Zebra Technologies T402 User Manual

T402

Stripe Series Thermal Transfer Printer

®

User s

Guide

'

T402

Stripe Series Thermal Transfer Printer

®

Users

'

Guide

AWARDS FOR

PUBLICATION EXCELLENCE

Customer order # 52007L

Rev. 3

Manufacturer part # 52007LB

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

DAT

Zebra Technologies Corporation

333 Corporate Woods Parkway

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

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

for Home, Office, Commercial, and Industrial use

if no unauthorized change is made in the equipment,
and if the equipment is properly maintained and operated.

®

402 and 402

manufactured by:

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

Getting Ready to Print

Loading the Media............................5

Tear-Off Mode............................5

Peel-Off Mode...........................10

Cutter Mode.............................16

Fanfold Media...........................20

Loading the Ribbon..........................22

Removing the Ribbon........................24

Auto Calibration............................25

Operator Controls...........................26

Power Switch............................26

Feed Button.............................26

Status LED.............................26

Printing a Test Label..........................27

Hooking Up the Printer and Computer.................27

Serial (RS-232) Interface Requirements..............27

Parallel Interface Requirements..................28

Serial and Parallel Cabling Requirements.............28

Communicating with the Printer....................29

Via the Parallel Port.........................29

Via the Serial Port.........................29

i

Using ZPL II..............................30

Adjusting the Print Width.......................30

Adjusting the Print Darkness......................30

Adjusting the Print Speed.......................30

Troubleshooting

What the Status LED is Telling You..................31

Print Quality Problems.........................32

Manual Calibration...........................34

Troubleshooting Tests.........................35

Printing a Configuration Label...................35

Recalibration............................35

Resetting the Factory Default Values................36

Communications Diagnostics....................36

Feed Button Modes...........................37

Maintenance

Cleaning................................39

Lubrication...............................39

Parts List................................41

Replacing the Printhead........................44

Specifications

Printing.................................45

Ribbon.................................45

Label/Tag................................46

Font/Bar Code.............................47

Physical/Environmental/Electrical...................47

Agency Approvals...........................48

Options.................................48

Serial (RS-232) Connector Technical Information..........49

Interconnecting to DTE Devices..................49

Interconnecting to DCE Devices..................49

Parallel Interface Technical Information................52

Index

ii

Introduction

Hello!

Thank you for choosing the Zebra T402 Printer. This rugged little printer
is certain to become a productive and efficient addition to your workplace!

n

This user’s guide gives you all 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 (part #46530L). If one was not ordered with your printer, simply
call your distributor or visit our web site at www.zebra.com.

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

What’s in the Box

Printer

Power

Supply

Quick

Product

Support Services

Brochure

Reference

Guide

User’s
Guide

CD-Rom

Registration

Card

Ribbon Core

Roll of Ribbon

Sample

Sample

Roll of Media

Test

Label

1

Unpacking and Inspection

In spect the printer for pos si ble ship ping dam age:

n

Check all exterior surfaces for damage.

n

Raise the top cover (refer to “Loading the Media” on page 5) and inspect
the media compartment for damage.

In case ship ping is re quired, save the car ton and all pack ing ma te rial.

Reporting Damage

If you dis cover ship ping dam age:

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.
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

AC

Power

Cord

Power

Switch

Power

Supply

Receptacle

Barrel

Connector

Power

Supply

Figure 1

3

Printer Overview

Printhead

Cutter Option

Roller

Feed

Button

Release

Lever

(2)

Status LED

Ribbon Core

Supply

Spindle

Take-Up

Spindle

Sensor

Housing

Bottom

Slot

Cutter Unit

Media

Supply Guides

Media Hanger

Tear Bar

Media

Guides

4

Media
Guide

Adjuster

Printhead

Release Lever

Figure 2

Peel

Bar

Platen

Getting Ready to Print

Loading the Media

You can op er ate this printer in three dif fer ent modes: tear-off, peel-off, or
with a cutter.

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.

