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Calibrating the Printer
This chapter of the user’s guide is so important that we’ve printed it on a different
color paper! That way, it will be easy for you to find when you must calibrate (set
up) the printer for your particular application.
Purpose
�
To calibrate the printer.
�
To verify that the printer is properly set up by printing a test label.
NOTE: This procedure must be performed when the printer is first
installed or when it cannot properly detect the top of the label.
To calibrate the printer, you must do the following (all of the instructions are
contained in this chapter):
�
Determine the type of media (labels) being used.
�
Choose the print method.
�
Position the media sensor (if necessary).
�
Configure the printer and software or driver based on the label being used.
�
Print a test label.
Choosing the Print Mode
�
Tear-off mode allows you to tear off each label, or a strip of labels, after it is
printed.
�
In peel-off mode, backing material is peeled away from the label as it is printed.
After this label is removed from the printer, the next one is printed.
�
When in cutter mode, the printer automatically cuts the label after it is printed.
�
In rewind mode, the media and/or backing are rewound onto a core as the labels
are printed.
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Loading the Media
Figure 6 illustrates one method of media loading. For more detailed instructions, as
well as information about how to load the different types of media and the various
printing modes, refer to the instructions that begin on page 22.
Media supply guide
Transmissive
sensor
Printhead
assembly
Dancer
Media
supply
Ribbon
Media guide
sensor
hanger
Printhead open lever
Figure 6
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Positioning the Media Sensor
The correct positioning of the media sensor is important. It can make the difference
between a perfect label and a call to Technical Support!
There are two media sensors in this printer: “reflective” and “transmissive.”
Reflective Sensor
The reflective sensor detects the “start-of-label indicator” (the notch, hole, black
mark, or gap between die-cut labels).
The reflective sensor must be positioned:
�
directly under the notch, hole, or black mark, or
�
anywhere along the width of the media if there is a gap between labels
The glow of the red light through the media will help you to accurately position the
reflective sensor.
NOTE: If you are using continuous media, position the reflective
sensor anywhere under the media so that the printer can detect an
out-of-paper condition.
NOTE: The reflective sensor is compatible with most types of media.
However, if you encounter difficulties with calibration, use the
transmissive sensor. See “Transmissive Sensor” on page 12.
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Adjusting the Reflective Sensor
Refer to Figure 7.
1. Open the printhead assembly by pressing the printhead open lever.
2. Locate the reflective sensor positioning lever.
3. Move the reflective sensor positioning lever across the width of the media until
the reflective sensor aligns with the start-of-label indicator. The glow of the red
light will assist in the proper placement of the reflective sensor.
4. Close the printhead assembly.
Printhead assembly
Reflective
sensor
Reflective
sensor
positioning
lever
Printhead open
lever
Figure 7
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Transmissive Sensor
The transmissive sensor is in a fixed position and enabled via the front panel (details
in “SENSOR SELECT” on page 41).
Loading the Ribbon
Refer to Figure 8.
For more detailed information, refer to the instructions that begin on page 34.
Ribbon take-up spindle
Ribbon
guide plate
Printhead
assembly
Ribbon
supply spindle
Printhead open lever
Figure 8
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Operator Controls
POWER Switch
The POWER switch is located at the back of the printer above the power cord. Turn
on the printer.
Front Panel
For a more detailed explanation of the front panel keys and lights (as shown in
Figure 9), refer to the instructions that begin on page 19.
PAUSE
Figure 9
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Configuring the Printer
The configuration procedure in the next table contains the information you need to
get your printer up and running, but it is not comprehensive. Refer to page 40 for
more information.
�
Press the SETUP/EXIT key at the “PRINTER READY” display to enter the
configuration mode.
NOTE: You will need to press the INCREMENT (+) key more than
once to advance to some of the displays.
�
Press the INCREMENT (+) or DECREMENT (-) key to scroll to the setting you
wish to change.
�
Press the SELECT key to toggle the functionality of the INCREMENT (+) and
DECREMENT (-) keys.
�
Press the INCREMENT (+) or DECREMENT (-) keys to increase or decrease the
value; answer “yes” or “no”; print a label; or, select the digit you wish to change.
�
Press the SELECT key again to use the INCREMENT (+) and DECREMENT (-)
keys to scroll to the desired menu item.
Parameter
PRINTER READY
DARKNESS
Selections/Explanation
You are ready to configure the printer.
0 to 30 (default setting is “10”)
Tear-off, peel-off, cutter, rewind (default is “tear-off”)
Non-continuous, continuous (default setting is “non-continuous”)
Web, mark (default setting is “web”)
PRINT MODE
MEDIA TYPE
SENSOR TYPE
PRINT METHOD
Thermal transfer, direct thermal (default setting is “thermal transfer”)
�
After you have configured the print method, press the SETUP/EXIT key to save
the changes and exit the configuration mode.
