Zebra Technologies Printer H 2824 Z User Manual

H 2824-Z  
Desktop Printer  
User Manual  
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© 2004 ZIH Corp.  
The copyrights in this manual and the label printer described therein are owned by  
Zebra Technologies. 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 product names and numbers are Zebra trademarks, and Zebra, the Zebra logo,  
ZPL, ZPL II, ZebraNet, ZebraLink, are registered trademarks of ZIH Corp. All  
rights reserved.  
All other brand names, product names, or trademarks belong to their respective  
holders.  
Customer Order # 980531-001 A  
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Proprietary Statement  
This manual contains proprietary information of Zebra Technologies Corporation and its  
subsidiaries (“Zebra Technologies”). It is intended solely for the information and use of parties  
operating and maintaining the equipment described herein. Such proprietary information may  
not be used, reproduced, or disclosed to any other parties for any other purpose without the  
expressed written permission of Zebra Technologies.  
Product Improvements  
Continuous improvement of products is a policy of Zebra Technologies. All specifications and  
designs are subject to change without notice.  
FCC Compliance Statement  
This device complies with Part 15 rules. Operation is subject to the following two conditions:  
1. This device may not cause harmful interference, and  
2. This device must accept any interference received, including interference that may  
cause undesired operation.  
This equipment has been tested and found to comply with the limits for Class B Digital  
Devices, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable  
protection against harmful interference when the equipment is operated in a residential  
environment. This equipment generates, uses, and can radiate radio frequency energy and, if  
not installed and used in accordance with the product manuals, may cause harmful interference  
to radio communications. However, there is no guarantee that interference will not occur in a  
particular installation. If this equipment does cause harmful interference to radio or television  
reception, the user is encouraged to do one or more of the following measures:  
Reorient or relocate the receiving antenna.  
Increase the separation between the equipment and 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.  
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Proprietary Statement  
The user is cautioned that any changes or modifications not expressly approved by Zebra  
Technologies could void the user’s authority to operate the equipment. To ensure compliance,  
this printer must be used with Shielded Communication Cables.  
Canadian DOC Compliance Statement  
This Class B digital apparatus complies with Canadian ICES-003.  
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.  
Liability Disclaimer  
Zebra Technologies takes steps to ensure that its published Engineering specifications and  
manuals are correct; however, errors do occur. Zebra Technologies reserves the right to correct  
any such errors and disclaims liability resulting therefrom.  
Limitation of Liability  
In no event shall Zebra Technologies or anyone else involved in the creation, production, or  
delivery of the accompanying product (including hardware and software) be liable for any  
damages whatsoever (including, without limitation, consequential damages including loss of  
business profits, business interruption, or loss of business information) arising out of the use  
of, the results of use of, or inability to use such product, even if Zebra Technologies has been  
advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or  
limitation of incidental or consequential damages, so the above limitation or exclusion may  
not apply to you.  
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Preface  
This section provides you with contact information, document structure and organization, and  
additional reference documents.  
Contacts  
You can contact Zebra Technologies at any of the following:  
Visit us at: www.zebra.com  
Our Mailing Addresses:  
Zebra Technologies Corporation  
333 Corporate Woods Parkway  
Vernon Hills, Illinois 60061.3109 U.S.A  
Telephone: +1 847.634.6700  
Fax: +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  
Fax: +44 (0)1494 450103  
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Preface  
Environmental Management  
Support  
You can contact Zebra support at:  
s
Note • The web address is case-sensitive.  
US Phone Number +1 847.913.2259  
UK/International Phone Number +44 (0) 1494 768289  
Environmental Management  
Do not dispose of this product in unsorted municipal waste. This product is recyclable, and  
should be recycled according to your local standards.  
For more information, please see our website at:  
Document Conventions  
The following conventions are used throughout this document to convey certain information:  
Alternate Color (online only) Cross-references contain links to other sections in this guide.  
If you are viewing this guide online, click the blue text to jump to its location.  
Command Line Examples All command line examples appear in CourierNew font.  
For example, type the following to get to the Post-Install scripts in the bindirectory:  
Ztools  
Files and Directories All file names and directories appear in Courier Newfont. For  
example, the Zebra<version number>.tarfile and the /root directory.  
Cautions, Important, Note, and Example  
Caution • Warns you of the potential for electrostatic discharge.  
Caution • Warns you of a potential electric shock situation.  
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Preface  
Related Documents  
Caution • Warns you of a situation where excessive heat could cause a burn.  
Caution • Advises you that failure to take or avoid a specific action could result in physical  
harm to you.  
Caution • Advises you that failure to take or avoid a specific action could result in physical  
harm to the hardware.  
Caution • Advises you need to wear protective eyeware.  