NOTE: The cutter is designed to cut through paper labels or the
backing between labels, not the adhesive backing of the label.
Adhesive build-up on the cutter blade may cause the cutter to jam.
See page 39 for cutter cleaning instructions.

Tear-Off Mode

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

Release

Lever

Release

Lever

Figure 3

5

2. Insert one end of the media hanger into one of the media supply guides
(refer to Figure 4).

3. Place the roll of media onto the media hanger.

4. Place the second media supply guide onto the other end of the media
hanger (refer to Figure 4).

NOTES: The media roll must be centered on the media hanger.
The media roll should rest against the smooth side of the media
supply guides. The textured side marked “out” should face the
outside of the printer. The media supply guides should just touch
the edges of the roll of media; they must not cause pressure or
excessive drag on the media roll.

5. Refer to Figure 5. If you are using labels, make sure the media
unwinds from the top of the roll. Tags unwind from the bottom of the
roll.

6. Place the media roll in the top cover (refer to Figure 6).

7. Release the printhead by pulling the printhead release lever toward you
(refer to Figure 6, “1”).

8. Lift the printhead (refer to Figure 6, “2”) until you feel it “lock” into
place. Be careful not to force the printhead past this position!

Smooth Side of

Textured

Side

Marked

"OUT"

Media Supply Guide

3

2

1

Media

Media

Supply

Guide

Figure 4

6

Hanger

Printhead

Release

Lever

Labels Tags

Figure 5

Printhead

2

1

Figure 6

7

9. 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 roll.

10.Continue to thread the media past the peel bar (refer to Figure 7).

11.Place the media hanger into the two mounting slots (refer to Figure 8).

12.Close the printhead by pressing down at both arrows (refer to Figure 9).

13.Close the top cover and turn on the printer or press the feed button if
the printer is already on (see “Auto Calibration” on page 25 for more
information).

Media

Guides

Media
Guide

Adjuster

Peel Bar

Figure 7

8

Mounting

Slot

Mounting

Slot

Figure 8

Printhead

Arrow

Arrow

Figure 9

9

Peel-Off Mode

1. Unlatch the top cover by pressing the two green release levers (refer to
Figure 10). Then, lift the top cover to expose the media compartment.

2. Insert one end of the media hanger into one of the media supply guides
(refer to Figure 11).

3. Place the roll of media onto the media hanger.

4. Place the second media supply guide onto the other end of the media
hanger (refer to Figure 11).

NOTES: The media roll must be centered on the media hanger.
The media roll should rest against the smooth side of the media
supply guides. The textured side marked “out” should face the
outside of the printer. The media supply guides should just touch
the edges of the roll of media; they must not cause pressure or
excessive drag on the media roll.

5. Place the media roll in the top cover (refer to Figure 12).

6. Release the printhead by pulling the printhead release lever toward you
(refer to Figure 12, “1”).

7. Lift the printhead (refer to Figure 12, “2”) until you feel it “lock” into
place. Be careful not to force the printhead past this position!

10

Release

Lever

Release

Lever

Figure 10

Textured

Printhead

Side

Marked

"OUT"

1

Media

Supply

Guide

Figure 11

Smooth Side of

Media Supply Guide

3

2

Media

Hanger

Printhead

2

Release

Lever

1

Figure 12

11

8. Refer to Figure 13. 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 13). The media guides should just touch, but not restrict,
the edges of the media roll.

9. Continue to thread the media until it is approximately 8” (203 mm) past
the peel bar (refer to Figure 13).

10.Place the media hanger into the two mounting slots (refer to Figure 14).

11.Remove approximately 6” (152.4 mm) of labels from the backing.

12.Insert the label backing into the peel-off feed slot (refer to Figure 15).
Continue to feed the label backing until it comes out of the bottom slot.

Media

Guides

12

Media

Guide

Adjuster

Peel Bar

Figure 13

Mounting

Slot

Mounting

Slot

Figure 14

Feed

Button

Bottom Slot

Peel-Off

Feed Slot

Figure 15

13

13.Gently pull the label backing to remove any slack in the media.