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Configuring the Software of Printer Driver
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.
Printing a Test Label
To print a test label:
1. Turn off the printer.
2. Press and hold the CANCEL key while
turning on the printer.
3. Release the key after the DATA light turns
off (approximately five seconds).
A configuration label, which shows the printer’s
currently stored parameters, will print (similar to
the one shown in Figure 10).
If you encounter any problems while you are
configuring the printer or printing a test label,
refer to Troubleshooting, which starts on
page 67. Otherwise, refer to Establishing
Communication on page 17 to set up the
communication parameters.
Figure 10
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Establishing Communication
System Considerations
Interfaces
The method of interfacing this printer to a data source depends on the
communication options installed in the printer. The standard interfaces are an
RS-232/RS-422/RS-485 serial data port and a bi-directional parallel port. The
optional ZebraNet PrintServer II enables printers to be connected to 10Base-T
Ethernet networks.
Data Specifications
Printer
Computer
When communicating via an asynchronous
serial data port (refer to Figure 11), the baud
rate, number of data and stop bits, parity,
and handshaking are user selectable (default
settings are 9600 baud, 8 data bits, 1 stop
bit, no parity, and XON/XOFF). Parity only
applies to data transmitted by the printer
since the parity of received data is ignored.
Male
25
25
Male
25
9
Female
Null modem adapter
(if using a standard
modem cable)
50’ (15 m) maximum
Figure 11
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When communicating via the parallel port
(refer to Figure 12), the previously
mentioned parameters are not considered.
Refer to page 46 to configure the
Printer
Computer
communication parameters for the printer.
The values selected must be the same as
those used by the host equipment connected
to the printer.
36-pin
male
PC
25-pin
female
For serial and parallel pinout and technical
information, refer to the Appendix on
page 85.
25-pin
male
Cabling Requirements
10’ (3 m) maximum
Data cables must be fully shielded and fitted
with metal or metalized connector shells.
Shielded cables and connectors are required
to prevent radiation and reception of
electrical noise.
Figure 12
To minimize electrical noise pickup in the cable:
�
Keep data cables as short as possible.
�
Do not bundle the data cables tightly with the power cords.
Do not tie the data cables to power wire conduits.
�
NOTE: Zebra printers comply with FCC “Rules and Regulations,”
Part 15, for Class B Equipment, using fully shielded data cables.
Use of unshielded cables may increase radiated emission above the
Class B limits.
NOTE: RS-422 and RS-485 applications should use twisted shielded
pairs as recommended in the Appendix of the TA/EA.-485
Specification.
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Printer Basics
Front Panel
This section discusses the functions of the various controls and indicators on the
printer. The operator should become familiar with each of these functions.
Front Panel Display
The front panel display communicates operational status and programming modes
and parameters.
PAUSE
Figure 13
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Front Panel Keys
Key
Function
Forces the printer to feed one blank label each time the key is pressed.
• Printer not printing: one blank label immediately feeds.
FEED
• Printing: one blank label feeds after the current batch of labels is complete.
Starts and stops the printing process.
• Printer not printing: no printing occurs. (Press PAUSE again to resume
printing.)
PAUSE
• Printing: printing stops once the current batch is complete.
When in the pause mode, this key will cancel print jobs.
• Printer not printing: the next stored label format will not print.
• Printing: the label format currently printing is canceled.
CANCEL
Press and hold for several seconds to cancel all print jobs in the printer’s
memory.
Enters and exits the configuration mode.
SETUP/EXIT
Toggles the function of the INCREMENT (+) and DECREMENT (-) keys between
the “scroll” and “change” modes.
• Press once to use the INCREMENT (+) and DECREMENT (-) keys to change the
value of the selection.
SELECT
• Press again to use the INCREMENT (+) and DECREMENT (-) keys to scroll
through the menu items.
INCREMENT (+)
(”scroll” mode)
Scrolls to the next selection.
• Increases the value
INCREMENT (+)
(”change” mode)
• Answers “yes”
• Prints a label (when applicable)
DECREMENT (-)
(”scroll” mode)
Scrolls to the previous selection.
• Decreases the value
DECREMENT (-)
(”change” mode)
• Selects the digit you wish to change
• Answers “no”
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Front Panel Lights
Light
Status
Off
Indication
The printer is off or no power is applied.
POWER
The printer is on.
On
Normal printer operation.
Off
The printer has stopped all printing operations.