Important • Advises you of information that is essential to complete a task.  
Note • Indicates neutral or positive information that emphasizes or supplements important  
points of the main text.  
Example • Provides an example, often a scenario, to better clarify a section of text.  
Tools • Tells you what tools you need to complete a given task.  
Video • (online only) Links to a motion picture that demonstrates a procedure.  
Related Documents  
The following documents might be helpful references:  
®
ZPL II Programming Guide Volume I (part number 45541L) and Volume II (part  
number 45542L).  
®
ZebraNet Wireless Print Server User Guide (part number 13422L)  
ZebraNet 10/100 Print Server User and Reference Guide (part number 47619L-001)  
ZebraNet PrintServer IIInstallation and User Guide (part number 45537L)  
Universal Serial Bus Specification available from the USB Implementation Forum  
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Preface  
Related Documents  
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Contents  
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Contents  
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1
Introduction  
This section describes what you get in your shipping box and provides an overview of printer  
parts. This section also has procedures that describe how to open and close the printer and  
report any problems.  
Hello!  
Thank you for choosing a Zebra® desktop printer, a high-quality on-demand printer  
manufactured by the industry leader in quality, service, and value—Zebra Technologies  
Corporation. For over 25 years, Zebra Technologies Corporation has provided customers with  
the highest caliber of products and support.  
Your printer is a high-quality on-demand printer. The printer provides thermal-transfer  
printing (which uses ribbon) and direct-thermal printing.  
This manual provides all of the information you will need to operate your printer on a daily  
basis. To create label formats, refer to your programming guide. This guide is available by  
contacting your distributor or dealer.  
Your printer, when connected to a host computer, functions as a complete system for printing  
labels and tags.  
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.  
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Introduction  
What’s in the Box?  
What’s in the Box?  
Save the carton and all packing materials in case you need to ship or store the printer later.  
After unpacking, make sure you have all parts. Follow the procedures for inspecting the  
printer to familiarize yourself with printer parts so you can follow the instructions in this book.  
Sample  
Labels  
Printer  
Documentation  
and Warranty  
Cleaning  
Pen  
Power Supply  
and Cords  
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Introduction  
Inspecting the Printer  
Inspecting the Printer  
Look at the outside of the printer and make sure that all parts are present.  
Status  
Light  
Feed  
Button  
Power  
Switch  
Interface  
Connectors  
(vary by option)  
Power  
Supply  
Receptacle  
Release  
Latches  
Opening the printer  
To access the media compartment, you must open the printer. Pull the release levers towards  
you and lift the cover.  
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Introduction  
Inspecting the Printer  
After opening the printer, check the media compartment.  
Tear Bar  
Print Head  
Open-Hanger  
Lock  
Head-Up  
Sensor  
Peel-Off Option  
Media  
Hangers  
Media  
Guides  
Platen  
Roller  
Roller  
Bar  
Sensor  
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Introduction  
Inspecting the Printer  
Closing the printer  
1. Hold the top cover and press the “kick-stand” cover lock to release.  
2. Lower the top cover. The ribbon carriage automatically folds up into place.  
3. Press down until the cover snaps closed.  
Reporting Damage  
If you discover damage or missing parts:  
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 the authorized reseller.  
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Introduction  
Inspecting the Printer  
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2
Getting Started  
This section describes how to set up your printer for the first time and use the most common  
operating procedures for loading media in tear-off mode and loading ribbon.  
Modes of Printing  
You can operate this printer in different modes:  
Standard tear-off mode allows you to tear off each label (or a strip of labels) after it is  
printed.  
In optional 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.  
In optional liner-free mode, labels have no backing. This option is only available with a  
special platen.  
In optional cutter mode, an attached unit cuts through the media.  
The printer typically uses roll media, but you can use fan-fold or other continuous media as  
well.  
For procedures to use optional modes and features, refer to the Operation and Options section.  
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Getting Started  
Attaching Power Supply  
Attaching Power Supply  
Check the power supply to make certain it is appropriate for your input voltage.  
Caution • Use the power supply that came with your printer. Never operate the printer  
and power supply in an area where they can get wet. Serious personal injury could result!  
1. Make sure the power switch is in the off position (forward).  
2. 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.  
3. Insert the separate AC power cord into the power supply.  
4. Plug the other end of the cord into an appropriate AC electrical outlet.  
Plug Varies  
by Country  
Barrel  
Connector  
AC Power  
Cord  
Power  
Switch  
Power  
Supply  
Receptacle  
Power  
Supply  
Power  
Indicator  
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Getting Started  
Loading Roll Media  
Loading Roll Media  
When you load media, you must place the roll on the media hangers and then adjust the media  
guides.  