14.Close the printhead by pressing down at both arrows (refer to

Figure 16).

15.Close the top cover. Activate the label taken sensor by pushing in on
the top of the sensor housing until it locks into position (refer to

Figure 17).

16.Turn on the printer or press the feed button if the printer is already on
(see “Auto Calibration” on page 25 for more information).

14

Arrow

Sensor

Housing

Printhead

Arrow

Figure 16

Figure 17

15

Cutter Mode (optional)

1. Unlatch the top cover by pressing the two green release levers (refer to
Figure 18). Then, lift the top cover to expose the media compartment.

2. Insert one end of the media hanger into one of the media supply guides
(refer to Figure 19).

3. Place the roll of media onto the media hanger.

4. Place the second media supply guide onto the other end of the media
hanger (refer to Figure 19).

NOTES: The media roll must be centered on the media hanger.
The media roll should rest against the smooth side of the media
supply guides. The textured side marked “out” should face the
outside of the printer. The media supply guides should just touch
the edges of the roll of media; they must not cause pressure or
excessive drag on the media roll.

5. Place the media roll in the top cover (refer to Figure 20).

6. Release the printhead by pulling the printhead release lever toward you
(refer to Figure 20, “1”).

7. Lift the printhead (refer to Figure 20, “2”) until you feel it “lock” into
place. Be careful not to force the printhead past this position!

16

Release

Lever

Release

Lever

Figure 18

Textured

Side

Marked

"OUT"

Printhead

Release

Lever

1

Media

Supply

Guide

Figure 19

Smooth Side of

Media Supply Guide

3

2

Media

Hanger

Printhead

2

1

Figure 20

17

8. Refer to Figure 21. 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 21). The media guides should just touch, but not restrict,
the edges of the roll

9. Refer to Figure 21. Thread the media through the cutter unit.

10.Place the media hanger into the two mounting slots (refer to Figure 22).

11.Close the printhead by pressing down at both arrows (refer to

Figure 23).

12.Close the top cover and turn on the printer or press the feed button if
the printer is already on (see “Auto Calibration” on page 25 for more
information).

18

Media

Guides

Media
Guide

Adjuster

Cutter

Unit

Figure 21

Mounting

Slot

Mounting

Slot

Figure 22

Printhead

Arrow

Arrow

Figure 23

19

Fanfold Media

Fanfold media loads from the outside of the printer.

1. Thread the media through the access slot in the back of the printer
(refer to Figure 24).

2. Open the top cover.

3. Release the printhead by pulling the printhead release lever toward you
(refer to Figure 24, “1”).

4. Lift the printhead (refer to Figure 24, “2”) until you feel it “lock” into
place. Be careful not to force the printhead past this position!

5. Refer to Figure 25. 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 25). The media guides should just touch, but not restrict,

the edges of the roll.

6. Continue to thread the media past the peel bar (refer to Figure 25).

7. Close the printhead by pressing down at both arrows (refer to

Figure 25).

8. Close the top cover and turn on the printer or press the feed button if
the printer is already on (see “Auto Calibration” on page 25 for more
information).

20

Access

Slot

2

Media
Guide

Adjuster

Arrow

Printhead

Release

Lever

Figure 24

Figure 25

1

Printhead

Media

Guides

Arrow

Peel Bar

21

Loading the Ribbon

Figure 26 shows the location of the ribbon supply spindle, ribbon take-up
spindle, and ribbon supply slot.

1. Open the top cover.

2. Install an empty ribbon core (notched end to the right) as shown in

Figure 27. This becomes the ribbon take-up spindle.

3. Remove the tape that secures the leader on the new roll of ribbon.

4. Install the ribbon roll on the ribbon supply spindle (refer to Figure 27).
Make sure the ribbon unwinds over the top of the roll and feeds toward
the back of the printer.

5. Open the printhead by pulling the printhead release lever toward you.

6. Lift the printhead until you feel it “lock” into place. Be careful not to
force the printhead past this position!

7. Thread the ribbon leader into the ribbon supply slot (refer to
Figure 26 for the location of the supply slot).

8. Wrap the ribbon leader around the printhead (refer to Figure 28). Then,
affix the ribbon leader to the ribbon take-up spindle with tape.

