEDs
•
areOn/Off/Flashing!”inTroubleshooting).
Battery Charging LED (Yellow)
Functions as a battery charging status indicator.
•
• “On” while the battery is fast charging.
“Flashing” when the printer is preparing the battery for fast charging or
•
the battery overheats while charging.
• “Off” if the battery is fully charged or the battery charger is not plugged
in.
Figure 18
Receptacle
Battery Charging LED
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Printing a Test Label
Before you connect the printer to your computer or portable data terminal,
make sure that the printer is in proper working order. You can do this by
printingaconfigurationlabel(referto“FeedButtonModes”in
Troubleshooting). If you can’t get this label to print, refer to
Troubleshooting.
Connecting the Printer and Computer
CAUTION: The power should be turned off before connecting
or disconnecting the communications cable.
This printer is configured as Data Terminal Equipment (DTE). There are
two types of cables available for the printer.
The straight through printer adapter cable connects to a null modem cable,
which connects to the computer or a portable data terminal (PDT). Consult
your computer/PDT reseller for the appropriate DB-9 null modem cable for
your device.
RefertoFigure19.
1. Plug the null modem cable into the serial data port of the computer.
2. Plug the other end of the null modem cable into the connector of the
printer adapter cable.
NOTE: The adapter cable maintains interface compatability with
the full line of Zebra printers.
3. Plug the adapter cable into the printer’s communications port (see
Figure1).
Null modem cables are also available for many popular portable data
terminal models. Consult your authorized Zebra reseller for available data
cables.
RefertoFigure20.
1. Turn off the portable data terminal and the printer.
2. Plug the communications cable into the communications port of both
the portable data terminal and the printer. A ferrite is built into the
cable near the connector that plugs into the printer.
3. Turn on the portable data terminal and the printer.
Forpinoutandcablinginformation,refertoSpecifications.
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Adapter
Cable
Null Modem
Cable
Figure 19
Computer
Communications
Ports
10101 10101
1010110101
Ferrite
Communications
Cable
Figure 20
21
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Communicating with the Printer
Setting the Communication Parameters
When using the printer’s serial port to transfer data, you will need to make
sure that the printer and the computer have identical communication
parameter settings. To initialize the communication parameters for the
printer:
Press and hold the Feed button until the Error LED flashes once, then
•
twice, then three times. Release the button. The baud rate for the
printer will be reset to 9600 baud, 8 bits per character, no parity, and 1
stop bit using software handshaking (XON/XOFF). Then, set the
communication parameters on your computer to match this.
Some computer programs use different settings than the default modes
•
(for example, computers operating in MS-DOS use hardware
handshaking instead of XON/XOFF). To use different settings than the
defaults and save these settings permanently, refer to your label
preparation software user’s manual.
Setting Up the Software
In order to create labels, you must decide whether you will use ZPL II or a
commercial label preparation system. To use ZPL II, refer to the ZPL II
Programming Guide. If you choose to use a label preparation system,
follow the installation instructions included in the package.
Adjusting the Print Width
Print width must be calibrated when you are using the printer for the first
time and whenever there is a change in the width of the media you are
using. Print width can be set via the software (consult your label
preparationsoftwareuser’smanual)orreferto“FeedButtonModes”in
Troubleshooting.
Adjusting the Print Darkness
The relative darkness setting is software controlled. Follow the instructions
in your label preparation software user’s manual.
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Adjusting the Printhead Pressure
Adjust printhead pressure if print darkness is inconsistent across the label.
NOTE: In general, use a higher setting for wide labels and a
lower setting for narrow labels.
There are four printhead pressure settings (see Figure 21). Depending on
whether you want to increase or decrease the printhead pressure, slide the
printhead pressure adjuster toward the back or front of the printer. Then,
print another test label. Repeat this procedure until you achieve the desired
results.
WARNING: NEVER tighten or loosen the two screws that
secure the printhead to the bracket! They are not used to
adjust printhead pressure!
Printhead Pressure Adjuster
Screws
Highest
Pressure
Setting
Lowest
Pressure
Setting
Securing
Printhead
to the
Bracket
Figure 21
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Adjusting the Strap
Hand/Shoulder Strap
To lengthen the strap:
Refer to Figure 22.