You must use the correct media for the type of printing you require. When printing without a  
ribbon, you must use direct thermal media. When using ribbon, you must use thermal transfer  
media. The printer's ribbon sensor detects motion of the supply spindle.  
Adjusting the Roll Holders  
Check the core of the media roll and adjust the holders if necessary.  
For a narrow core, lift the adjusters up.  
For a wide core, press the adjusters down.  
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Getting Started  
Loading Roll Media  
Placing the Roll in the Media Compartment  
Whether your roll media is inside or outside wound you load it into the printer the same way.  
1. Open the printer. Remember that you need to pull the release levers toward the front of  
the printer.  
2. Remove the outside length of media. During shipment, the roll may become dirty when  
handled or dusty when stored. Removing the outside length avoids dragging adhesive or  
dirty media between the print head and platen.  
3. Separate and hold open the media hangers.  
4. Orient the media roll so that its printing surface will be up as it passes over the platen.  
5. Lower the roll between the hangers and close them onto the core.  
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Getting Started  
Loading Roll Media  
Adjusting the Guides  
The guides direct the media toward the platen and print head.  
1. Thread the media through the guides. They should just touch the edges of the media.  
2. Close the top cover. Remember that you need to lower the top cover and press down until  
the latches snap into place.  
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Getting Started  
Operator Controls  
Operator Controls  
Power Switch  
Press backward to turn ON or forward to OFF the printer.  
Caution • The power should be turned off before connecting or disconnecting the  
communications and power cables.  
Feed Button  
Tapping the Feed button forces the printer to feed one blank label.  
Holding the Feed button forces the printer to feed continuously.  
Pressing the Feed button takes the printer out of a “pause” condition. The printer is put  
into “pause” by either a programming command or an error condition. See “What the  
Status Light is Telling You” in the Troubleshooting chapter.  
Use the Feed button for printer setup and status (see “Feed Button Modes” in the  
Troubleshooting chapter).  
Status Light  
Functions as a printer operational indicator (see “What the Status Light is Telling You” in the  
Troubleshooting chapter).  
Status  
Light  
Feed  
Button  
Power  
Switch  
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Getting Started  
Printing a Test Label  
Printing a Test Label  
Before you connect the printer to your computer, make sure that the printer is in proper  
working order.  
You can do this by printing a configuration label.  
1. Make sure the media is properly loaded and the top cover of the printer is closed. Then,  
turn the printer power on if you have not already done so.  
2. When the status light is solid green, press and hold the feed button until the status light  
flashes once.  
3. Release the feed button. A configuration label will print.  
If you cannot get this label to print, refer to the Troubleshooting chapter.  
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Getting Started  
Hooking Up the Printer and Computer  
Hooking Up the Printer and Computer  
Your printer will have one of these combinations of interfaces:  
Parallel  
Universal Serial Bus (USB) and DB-9 serial  
Ethernet and RJ-11 serial  
Each specific interface option—USB, parallel, ethernet, serial—is discussed individually.  
You must supply the required interface cable for your application.  
Caution • Keep the power switch in the OFF position when attaching the interface cable.  
The power supply barrel connector must be inserted into the power supply receptacle on  
the back of the printer before connecting or disconnecting the communications cables.  
.
Important • This printer complies with FCC “Rules and Regulations,” Part 15, for Class B  
Equipment, using fully shielded six-foot data cables. Use of longer cables or unshielded  
cables may increase radiated emissions above the Class B limits.  
Interface Cable 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:  
Keep data cables as short as possible (6’ [1.83 m] recommended).  
Do not tightly bundle the data cables with power cords.  
Do not tie the data cables to power wire conduits.  
USB Interface Requirements  
Universal Serial Bus (version 1.1) provides a high-speed interface that is compatible with your  
existing PC hardware. USB’s “plug and play” design makes installation easy. Multiple  
printers can share a single USB port/hub.  
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. The other end of the parallel interface cable connects to the printer connector at the  
host computer.  
For pinout information, refer to Parallel Interface on page 56.  
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Getting Started  
Hooking Up the Printer and Computer  
Ethernet Interface Requirements  
Ethernet provides a powerful networking capability that can be of use in a variety of internet/  
intranet printing solutions. After you load media and close the top cover, you can press the test  
button next to the connector on the rear of the printer to get an ethernet configuration label.  
Serial Interface Requirements  
The standard 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.  
There is an optional serial interface that uses a 6-pin RJ-11 male connector on one end, which  
is plugged into the mating RJ-11 alternative serial port located on the back of the printer.  
The other end of the signal interface cable connects to a serial port at the host computer.  
Depending on the specific interface requirements, this will most likely be a straight-through  
cable.  