9. Wind the ribbon onto the ribbon take-up spindle until the ribbon leader
is no longer visible.

Supply

Spindle

22

Supply

Slot

Take-Up

Spindle

Figure 26

Supply

Spindle

Take-Up

Spindle

Ribbon

Core

Notch

Figure 27

Figure 28

Printhead

23

10.Close the printhead by pressing down at both arrows.

11.Close the top cover and turn on the printer or press the feed button if
the printer is already on (see “Auto Calibration” on page 25 for more
information).

Removing the Ribbon

1. Open the printhead.

2. Cut the ribbon below the ribbon take-up spindle (refer to Figure 29).

3. Remove the roll of unused ribbon.

Hint: Tape the end of the ribbon to prevent the roll from
unwrapping.

4. Remove the ribbon take-up spindle. Remove and discard the spent
ribbon from the core.

5. Keep the core for future use.

Take-Up

Spindle

24

Figure 29

Auto Calibration

NOTE: If you are using pre-printed labels, pre-printed label
backing, or continuous media, see “Manual Calibration” on
page 34.

An auto calibration is performed when the printer is turned on (if media is
loaded) or after an error is cleared. When it is auto calibrating, the printer
sets the sensor levels for, and determines the length of, the label you are
using.

If the status LED flashes red, refer to “Manual Calibration” on page 34.

25

Operator Controls

Refer to Figure 30.

Power Switch

n

Press to turn on and turn off the printer.

CAUTION: The power should be turned off be fore con nect ing
or dis con nect ing the com mu ni ca tions and power ca bles.

Feed Button

n

Forces the printer to feed one blank label.

n

When printing, puts the printer into a “pause” condition.

n

Takes the printer out of a “pause” condition. (The printer is put into
“pause” by either a ZPL II command or an error condition.) See “What

the Status LED is Telling You” on page 31.

n

Used for printer setup and status (see “Feed Button Modes” on page 37).

Status LED

n

Functions as a printer operational indicator (see “What the Status LED is

Telling You” on page 31).

Status

Feed

Button

LED

26

Power

Switch

Figure 30

Printing a Test Label

Be fore you con nect the printer to your com puter, make sure that the printer
is in proper work ing or der. You can do this by print ing a configuration
la bel:

1. Make sure the media is properly loaded and the top cover of the printer

is closed. Then, turn the printer power on if you have not already done
so.

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

the status LED flashes once.

3. Release the feed button. A configuration label will print.
If you cannot get this label to print, refer to Troubleshooting.

Hooking Up the Printer and Computer

CAUTION: The power supply barrel connector must be
inserted into the power supply receptacle on the back of the
printer before con nect ing or dis con nect ing the
communications ca bles. (If necessary, refer to Figure 1.)

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

CAUTION: This printer com plies with FCC “Rules and
Regu la tions,” Part 15, for Class B Equip ment, us ing fully
shielded six- foot data ca bles. Use of longer ca bles or
un shielded ca bles may in crease ra di ated emis sions above the
Class B lim its.

Serial (RS-232) Interface Requirements

The required cable must have a nine-pin “D” type (DB-9P) male connector
on one end, which is plugged into the mating (DB-9S) serial port located on
the back of the printer (refer to Figure 31). The other end of this serial
interface cable connects to a serial port at the host computer. Depending on
the specific interface requirements, this will most likely be a null modem
cable.

For pinout and technical information, refer to page 49.

27

Parallel Interface Requirements

The required cable (IEEE 1284-compliant is recommended) must have a
standard 36-pin parallel connector on one end, which is plugged into the
parallel port located on the back of the printer (refer to Figure 31). The
other end of the parallel interface cable connects to the printer connector at
the host computer.

For pinout information, refer to page 52.

Serial and Parallel Cabling Requirements

Data cables must be of fully shielded construction and fitted with metal or
metalized connector shells. Shielded cables and connectors are required to
prevent radiation and reception of electrical noise.