1. With the printer in front of you, unwrap the padded handle by lifting up
the loose end of the handle.
2. Unlatch the buckle by squeezing both sides of the fastener.
3. Let the loose end of the strap fall to the side.
4. Pull up the handle.
1
4
Handle
2
24
(Pull Up)
Fastener
Buckle
3
Figure 22
Page 34
To shorten the strap:
Refer to Figure 23.
1. Pull the buckle until the strap is taut.
2. Latch by inserting the fastener into the buckle.
3. Wrap and secure the padded handle around the strap.
2
Fastener
2
3
Handle
Buckle
1
Figure 23
25
Page 35
Adjustable Shoulder Strap
Refer to Figure 24.
Slide the two buckles toward either the printer or shoulder pad until you
achieve the desired length.
Grip
Buckle
Here
Shoulder
Pad
26
Pull Strap
Here to
Shorten
Pull Strap
Here to
Lengthen
Figure 24
Page 36
Calibration
Auto Calibration
NOTE: The printer will not auto calibrate when you are using
pre-printed labels or pre-printed label backing. If you are using
thistypeofmedia,see“ManualCalibration.”
By default, this printer automatically sets the sensor levels for, and
determines the length of, the label you are using. To auto calibrate:
1.Loadthemediaaccordingtotheinstructionsin“LoadingtheMedia”in
Getting Ready to Print.
2.TurnontheprinterorpresstheFeedbuttoniftheprinterisalreadyon.
3. Some blank labels will feed, completing auto calibration.
4.IftheErrorLEDbeginsflashing,referto“ManualCalibration.”
Hints:
• Auto calibration only works when you are using non-continuous media
(a gap, notch, or black mark separates each label).
•
When auto calibration is selected, it occurs when the printer is turned on
(if the printhead has been opened), whenever an error is cleared, or if the
battery (or other power source) has been removed.
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Manual Calibration
A manual calibration should be performed whenever you are using
pre-printed labels (or label backing) or if the printer will not auto calibrate.
1. Turn on the printer power.
2. Remove 4-6” (102-152 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 Error LED flashes once, then
twice. Release the button.
4. The printer will set the media sensor for the label backing you are
using. 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 will print (similar to the example
in Figure 25). 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 should feed. If this
doesn’thappen,trydefaulting(referto“FeedButtonModes”in
Troubleshooting) and recalibrating the printer.
NOTE: Performing a manual calibration disables the auto
calibration function. To return to auto calibration, either default
theprinter(see“FeedButtonModes”inTroubleshooting)or
refer to your label preparation software user’s manual.
28
NOTE: When using non-continuous media, set the appropriate
software command (see your label preparation software user’s
manual) before you perform a manual calibration.
Figure 25
Page 38
Preventive Maintenance
WARNING: To avoid possible personal injury or damage to
the printer, never insert any pointed or sharp objects into the
printer.
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.
Area Method Interval
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
(Figure1)
Platen roller
(Figure1)
Head open
sensor plate
(Figure26)
Peel bar
(Figure1)
Tear bar
(Figure8)
Exterior Water-dampened cloth As needed
Interior Brush/air blow As needed
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 Zebra reseller
for more information.
With the printer turned off, rotate the platen
roller and clean it thoroughly with 70%
isopropyl alcohol and a cotton swab or
lint-free cloth.
With the printer power turned off and battery
removed, press down on the top of the
printhead. Then, clean the area beneath the
screw with 70% isopropyl alcohol and a
cotton swab. Caution: Do not turn the screw.
Clean it thoroughly with 70% isopropyl
alcohol and a cotton swab.
Clean it thoroughly with 70% isopropyl
alcohol and a cotton swab.
After every
five rolls of
media or
three ribbon
cartridges
(or more
often, if
needed)
As needed
As needed
29
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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.
PRESS
DOWN
Head Open Sensor Plate
Clean under screw
Figure 26
Extending Battery Life
•
Never expose the battery to direct sunlight or temperatures over 104° F
(40° C).
•
Choose the media or ribbon that is easiest to “burn.” An authorized
Zebra reseller can help you determine this.
•
Make sure you’re using the optimal ribbon/media combination for your
application. An authorized Zebra reseller can help you determine this.
•
If you print the same text or graphic on every label, consider using a
pre-printed label.