For pinout information, refer to Serial (RS-232) Connector on page 58.  
Communicating with the Printer  
Universal Serial Bus (USB) Communications  
The printer is a terminal device when using a universal serial bus interface. You can refer to  
the Universal Serial Bus Specification for details regarding this interface.  
Parallel Communications  
When using the parallel port, typically there is 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.  
Internal ZebraNet® PrintServer II™ Ethernet Communications  
You can refer to the ZebraNet® PrintServer II™ for Ethernet Networks Installation and  
Operation Guide for details regarding this interface.  
Serial Communications  
Serial communications between the printer and the host computer can be set by either  
autobaud synchronization or the ^SCcommand.  
Autobaud  
Autobaud synchronization allows the printer to automatically match the communication  
parameters of the host computer. To autobaud:  
1. Press and hold the feed button until the green status LED flashes once, twice, and then  
three times.  
2. While the status LED flashes, send a ZPL II format to the printer.  
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Getting Started  
Adjusting the Print Width  
3. When the printer and host are synchronized, the LED changes to solid green. (No labels  
will print during autobaud synchronization.)  
^SC Command  
Use the Set Communications (^SC) command to change the communications settings on the  
printer.  
4. 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.  
5. Change the host computer settings to match the new printer settings.  
Refer to the ZPL II Programming Guide for more information about this command.  
Default the Serial 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:  
6. Press and hold the feed button until the green status LED flashes once, twice, and then  
three times.  
7. While the status LED rapidly flashes amber and green, press the feed button.  
Adjusting the Print Width  
Print width must be calibrated when:  
You are using the printer for the first time.  
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 )  
or refer to the Print Width (^PW) command (consult your ZPL II Programming Guide).  
Adjusting the Print Quality  
Print quality is influenced by the heat of the print head, the speed of the media and the type of  
media you are using. Only by experimenting will you find the optimal mix for your  
application.  
The relative darkness setting is controlled by either the six-flash sequence in “Feed Button  
Modes” (see page ) or the Set Darkness (~SD) ZPL II command (follow the instructions in the  
ZPL II Programming Guide).  
If you find that the print speed needs to be adjusted, refer to the Print Rate (^PR) command in  
the ZPL II Programming Guide.  
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3
Operations & Options  
This section helps you get the most from your printer.  
You must use programming to control many of the printer’s functions.  
Example • The ~JLcommand controls label length.  
The ^XA^JUS^XZcommand saves the new settings to flash memory  
For detailed information about creating labels using ZPL II, refer to the ZPL II Programming  
To improve print quality, changing both print speed and density may be required to achieve the  
desired results. Your application’s printer driver provides control of the speed and heat  
(density).  
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Operations & Options  
Thermal Printing  
Thermal Printing  
Caution • The print head becomes hot while printing. To protect from damaging the print  
head and risk of personal injury, avoid touching the print head. Use only the cleaning pen  
to perform maintenance.  
Caution • The discharge of electrostatic energy that accumulates on the surface of the  
human body or other surfaces can damage or destroy the print head or electronic  
components used in this device. You must observe static-safe procedures when working  
with the print head or the electronic components under the top cover.  
You must use the correct media for the type of printing you require. You must use direct  
thermal media.  
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Operations & Options  
Replacing Supplies  
Replacing Supplies  
If labels run out while printing, leave the printer power on while reloading (data loss results if  
you turn off the printer). After you load a new ribbon roll, press the Feed button to restart.  
Always use high quality, approved labels and tags. If adhesive backed labels are used that  
don’t lay flat on the backing liner, the exposed edges may stick to the label guides and rollers  
inside the printer, causing the label to peel off from the liner and jam the printer. Approved  
supplies can be ordered from your dealer.  
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Operations & Options  
Printing in Peel-Mode  
Printing in Peel-Mode  
The optional dispenser allows you to print in “peel-mode” where the label backing follows a  
different path and the labels are presented one at a time for subsequent placement.  
Before using peel-mode, you must send the programming commands to the printer.  
^XA ^MMP ^XZ  
^XA ^JUS ^XZ  
Refer to your ZPL II Programmer’s Manual.  
1. Remove several labels from the backing material.  
2. Open the top cover.  
3. Open the dispenser door.  
4. Using a stylus, switch on the label-taken sensor.  
5. Insert the backing in front of the peel bar and behind the peel roller.  
6. Close the dispenser door.  
7. Close the top cover.  
8. Press the Feed button to advance the label.  
9. During the print job, the printer will peel off the backing and present a single label. Take  
the label from the printer so it will print the next label.  