To minimize electrical noise pickup in the cable:

n

Keep data cables as short as possible (6’ [1.83 m] recommended).

n

Do not tightly bundle the data cables with power cords.

n

Do not tie the data cables to power wire conduits.

28

Parallel

Port

Figure 31

Serial

Port

Connects to

Serial Port on

Host Computer

Connects to

Parallel Port on

Host Computer

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
communications parameters of the host computer. To autobaud:

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

twice, 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

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 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 flashes, 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.

29

Using ZPL II

For information about creating labels using ZPL II, refer to the ZPL II
Programming Guide or visit our web site at www.zebra.com.

Adjusting the Print Width

Print width must be calibrated when:

n

You are using the printer for the first time.

n

There is a change in the width of the media.

Print width may be set by way of the five-flash sequence in “Feed Button

Modes” (see page 37) or refer to the Print Width (^PW) command (consult

your ZPL II Programming Guide).

Adjusting the Print Darkness

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

“Feed Button Modes” (see page 37) or the Set Darkness (~SD) command

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

Adjusting the Print Speed

Print quality is affected by print speed and the media you are using. Only
by experimenting will you find the optimal mix for your application.

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

30

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.

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

n

If the 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 automatically resumes operation.

31

5. The media or ribbon is not loaded.

n

Load a roll of media or ribbon, following the instructions in

“Loading the Media” on page 5 or “Loading the Ribbon” on

page 22. Then, press the feed button to resume printing.

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 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

Are the media and ribbon loaded correctly? Follow the instructions in

“Loading the Media” on page 5 and “Loading the Ribbon” on page 22.

The printed image does not look right.

n

The printhead is dirty. Clean the printhead according to the instructions
on page 39.

n

The printhead is under temperature.

n

Adjust the print darkness and/or print speed. Refer to the six-flash
sequence in “Feed Button Modes” on page 37, and/or the ^PR and ~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.

32

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

n

The printhead is dirty. Clean the printhead according to the instructions
on page 39.

n

The printhead elements are damaged. Replace the printhead (see

“Replacing the Printhead” on page 44).

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

“Loading the Media” on page 5.

n

The printer needs to be calibrated. Refer to “Auto Calibration” on
page 25.

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

If the status LED is on or flashing, refer to “What the Status LED is

Telling You” on page 31.

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.
Refer to “Communicating with the Printer” on page 29.

33

Manual Calibration

A manual calibration should be performed 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 6” (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. Use the Media Tracking (^MN) command to select the appropriate
media type (refer to the ZPL II Programming Guide).

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

5. 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.

6. A profile of the media sensor settings (similar to the example in
Figure 32) will print. Upon completion, the printer will save the new
settings in memory and the printer is ready for normal operation.

7. Press the feed button. One entire blank label should feed. If this does
not happen, try defaulting (refer to the four-flash sequence in “Feed

Button Modes” on page 37) and recalibrating the printer.

NOTE: Performing a manual calibration disables the auto
calibration function. To return to auto calibration, default the
printer (see the four-flash sequence in “Feed Button Modes” on
page 37).

34

Figure 32

Troubleshooting Tests

Printing a Configuration Label

To print out a list ing of the printer’s cur rent con figu ra tion (an exam ple is
shown in Fig ure 33), re fer to the one-flash sequence in “Feed But ton

Modes” on page 37.

Recalibration

Re cali brate the printer if it starts to dis play un usual symp toms, such as
skip ping la bels. See “Auto Calibration” on page 25.

Figure 33

35

Resetting the Factory Default Values

Some times, re set ting the printer to the fac tory de faults solves some of the
prob lems. Fol low the four-flash sequence in struc tions in “Feed But ton

Modes” on page 37.

Communications Diagnostics

If there is a problem transferring data between the computer and printer, try
putting the printer in the communications diagnostics mode. The printer
will print the ASCII char ac ters and their respective hexide ci mal val ues (see
Figure 34) for any data re ceived from the host com puter. To find out how,
re fer to the power off mode procedure in “Feed But ton Modes” on page 37.