•
Choose the correct print darkness, print speed, and printhead pressure
for your media and ribbon.
•
Use software handshaking (XON/XOFF) whenever possible.
30
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Select Tear-Off mode whenever possible (Peel-Off mode uses more
•
power).
Pull the battery out of the printer if the printer won’t be used for a day or
•
more and you’re not performing a maintenance charge.
Completely discharge the battery before recharging. Wait until you get
•
a “battery under voltage - level 1” indication (Error LED off and Power
LED flashing) before you recharge.
Consider purchasing an extended life battery, which offers double the
•
life of a standard battery.
Battery Disposal
The EPA certified RBRCBattery Recycling Seal on the nickel-cadmium
(Ni-Cd) battery indicates Zebra Technologies Corporation is voluntarily
participating in an industry program to collect and recycle these batteries at
the end of their useful life, when taken out of service in the United States or
Canada. The RBRC
program provides a convenient alternative to placing
used Ni-Cd batteries into the trash or the municipal waste stream, which
may be illegal in your area. Please call 1-800-8-BATTERYfor
information on Ni-Cd battery recycling and disposal bans/restrictions in
your area. Zebra Technologies Corporation’s involvement in this program
is part of our commitment to preserving our environment and conserving
our natural resources.
Outside North America, please follow local battery recycling guidelines.
31
Page 41
32
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Troubleshooting
Try as you may, you can’t seem to get the label to look right. Or, the LEDs
are on or flashing when they’re normally off. This is the section of the
User’s Guide that can help you solve your printer’s problems! If, after
reading this section, you’re still having difficulty getting your printer to
print, contact a qualified Zebra service technician.
Help! The LEDs are On/Off/Flashing!
Error LED
(Orange)
Off Off Off 1
Flashing On Stopped 2
Double Flashing On Paused 3
On On On 4
On On Stopped 5
Off Flashing On 6
Off Flashing Stopped 7
Alternate Flashing Needs Service 8
Simultaneous Flashing Various 2 and 6
On Flashing On 4 and 6
On Flashing Various 5 and 6
Double Flashing Flashing Yes 3 and 7
Power LED
(Green)
Printer
Status
For a Resolution,
Resolutions:
1. The printer is not receiving power.
•
Have you turned on the printer power?
•
Ensure that the battery is fully charged. Follow the instructions in
“ChargingtheBattery”inGettingReadytoPrint.
•
Makesurethebatteryisproperlyinstalled.Referto“Installingthe
Battery”inGettingReadytoPrint.
Refer to:
33
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2. The printhead is open.
Close the top cover and media access door. Then, press the Feed button
•
to resume printing.
The media is out.
Loadarollofmedia,followingtheinstructionsin“LoadingtheMedia”
•
in Getting Ready to Print. Then, press the Feed button to resume
priting.
The ribbon is out (PT400 only).
Loadtheribbon,followingtheinstructionsin“LoadingtheRibbon”in
•
Getting Ready to Print. Then, press the Feed button to resume printing.
The head open sensor plate is dirty.
Clean the head open sensor plate according to the instructions in
•
PreventiveMaintenance.
3. The printer is paused.
Press the Feed button to resume printing.
•
4. The printhead is under temperature.
• Continue printing while the printhead reaches the correct operating
temperature.
5. The printhead is over temperature.
•
Printing automatically stops until the printhead cools to an acceptable
printing temperature; then, the printer automatically resumes operation.
The battery is over temperature.
•
Printing automatically stops until the printer and battery cool to an
acceptable operating temperature; then, the printer automatically
resumes operation.
6. The battery is under voltage (level 1).
•
Wait until the current label finishes printing, then plug the battery
charger into the printer (you don’t have to turn off the printer to do this).
34
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7. The battery is under voltage (level 2).
The battery may not have enough power to print the next label and can
•
reset the printer, losing formats in the printer. Plug the battery charger
into the printer (you don’t have to turn off the printer to do this). After
the battery is charged, press the Feed button.
8. FLASH memory is not programmed.
Return the printer to an authorized Zebra reseller.
•
Print Quality Problems
No print on the label.
If you aren’t using ribbon, 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 doesn’t produce dark marks, the wrong media
(thermal transfer) is loaded.