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Operations & Options  
Printing in Peel-Mode  
B
A
C
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Operations & Options  
Printing on Fan-Fold Media  
Printing on Fan-Fold Media  
Printing on fan-fold media requires you to set both the media hangers and the media guides in  
position.  
1. Open the top cover.  
2. Open the hangers to their widest position.  
3. Snap the holder-open lock towards the front of the printer.  
4. With a sample of your media, adjust the guides to the width of the media. The guides  
should just touch, but not restrict, the edges of the media.  
5. Insert the media through the slot at the rear of the printer.  
6. Run the media between the hangers and guides.  
7. Close the top cover.  
A
B
C
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Operations & Options  
Using the Cutter Option  
Using the Cutter Option  
Printers that have a bezel with a motorized blade can dispense one or more forms that are then  
automatically cut from the media supply. This option cuts through continuous paper from rolls  
and liner between labels. Keep the cutter dry. Never use any solutions or solvents to clean the  
blade.  
Use the ^MMcommand to activate the cutter and the ^LLcommand to set the form length and  
gap distance. See the ZPL II Programmer's Manual.  
If the blade cuts through labels, adhesive can jam the cutter.  
1. Turn OFF (O) printer power and unplug the power and interface cables before clearing the  
cutter.  
2. After removing debris, plug in the power and interface cables, turn on the printer, then test  
for normal operation.  
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Operations & Options  
Using the Cutter Option  
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4
Maintenance  
Cleaning  
When you clean the printer, use one of the following supplies that best suits your needs:  
:
Cleaning Supplies  
Cleaning pens (12)  
Cleaning swabs (25)  
The cleaning process takes just a couple of minutes using the steps outlined below.  
Printer Part  
Method  
Interval  
Print head  
Let the print head to cool for a minute, then use a When using direct  
new cleaning pen to swab the the thin gray line  
on the print head from end to end.  
thermal: after every  
roll of media.  
NOTE: You do not have to turn off the printer to  
do this.  
Platen roller  
See “Platen Considerations” in the Maintenance As needed.  
chapter. Manually rotate the platen roller. Clean  
it thoroughly with 95% medical-grade alcohol  
and a cleaning swab, cleaning card, or lint-free  
cloth.  
Peel bar  
Clean it thoroughly with 95% medical-grade  
alcohol and a cotton swab.  
Tear bar  
Let alcohol disappate and the printer dry  
completely.  
Media path  
Exterior  
Interior  
Cutter  
Water-dampened cloth.  
Brush or air blow.  
Use tweezers to remove scraps.  
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Maintenance  
Cleaning  
Caution • Adhesives and coatings of media can over time transfer onto the printer  
components along the media path including the platen and print head. This build-up can  
accumulate dust and debris. Failure to clean the print head, media path and platen roller  
could result in inadvertent loss of labels, label jams and possible damage to the printer.  
Important • Using too much alcohol can result in contamination of the electronic components  
requiring a much longer drying time before the printer will function properly.  
Print Head Considerations  
Always use a new cleaning pen on the print head (an old pen carries contaminants from its  
previous uses that may damage the print head).  
Caution • The print head becomes hot while printing. To protect from damaging the print  
head and risk of personal injury, avoid touching the print head. Use only the cleaning pen  
to perform maintenance.  
When you load new media, you can also clean the print head.  
1. Rub the cleaning pen across the dark area of the print head.  
2. Wait one minute before closing the printer.  
Do not clean the platen roller.  
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Maintenance  
Cleaning  
Media Path Considerations  
Use a cleaning swab or pen to remove debris, dust or crust that has built-up on the holders,  
guides and media path surfaces.  
1. Use the alcohol in the cleaning swab or pen to soak the debris so that it breaks up.  
2. Wipe the knobs to remove accumulated debris.  
3. Wipe the inside edges of both edge guides to remove any built-up residue.  
4. Wait one minute before closing the printer.  
Discard the cleaning swab or pen after use.  
Edge  
Guides  
Knobs  
Platen  
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Maintenance  
Cleaning  
Sensors  
Dust can accumulate on the media and head-up sensors.  
1. Gently blow away dust; if necessary, use a dry swap to brush away dust. If adhesives or  
other contaminates remain, use an alcohol moistened swab to break up.  
2. Use a dry swab several times to remove any residue that may be left from the first cleaning  
.
Media  
Sensors  
Head-Up  
Sensor  
Linerless Media  
If you use linerless media in your application, sticky residue can build up quickly on the  
media-path knobs and edge guides; dust and debris then accumulates in this sticky residue.  
Make certain to clean these areas as needed.  
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Maintenance  
Lubrication  
Platen Considerations  
The standard platen (drive roller) normally does not require cleaning. Paper and liner dust can  
accumulate without effecting print operations. Contaminates on the platen roller can damage  
the print head or cause the media to slip when printing. Adhesive, dirt, general dust, oils and  
other contaminates should be cleaned immediately off the platen.  