36

Figure 34

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. The printer prints out a listing of its current configuration (see Figure 33).
After printing the label, the printer automatically enters a diagnostic mode in which
the printer prints out a literal representation (see Figure 34) of all data subsequently
received. To exit the diagnostic mode and resume printing, turn off and then turn on
the printer.

Power On Modes

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

Flash

Sequence Action

* A configuration label prints.
*

**

*
**
***

*
**

***
****

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

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

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

Manual Calibration and Figure 32 on page 34).

To reset the communications parameters: Press and release the feed
button while the LED flashes. 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 flashes. When the printer and host are synchronized, the
LED changes to solid green. Note: No labels 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 communications
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.

37

38

Maintenance

Cleaning

CAUTION: Use only the clean ing agents in di cated. Ze bra
Tech nolo gies Cor po ra tion will not be re spon si ble for dam age
caused by any other clean ing ma te ri als used on this printer.

If necessary, refer to Figure 2 for part locations.

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

Printhead

Platen roller

Peel bar

Tear bar

Cutter

Exterior Water-dampened cloth As needed
Interior Brush/air blow As needed

to do this.

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

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 the printer power off. Use tweezers to remove the
media. Never use solutions or solvents to clean the
blade, as blade lubrication and sharpness may be
effected.

After every
five rolls of
media or
ribbon

As needed

As needed

As needed

Lubrication

CAUTION! No lu bri cat ing agents of any kind should be used
on this printer! Some com mer cially avail able lu bri cants, if
used, will dam age the fin ish and the me chani cal parts in side
the printer.

39

8

1

2

3

4

5

7

6

Figure 35

40

Parts List

Refer to Figure 35.

Item

Number Description

1 Ribbon Detector Sensor Kit (set of 3) 105903-026

Printhead Assembly (4”) 105950-020

2

Printhead Cable (set of 5) 105903-028
3 Media Gap Sensor Kit (4”) (set of 2) 105903-029
4 Stepper Motor 105903-132
5 Blackline Media Sensor Kit (set of 3) 105903-003
6 Main Logic Board Maintenance Kit 52050M
7 Feed Switch Assembly (set of 5) 105903-015
8 Peel-Off Sensor Assembly (set of 3) 105903-039

Cutter 105903-073

Universal Power Supply Assembly (90-264 VAC, 47-63 Hz) 808080-001

Power Cord, 110V (set of 5) 105950-038

Not

Shown

Power Cord, 230V European (set of 5) 105950-039

Power Cord, 230V UK (set of 5) 105950-040

Power Cord, 230V Australian (set of 5) 105950-041

8M FLASH Memory w/Real Time Clock Option Kit 52054

User’s Guide 52007L

Quick Reference Guide 52008L

Number

Part

41

6

7

1

2

3

5

Figure 36

42

4

Refer to Figure 36.

Item

Number Description

1 Print Mechanism Assembly 105903-131
2 Upper Frame w/Ribbon Handler Kit 105903-049
3 Lower Frame Kit 105903-050
4 Rubber Foot Kit (set of 100) 105903-019
5 Option Port Cover (set of 20) 105903-051
6 Media Roll Holder Kit (set of 5) 105903-065
7 4” Notched Ribbon Core 105903-053

Battery Pack Adapter Plate 105903-022

Not

Shown

Ribbon Clutch Assembly 105903-080
Printhead Tension Bar 105903-082
Hardware Kit 105903-079

Number

Part

43

Replacing the Printhead

Refer to Figure 37.

1. Release the printhead by pulling the printhead release lever toward you.

2. Lift the printhead until you feel it “lock” into place. Be careful not to
force the printhead past this position!

3. Remove the screw that secures the printhead to the upper frame.

4. Remove the printhead wire harness connector from the receptacle.

5. Insert the printhead wire harness connector into the receptacle of the
new printhead. Make sure the connector is fully seated in the
receptacle.