Are the media and ribbon loaded correctly? Follow the instructions in
•
“LoadingtheMedia”and“LoadingtheRibbon”inGettingReadyto
Print.
•Youmaybetryingtousetheprinteroutsideofitsenvironmentallimits.
The correct operating temperature range for this printer is between 32° F
and 104° F(0° to 40° C).
The printed image doesn’t look right.
•
The printhead is dirty. Clean the printhead according to the instructions
inPreventiveMaintenance.
•
Printheadpressureneedstobeadjusted.Followthestepsin“Adjusting
thePrintheadPressure”inGettingReadytoPrint.
•
Theprintdarknessneedstobeadjusted.See“AdjustingthePrint
Darkness”inGettingReadytoPrint.
•
The print mode may be incompatible with the media you are using. If
your printer is set for thermal transfer mode, you must use thermal
transfer, rather than direct thermal, media and a ribbon cartridge.
•
The media being used is incompatible with the printer. Be sure to use
the Zebra-recommended media for your application.
•
Batteryvoltageislow.See“ChargingtheBattery”inGettingReadyto
Print.
35
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There are long tracks of missing print (blank vertical lines) on
several labels.
The printhead is dirty. Clean the printhead according to the instructions
•
inPreventiveMaintenance.
The printhead elements are damaged. Call a qualified service technician
•
to replace the printhead.
Misregistration of labels (the printing does not start at the top of
the label) and misprinting of 1 to 3 labels.
The media may not be threaded under the media guides. Refer to
•
“LoadingtheMedia”inGettingReadytoPrint.
The printer needs to be calibrated. Refer to Calibration.
•
Printhead pressure needs to be adjusted. Follow the instructions in
•
“AdjustingthePrintheadPressure”inGettingReadytoPrint.
The correct media sensor may not be activated. In manual calibration,
•
select the media sensing method for the labels you are using (refer to
your label preparation software user’s manual).
A label format was sent to, but not recognized by, the printer.
• Is the printer in pause mode? If so, press the Feed button.
•
IftheLEDsareonorflashing,referto“Help!TheLEDsare
On/Off/Flashing!”inTroubleshooting.
•Makesurethedatacableisinstalledcorrectly.Also,makesureyouare
using a null modem cable between the printer’s adapter cable and the
computer(seeFigure19),ortheappropriatenullmodemcable.
•
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 communication parameters of the printer and the
computermatch.Referto“CommunicatingwiththePrinter”inGetting
Ready to Print.
36
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Troubleshooting Tests
Printing a Configuration Label
To print out a listing of the printer’s current configuration (a sample is
showninFigure27),referto“FeedButtonModes”inthischapter.
Recalibration
Recalibrate the printer if it starts to display unusual symptoms, such as
skippinglabels.SeeCalibration.
Resetting the Factory Default Values
Sometimes, resetting the printer to the factory defaults solves some printer
problems.Followtheinstructionsin“FeedButtonModes”inthischapter.
Communications Diagnostics
If there’s 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 hexidecimal values for
anydatareceivedfromthehostcomputer(seeFigure28).Tofindouthow,
referto“FeedButtonModes”inthischapter.
37
Page 47
38
Figure 27
Figure 28
Page 48
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(seeFigure27).
After printing the label, the printer will automatically enter a diagnostic mode in
whichtheprinterprintsoutaliteralrepresentation(seeFigure28)ofalldata
subsequently received.
Power On Modes
With the printer power on, printhead closed, and Error LED off, press and hold the
Feed button for several seconds. The Error 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 is held down for six flashes and quickly released, the printer will
ignore the button. For additional information, refer to the maintenance manual.
The media sensor calibrates and a media sensor profile prints (see
CalibrationandFigure25).
Theserialcommunicationparametersareresetto9600baud,8bitsper
character, no parity, 1 stop bit, and XON/XOFF.
Resets the factory defaults, auto calibrates, and saves settings into
memory.
The print width is calibrating. While the Error LED rapidly flashes, a
series of stacking rectangles prints 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.
39
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40
Page 50
Specifications
NOTE: Printer specifications are subject to change without
notice.