Keep a new platen available as a spare and install it whenever the printer has significantly  
poorer performance, print quality or media handling. If sticking or jamming continues even  
after cleaning, you must replace the platen.  
The platen can be cleaned with a fiber-free swab (such as a Texpad swab) or a lint free, clean,  
damp cloth very lightly moistened with medical grade alcohol (95% pure or better).  
1. Open the media door and remove the media.  
2. Remove the platen from the printer (see “Replacing the Platen” in this section).  
3. Clean the platen surface with the alcohol moistened swab. Rotate the platen while  
swabbing. Repeat this process two to three times with a new swab to remove residual  
contaminates. Adhesives and oils, for example, may be thinned by the initial cleaning but  
not completely removed.  
4. Replace the platen in the printer (see “Replacing the Platen” in this section).  
5. Discard the cleaning swab or pen after use.  
Allow the printer to dry for one minute before loading labels.  
Important • Cleaning shortens the life of non-stick platens user for linerless media. Cleaning  
the non-stick platen removes the outer layer of non-stick material. You may need to feed over  
three feet (a meter or more) of media to restore the non-stick properties.  
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.  
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Maintenance  
Replacing the Platen  
Replacing the Platen  
Tools • You will need to use a pointed stylus (such as tweezers, small slot-head screwdriver or  
razor-knife during this procedure.  
Removal  
Open the printer and remove any media.  
1. Using a pointed stylus, unhook the tabs on the right and left sides. Then rotate them  
forward.  
2. Lift the platen out of the printer’s bottom frame.  
Assembly  
Make sure the right bearing is on the shaft of the platen.  
1. Align the platen with the gear to the left and lower it into the printer’s bottom frame.  
2. Rotate the tabs back and snap them into place.  
A
B
D
C
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Maintenance  
Replacing the Print Head  
Replacing the Print Head  
In the event you need to replace the print head, read the procedure and review the removal and  
installation steps before actually replacing the print head.  
Caution • Prepare your work area by protecting against static discharge. Your work area  
must be static-safe and include a properly grounded conductive cushioned mat to hold the  
printer and a conductive wrist strap for yourself.  
Caution • Turn the printer power off and unplug the power cord before replacing the print  
head.  
Tools • You will need to use a #1 Phillips driver during this procedure.  
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Maintenance  
Replacing the Print Head  
Thermal-Transfer LP Model  
Before following the steps in this procedure, open the printer by pulling the release latches  
forward then lifting the top cover.  
Removal  
1. Grasp the print head spring and pull it to the left; then, slide it free of the carriage.  
2. Use the spring to pry the print head clip off the right side of the carriage.  
3. Pull the print head and bracket forward.  
4. Use a #2 Phillips driver to remove the screw that holds the ground wire.  
5. Unplug both bundles of print head wires from their connectors.  
A
B
C
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Maintenance  
Replacing the Print Head  
Replacing the LP Print Head (Continued)  
Assembly  
1. Align the print head to plug the left and right connectors into the wire bundles.  
2. Slip the ground wire under the right screw and use a #1 Phillips driver to tighten it.  
3. Slide the print head into one side and jog it into the other side.  
4. Align the pivots of the bracket onto the posts; then, snap the bracket into place.  
5. Clean the print head with the cleaning pen.  
Reload media. Plug in the power cord, turn on the printer and print a status report to ensure  
proper function.  
A
B
C
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Maintenance  
Replacing the Print Head  
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5
Troubleshooting  
What the Status Light is Telling You  
Fora Resolution,  
Refer to Number:  
LED Status and Color  
Printer Status  
Off  
Solid Green  
Off  
On  
1
2
3
4
5
6
7
8
Flashing Amber  
Stopped  
Flashing Green  
Normal Operation  
Stopped  
Flashing Red  
Double Flashing Green  
Solid Amber  
Paused  
Various  
Alternately Flashing Green and Red  
Needs Service  
Resolutions  
1. The printer is not receiving power.  
Have you turned on the printer power?  
Check power connections from the wall outlet to the power supply, and from the power  
supply to the printer.  
2. The printer is on and in an idle state.  
No action necessary.  
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Troubleshooting  
Resolutions  
3. The printer has failed its power on self test (POST).  
If this error occurs right after you turn on the printer, contact an authorized reseller for  
assistance.  
There is a shortage of memory.  
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.  
As soon as all of the data has been received, the status LED will turn green; then, the  
printer will automatically resume operation.  
5. Either the media or ribbon is out.  
Load a roll of media, following the instructions in “Loading the Media” in the Getting  
Started chapter. Then, press the feed button to resume printing.  