6. Correctly position the printhead into the upper frame.

7. While holding the printhead in place, reinstall the screw that secures
the printhead to the upper frame.

Screw

Upper
Frame

Wire

Harness

Connector

Screw

Receptacle

44

Printhead

Figure 37

Specifications

NOTE: Printer specifications are subject to change without
notice.

Printing Specifications

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

Tear-off and cutter: 1.5” (38 mm), 2” (51 mm), and

Print Speed (per second)

Print Width 1.12” to 4.09” (28 mm to 104 mm)
Print Length

Registration Tolerance

FLASH Memory
(User Available)

DRAM Memory
(User Available)

Ribbon Specifications

2.5” (64 mm)
Peel-off: 1.5” (38 mm) and 2” (51 mm)

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

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

1 MB

1 MB

Ribbon Width 1.3” (33 mm) to 4.3” (109 mm)
Ribbon Length Approximately 3600” (91 m)
Ribbon Roll (Maximum Outer Diameter) 1.39” (35 mm)

Notched Core

Inner Diameter
Outer Diameter 0.75” (19 mm)

0.5” (13 mm)

45

Label/Tag Specifications

Label/Tag Width 1.12” to 4.65” (28 mm to 118 mm)
Label/Tag Length

Interlabel Gap
Label/Tag Thickness .003” to .0075” (.08 mm to .19 mm)

Label
Roll
Size

Media Requirements

Max. Outer
Diameter

Inner Core

0.38” to 22” (10 mm to 559 mm) with standard memory

0.5” (13 mm) to 22” (559 mm) in peel-off mode

0.08” to 0.16” (2 mm to 4 mm)
Recommended: 0.118” (3 mm)

5” (127 mm)
1” (25.4 mm)

Use Zebra-brand thermal transfer 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 of

the media.

46

Font/Bar Code Specifications

ü CG Triumvirate Bold Condensed scaleable smooth (0)

Fonts Available

Bar Codes
Available (1D)

Bar Codes
Available (2D)

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

ü Zebra fonts A-H, GS, P-V
ü IBM Code Page 850 International Symbols

ü Codabar (supports ratios

of 2:1 to 3:1)

ü

Code 11

ü Code 128/USD 8 (supports

serialization in all subsets
and UCC Case Codes)

ü Code 39 (supports ratios

of 2:1 to 3:1)

ü Code 93

EAN 8/JAN 8

ü

ü EAN 13/JAN 13
ü EAN 14/UPC-A

ü Codablock
ü Code 49

Data Matrix

ü

ü MaxiCode

ü Industrial 2 of 5
ü Standard 2 of 5
ü Interleaved 2 of 5

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

ü LOGMARS
ü MSI

ü

Plessey

ü POSTNET
ü UPC-E
ü UPC/EAN Extensions

ü MicroPDF417
ü PDF 417

QRcode

ü

Physical/Environmental/Electrical
Specifications

Physical Size (L x W x H) 9.8” x 7.9” x 6.75” 249 mm x 200 mm x 171 mm

Weight

Temperature
Range

Relative
Humidity

Electrical

Printer
Shipping 7.5 lbs. 3.40 kg
Operation
Storage
Operation
Storage

4 lbs. 1.81 kg

40° to 105° F 5° 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.

47

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

Cutter

n

Black mark (reflective) sensor

n

Real time clock with 8MB FLASH memory

n

External ZebraNet (10Base-T)

n

External ZebraNet PrintServer II (10Base-T)

For details, call your author ized reseller.

48

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.

Figure 38 shows the required cable connections.

Interconnecting to DCE Devices

When the printer is connected via its RS-232 interface to data
communication equipment (DCE) such as a modem, a STANDARD
RS-232 (straight-through) interface cable must be used. Figure 39 shows
the connections required for this cable.