Printing Specifications
Print Density 203 dots/inch (8 dots/mm)
Print Width Up to 4.1” (104 mm)
Print Speed 1.5” or 2” per second (38.1 mm or 50.8 mm per second)
Horizontal +/- 0.059” (+/- 1.5 mm)
+/- 0.0393” (+/- 1.0 mm) on media >2” (50.8 mm) in
Registration
Tolerance
Distance from Center Print
Element to Center of Label
Maximum Duty Cycle
Vertical
Ribbon Cartridge Specifications (PT400)
ü
height
+/- 0.1180” (+/- 3.0 mm) on media < 2” (50.8 mm) in
ü
height unless they are run without backfeed
+/- 0.0393” (+/- 1.0 mm)
ü Up to 18% black per batch
ü Up to 60 linear inches of media per batch
ü Up to four batches per hour
Ribbon Width 4.33” (110 mm)
Ribbon Outer Diameter .66” (16.8 mm)
41
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Label Specifications
Label/Tag Width 1” to 4.25” (25.4 mm to 108 mm)
Fanfold Width 3.5” to 4.25” (89 mm to 108 mm)
Label/Tag Length 0.5” to 10” (12.7 mm to 254 mm)
Interlabel Gap
Label/Tag Thickness .0030” to .0106” (.076 mm to .269 mm)
Label Roll
Size
Media Requirements
Max. Outer
Diameter
Inner Core 1” (25.4 mm)
.08” to .16” (.12” preferred)
2 mm to 4 mm (3 mm preferred)
2.1” (53.3 mm)
Use Zebra-brand direct thermal or thermal transfer roll
ü
media that is outside wound. Media may be reflective
(black mark) sensing or transmissive sensing, die-cut,
notched, or continuous.
For die-cut labels, use only full auto dies.
ü
Notched media must have a 0.5” (12.7 mm) wide x 0.094”
ü
(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” (12.7 mm) perpendicular to the edge of
the media.
ü
Mark length: 0.094” (2.4 mm) parallel to the edge of the
media.
Memory/Communications Specifications
ROM Memory 8 megabit flash (512 kilobyte x 16 data bit width)
RAM Memory 4 megabit DRAM (256 kilobyte x 16 data bit width)
Communications RS-232 serial port (RJ45 connector)
42
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Font/Bar Code Specifications
CG Triumvirate Bold Condensed scalable smooth
Fonts Available
1D
Bar Codes
Available
2D
Bar Codes
Available
Rotation Angles 0°,90°, 180°, and 270°
ü
Zebra fonts A, B, C, D, E, H, GS
ü
Codabar (supports ratios of
ü
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 of
ü
2:1 to 3:1)
Code 93
ü
EAN 8/JAN 8
ü
EAN 13/JAN 13
ü
EAN 14/UPCA
ü
Codablock
ü
Code 49
ü
Data Matrix
ü
ü MaxiCode
Industrial 2 of 5
ü
Standard 2 of 5
ü
Interleaved 2 of 5 (supports
ü
ratios of 2:1 to 3:1, Modulus
10 Check Digit)
LOGMARS
ü
MSI
ü
Plessey
ü
POSTNET
ü
UPC E
ü
UPC/EAN Extensions
ü
MicroPDF417
ü
PDF 417
ü
QRcode
ü
Physical/Environmental/Electrical
Specifications
Physical Size (LxWxH) 2.8” x 9.2” x 7.9” 72 mm x 233 mm x 200 mm
Weight (without battery)
Operating 32° to 104° F0° to 40° C
Temperature
Range
Relative
Humidity
Electrical
Storage
(w/battery)
Storage
(w/o battery)
Operation 10% to 90% (non-condensing)
Storage 5% to 95% (non-condensing)
3.5 lbs. 1.6 kg.
-22° to 122° F -30° to 50°C
-40° to 140° F -40° to 60°C
External 120 or 230 VAC battery charger, depending on
which model you order. Additional custom line cords
may also be available.
43
Page 53
Agency Approvals
UL 544 Medical Equipment Standard Part 42.5
•
CSA 22.2 number 950 Canadian Safety Standard
•
IEC 950/EN 60950 International Safety Standard
•
FCC Part 15 Subpart B Class B Electromagnetic Radiation Standard
•
UL 1950 Domestic Safety Standard
•
Canadian DOC Class A
•
SOR/88-475 Canadian Electromagnetic Radiation Standard
•
EN50082-1 International Immunity Standard
•
EN55022 Class B European Electromagnetic Radiation Standard
•
Options
Hand/shoulder strap
•
Adjustable shoulder strap
•
• Weather-resistant protective case
Vibration mount, U-arm bracket, and media catch tray
•
• Standard battery
• Extended life battery
•
120 VAC battery charger
•
Universal switching battery charger
•
Battery eliminator
•
Data cables
For details, call your authorized Zebra reseller.