Load a roll of ribbon, following the instructions in “Loading the Ribbon” in the Getter  
Started chapter. Then, press the feed button to resume printing.  
The print head is open.  
Close the top cover. Then, press the feed button to resume printing.  
6. The printer is paused.  
Press the feed button to resume printing.  
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Troubleshooting  
Resolutions  
7. The print head is under temperature.  
Continue printing while the print head reaches the correct operating temperature.  
The print head is over temperature.  
Printing will stop until the print head cools to an acceptable printing temperature. When it  
does, the printer will automatically resume operation.  
8. FLASH memory is not programmed.  
Return the printer to an authorized reseller.  
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Troubleshooting  
Print Quality Problems  
Print Quality Problems  
No print on the label.  
You must use the correct media for the method of printing you require. You must use  
thermal transfer media.  
Is the media loaded correctly? Follow the instructions in “Loading the Media”in the  
Getting Started chapter.  
The printed image does not look right.  
The print head is dirty. Clean the print head.  
The print head is under temperature.  
Adjust the print darkness and/or print speed. Refer to the six-flash sequence in “Feed  
Button Modes” later in this chapter, or the ^PRand ~SDcommands in the ZPL II  
Programming Guide.  
The media being used is incompatible with the printer. Be sure to use the recommended  
media for your application, and always use Zebra-approved labels and tags.  
There are long tracks of missing print (blank vertical lines) on  
several labels.  
The print head is dirty. Clean the print head.  
The print head elements are damaged. Replace the print head (see “Replacing the Print  
Head” in the Maintenance chapter).  
The ribbon sensor settings did not print.  
The printer is set for direct thermal printing; use the ^XA^MTT^XZcommand to reset the  
printer for thermal transfer printing and calibrate again.  
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Troubleshooting  
Print Quality Problems  
The printing does not start at the top of the label, or misprinting of  
one to three labels.  
The media may not be threaded under the media guides. Refer to “Loading the Media” in  
the Getting Started chapter.  
The printer needs to be calibrated. Refer to “Auto Calibration” in the Getting Started  
chapter.  
The correct media sensor may not be activated. Manual calibration selects the media  
sensing method for the labels being used (refer to the ^MNcommand in the ZPL II  
Programming Guide).  
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.  
Is the printer in pause mode? If so, press the feed button.  
If the status LED is on or flashing, refer to “What the Status Light is Telling You” in this  
chapter.  
Make sure the data cable is correctly installed.  
A communications problem has occurred. First, make sure that the correct  
communications port on the computer is selected. Refer to “Communicating with the  
Printer” in the Getting Started chapter.  
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Troubleshooting  
Manual Calibration  
Manual Calibration  
Manual calibration is recommended whenever you are using pre-printed media or if the printer  
will not correctly auto calibrate.  
1. Make sure media is loaded.  
2. Turn on the printer power.  
3. Press and hold the feed button until the green status LED flashes once, then twice.  
Release the feed button.  
4. The printer will set the media sensor for the label backing being used. After it is done  
making this adjustment, the roll will automatically feed until a label is positioned at the  
print head.  
5. A profile of the media sensor settings (similar to the example below) will print. Upon  
completion, the printer will save the new settings in memory and the printer is ready for  
normal operation.  
6. Press the feed button. One entire blank label will feed. If this does not happen, try  
defaulting (refer to the four-flash sequence in “Feed Button Modes” later in this chapter)  
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” later  
in this chapter).  
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Troubleshooting  
Troubleshooting Tests  
Troubleshooting Tests  
Printing a Configuration Label  
To print out a listing of the printer’s current configuration, refer to the one-flash sequence in  
“Feed Button Modes” later in this chapter.  
Recalibration  
Recalibrate the printer if it starts to display unusual symptoms, such as skipping labels. See  
“Printing a Test Label” in the Getting Started chapter.  
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Troubleshooting  
Resetting the Factory Default Values  
Resetting the Factory Default Values  
Sometimes, resetting the printer to the factory defaults solves some of the problems. Follow  
the four-flash sequence instructions in “Feed Button Modes” later in this chapter  
Communications Diagnostics  
If there is a problem transferring data between the computer and printer, try putting the printer  
in the communications diagnostics mode. The printer will print the ASCII characters and their  
respective hexadecimal values (a sample is shown below) for any data received from the host  
computer. To find out how, refer to the power off mode procedure in “Feed Button Modes”  
later in this chapter.  
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Troubleshooting  
Feed Button Modes  
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. After printing the label, the printer will automatically enter a diagnostic mode in which the  
printer prints out a literal representation 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.  