49

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-9P

Connector

to Printer

DCD

1
2

TXD

3

DTR

4

GND

5

DSR

6

RTS

7

CTS

8
9

DB-9S

Connector

to DTE Device (PC)

1
2
3
4
5
6

RTS

7

CTS

8
9

Figure 38

50

DB-9P

Connector

to Printer

DCDDCD

1

RXDRXD

2

TXDTXD

3

DTRDTR

4

GNDGND

5

DSRDSR

6

RTS

7

CTS

8
9

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-9P

Connector

to Printer

DCD

1

RXD

2

TXD

3

DTR

4

GND

5

DSR

6

RTS

7

CTS

8
9

DB-9S

Connector

to DCE Device

1

TXD

2

RXD

3

DSR

4
5

DTR

6

CTS

7

RTS

8
9

Figure 39

DB-9P

Connector

to Printer

DCDDCD

1

RXD

2

TXD

3

DTR

4

GNDGND

5

DSR

6

RTS

7

CTS

8
9

51

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/HostClk
Data Bits 1-8
nACK/PtrClk
Busy/PtrBusy
PError/ACKDataReq
Select/Xflag
nAutoFd/HostBusy
Not Used
Ground
+5V @ 0.75A Fused
Ground
nInit
nFault/nDataAvail
Not Used
+5V through a 1.8 KΩ Resistor
nSelectIn/1284 active

52

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

Index

A

Ad just ments

Print dark ness........30

Print speed.........30

Print width.........30

Agency ap prov als........48

Auto cali bra tion.........25

Auto baud............29

C

Cali bra tion

Auto.............25

Man ual...........34

Clean ing

Cut ter............39

Ex te rior...........39

In te rior...........39

Peel bar...........39

Platen roller.........39

Print head..........39

Tear bar...........39

Com mu ni ca tions pa rame ters,

set ting...........29, 37

Com mu ni ca tions di ag nos tics..36

Con figu ra tion la bel.......35

Cut ter mode...........16

D

Dam age, ship ping........2

Dark ness, ad just ing.......30

DCE de vices, in ter con nect ing.49

De fault ing the printer......37

DTE de vices, in ter con nect ing.49

F

Fac tory de faults, re set ting...36

Fan fold me dia..........20

Feed but ton...........26

Feed but ton modes.......37

I

In spec tion............2

L

Load ing the me dia

Cut ter mode.........16

Fan fold...........20

Peel- off mode........10

Tear- off mode........5

Load ing the rib bon.......22

Lu bri ca tion...........39

53

M

Main te nance parts........41

Man ual cali bra tion.......34

Me dia load ing

Cut ter mode.........16

Fan fold...........20

Peel- off mode........10

Tear- off mode........5

O

Op era tor con trols........26

Op tions.............48

P

Par al lel con nec tor pin outs...52

Parts list.............41

Peel- off mode..........10

Pin outs

Par al lel...........52

Se rial............49

Power switch..........26

Print dark ness, ad just ing..30, 37

Print speed, ad just ing......30

Print width, ad just ing....30, 37

Print head, re plac ing.......44

S

Se rial con nec tor pin outs....49

Set com mu ni ca tions (^SC)...29

Speci fi ca tions

Font/bar code........47

La bel/tag..........46

Physi cal/en vi ron mental/

elec tri cal..........47

Print ing...........45

Rib bon............45

Status LED.........26, 31

T

Tear- off mode..........5

Trou ble shoot ing.........31

Trou ble shoot ing tests......35

U

Un pack ing............2

Z

ZPL II..............30

ZPL II Pro gram ming Guide.1, 30

R

Re mov ing the rib bon......24

Re pair parts...........41

Re plac ing the print head.....44

Re port ing dam age, ship ping...2

Rib bon

Load ing...........22

Re mov ing..........24

54

Zebra Technologies Corporation

333 Corporate Woods Parkway

Vernon Hills, Illinois 60061.3109 U.S.A.

Telephone [phone]

Facsimile +1 847.913.8766

Zebra Technologies Europe Limited

Zebra House

The Valley Centre, Gordon Road

High Wycombe

Buckinghamshire HP13 6EQ, UK

Telephone [phone]

Facsimile [phone]

Customer order #52007L
Manufacturer part #52007LB
© Zebra Technologies Corporation