44
Page 54
9-Pin D to RJ45 Connection Table
DB-9S
Connector to
Null Modem Cable
UNUSED
1
2
3
4
5
6
7
8
9
Adapter Cable Pinouts
RXD
TXD
DTR
GND
DSR
RTS
UNUSED
RJ45
Connector
to Printer
1
2
3
4
5
6
7
8
Pin 1 Pin 8
RJ45 Connector Pin Identification
45
Page 55
25-Pin D to 9-Pin D Null Modem Cable
DB-25S
Connector
to P.C.
TXD
2
RXD RXD
3
RTS
4
CTS
5
DSR
6
GND
7
DCD
8
DTR
20
DB-9P
Connector
to Adapter Cable
DCD
1
2
TXD
3
DTR
4
GND
5
DSR
6
RTS
7
CTS
8
9-Pin D to 9-Pin D Null Modem Cable
DB-9S
Connector
to P.C.
DCD
1
2
3
4
5
6
RTS
7
CTS
8
DB-9P
Connector
to Adapter Cable
DCD
1
RXDRXD
2
TXDTXD
3
DTRDTR
4
GNDGND
5
DSRDSR
6
RTS
7
CTS
8
46
Null Modem Cable Pinouts
Page 56
Index
A
Adaptercable..........20
Adaptercablepinouts......45
Adjustingthestrap.......24
Adjustments
Printdarkness........22
Printwidth.........22
Printheadpressure......23
Agencyapprovals........44
B
BatterychargingLED......19
Batterydisposal.........31
Batterylife,tips.........30
Battery,charging.........4
Battery,installing........3
C
Calibration,automatic.....27
Calibration,manual.......28
Cleaning
Exterior...........29
Headopensensorplate...29
Interior...........29
Peelbar...........29
Platenroller.........29
Printhead..........29
Tearbar...........29
Communicationparameters,
setting.............22
Communicationsdiagnostics..37
Configurationlabel.......37
D
Damage,shipping........1
Darkness,adjusting.......22
DataTerminalEquipment
(DTE).............20
Defaultingtheprinter......39
E
ErrorLED..........19,33
F
Factorydefaults,resetting...37
Fanfoldmedia..........13
Feedbutton...........18
Feedbuttonmodes.......39
H
Handshaking..........22
I
IndicatorLEDs.........19
Inspection............1
47
Page 57
L
R
Loading the media
Fanfoldmedia........13
Peel-offmode........10
Tear-offmode........5
Loadingtheribbon.......16
Lubrication...........30
M
Maintenancemanual.......1
Media loading
Fanfoldmedia........13
Peel-offmode........10
Tear-offmode........5
N
Nullmodemcable........20
Nullmodemcablepinouts...46
O
Operatorcontrols........18
Options.............44
P
Peel-offmode..........10
Powerbutton..........18
PowerLED.........19,33
Printdarkness,adjusting....22
Printwidth,adjusting....22,39
Printheadpressure,adjusting..23
Reportingdamage,shipping...1
Ribbonloading.........16
RJ45connectorpin
identification.........45
S
Software.............22
Specifications
Font/barcode........43
Label............42
Memory/communications..42
Physical/environmenal/
electrical..........43
Printing...........41
Ribboncartridge......41
Strap, adjusting
Hand/shoulderstrap.....24
Adjustableshoulderstrap..26
T
Tear-offmode..........5
Troubleshooting.........33
Troubleshootingtests......37
U
Unpacking............1
Z
ZPLII............1,22
ZPLIIProgrammingGuide,
ordering............1
48
Page 58
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109 U.S.A.
Telephone +1 847.634.6700
Facsimile +1 847.913.8766
Zebra Technologies Europe Limited
Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
Telephone +44 (0)1494 472872
Facsimile +44 (0)1494 450103
Customer order #52600L
Manufacturer part #52600LB
' Zebra Technologies Corporation
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