*
The media sensor calibrates and a media sensor profile prints (see “Manual Calibration”  
earlier in this chapter).  
*
**  
To reset the communication parameters. Press and release the feed button while the LED  
rapidly flashes amber and green.  
*
**  
***  
For autobaud synchronization: Send a ZPL II format to the printer while the LED rapidly  
flashes amber and green. When the printer and host are synchronized, the LED changes to  
solid green. NOTE: No labels will print during autobaud synchronization.  
Resets the factory defaults, auto calibrates, and saves settings into memory.  
*
**  
***  
****  
The print width calibrates. While the status LED alternately flashes green and amber, a  
series of stacking rectangles print on the label. When the rectangle prints to the outer  
edges of the label, press and release the feed button. The label width and current  
communication parameters will be saved into memory.  
*
**  
***  
****  
*****  
The print darkness calibrates. A series of nine samples print, starting with the lightest and  
ending with the darkest image. When the desired print darkness is achieved, press and  
release the feed button. The print darkness will be saved into memory  
*
**  
***  
****  
*****  
******  
If the feed button remains pressed after a 7-flash sequence, the printer will ignore the button when it is  
released  
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Troubleshooting  
Battery  
Battery  
The optional Real Time Clock requires a three-volt lithium battery on the main printed circuit  
board. You can discern a low or flat battery if the printer provides a consistently delayed date  
stamp. Only a qualified technician observing precautions against both static discharge and  
electric shock can replace the battery.  
Caution • Risk of explosion if battery is replaced with an incorrect type.  
Important • Recycle batteries according to local your guidelines and regulations.  
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6
Interfaces  
Universal Serial Bus (USB) Connector  
The figure below displays the cable wiring required to use the printer’s USB interface.  
Pin No.  
Description  
1
Vbus  
2
D–  
3
D+  
4
Ground  
Shell  
Shield/Drain Wire  
For printer supported operating systems and drivers, see the software and documentation CD  
or visit the Zebra printer web site at:  
For information on the USB interface, go to the USB web site at:  
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Interfaces  
Parallel Interface  
Parallel Interface  
The maximum current available through the interface port is not to exceed a total of 0.75  
amps.  
Pin No.  
1
Description  
NStrobe/Host Clk  
Data Bits 1-8  
2-9  
10  
nACK/PtrClk  
11  
Busy/Per Busy  
PError/ACK Dat Req.  
Select/Xflag  
12  
13  
14  
NAuto Fd/Host Busy  
Not Used  
15  
16-17  
18  
Ground  
+5 V @ 0.75 A Fused  
Ground  
19-30  
31  
nInit  
32  
NFault/nData Avail.  
Not Used  
33-34  
35  
+5 V throught 1.8 K Ohms Resistor  
NSelectin/1284 active  
36  
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Interfaces  
ZebraNet® PrintServer II for Ethernet Networks  
ZebraNet® PrintServer II for Ethernet Networks  
This interface uses an RJ-45 straight-through cable type. The table below provides the pinout  
assignments.  
Signal  
Tx+  
Tx-  
Rx+  
---  
Pin  
1
Pin  
1
Signal  
Tx+  
Tx-  
Rx+  
---  
2
2
3
3
4
4
---  
5
5
---  
Rx-  
---  
6
6
Rx-  
---  
7
7
---  
8
8
---  
The figure above has the perspective looking into the printer RJ-45 modular connector.  
You can refer to the ZebraNet® PrintServer IITM for Ethernet Networks Installation and  
Operation Guide for details regarding this interface.  
The RJ-11 jack on Ethernet boards is used for factory tests only.  
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Interfaces  
Serial (RS-232) Connector  
Serial (RS-232) Connector  
Pin No.  
Description  
1
2
3
4
Not used  
RXD (receive data) input to the printer  
TXD (transmit data) output from printer  
DTR (data terminal ready) output from the printer -- controls when the  
host may send data  
5
6
7
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  
8
9
CTS (clear to send) input to the printer  
+5 V @ 0.75 A fused  
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.  
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.  
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Interfaces  
Serial (RS-232) Connector  
Connecting the Printer to a DTE Device  
DB-25S  
Connector  
to DTE Device (PC)  
DB-9P  
Connector  
to Printer  
DB-9S  
Connector  
to DTE Device (PC)  
DB-9P  
Connector  
to Printer  
Connecting the Printer to a DCE Device  
DB-25S  
Connector  
to DCE Device (PC)  
DB-9P  
Connector  
to Printer  
DB-9S  
Connector  
to DCE Device (PC)  
DB-9P  
Connector  
to Printer  
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Serial (RS-232) Connector  
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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 # 980531-001A  
© 2004 ZIH Corp.  
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