On
PAUSE
In peel-off mode, the PAUSE light flashes when the label is
available for removal, and when initializing FLASH or
PCMCIA memory.
Flashing
Off
Normal printer operation (no errors).
“RIBBON IN” warning, “HEAD UNDER TEMP” warning, or
“HEAD OVER TEMP” error
Slow flashing
ERROR
“HEAD OPEN” error
Fast flashing
On
“PAPER OUT,” “RIBBON OUT,” or “CUTTER JAM” errors
Normal printer operation (no data being received or
processed).
Off
The CANCEL key is pressed and a format is successfully
canceled.
One flash
DATA
The printer is unable to accept more data from the host.
The printer is receiving data.
Slow flashing
Fast flashing
A partial format has been received and there has been no
subsequent data activity.
On
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Roll Media Loading
Tear-Off Mode
Refer to Figure 14.
1. Press the printhead open lever. The printhead assembly springs up.
2. Flip down the media supply guide.
3. Slide out the media guide as far from the printer frame as possible.
4. Place the roll of media on the media supply hanger.
5. Flip up the media supply guide. Slide in the media supply guide so that it just
touches, but does not restrict, the edge of the roll.
6. Feed the media under the dancer, through the slot in the transmissive sensor,
under the ribbon sensor, and out the front of the printer.
7. Ensure that the media is against the back of the transmissive sensor. Slide in the
media guide so that it just touches, but does not restrict, the edge of the media.
8. Close the printhead assembly.
Media supply guide
Transmissive
sensor
Printhead
assembly
Dancer
Media
supply
Ribbon
sensor
Media guide
hanger
Printhead open lever
Figure 14
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Cutter Mode
(Cutter option required)
Refer to Figure 15.
1. Press the printhead open lever. The printhead assembly springs up.
2. Flip down the media supply guide.
3. Slide out the media guide as far from the printer frame as possible.
4. Place the roll of media on the media supply hanger.
5. Flip up the media supply guide. Slide in the media supply guide so that it just
touches, but does not restrict, the edge of the roll.
6. Feed the media under the dancer, through the slot in the transmissive sensor,
under the ribbon sensor, and through the cutter module.
7. Ensure that the media is against the back of the transmissive sensor. Then, slide
in the media guide so that it just touches, but does not restrict, the edge of the
media.
8. Close the printhead assembly.
Media supply guide
Printhead
assembly
Ribbon
sensor
Cutter
module
Dancer
Media
supply
hanger
Media guide
Transmissive
sensor
Printhead open lever
Figure 15
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Value Peel-Off Mode
(Value peel option required)
Refer to Figure 16.
1. Press the printhead open lever. The printhead assembly springs up.
2. Flip down the media supply guide.
3. Slide out the media guide as far from the printer frame as possible.
4. Place the roll of media on the media supply hanger.
5. Flip up the media supply guide. Slide in the media supply guide so that it just
touches, but does not restrict, the edge of the roll.
6. Feed the media under the dancer, through the slot in the transmissive sensor, and
under the ribbon sensor.
7. Pull approximately 12” (305 mm) of media through the front of the printer.
8. Ensure that the media is against the transmissive sensor. Then, slide in the media
guide so that it just touches, but does not restrict, the edge of the roll.
9. Pull down the lever to open the pivot bracket assembly.
10. Feed the media over the tear-off/peel-off bar and behind the pivot bracket
assembly.
11. Close the printhead assembly.
12. Close the pivot bracket assembly.
13. Peeling will automatically start. Press the FEED key to test.
Media supply guide
Transmissive
sensor
Printhead
assembly
Lever
Dancer
Media
supply
hanger
Ribbon Media guide
sensor
Label
Printhead open lever
Figure 16
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Power Peel-Off Mode
(Power peel-off option required)
Refer to Figure 17.
1. Press the printhead open lever. The printhead assembly springs up.
2. Flip down the media supply guide.
3. Slide out the media guide as far from the printer frame as possible.
4. Place the roll of media on the media supply hanger.
5. Flip up the media supply guide. Slide in the media supply guide so that it just
touches, but does not restrict, the edge of the roll.
6. Feed the media under the dancer, through the slot in the transmissive sensor, and
under the ribbon sensor.
7. Pull approximately 36” (1 m) of media through the front of the printer.
8. Ensure that the media is against the transmissive sensor. Then, slide in the media
guide so that it just touches, but does not restrict, the edge of the media.
9. Open the front housing assembly by lifting the handles; then, pivot down the
front housing assembly.
10. Remove at least 12” (305 mm) of labels from the backing material.
11. Feed the backing material over the tear-off/peel-off bar, through the rectangular
cutout in the mounting bracket, and under the media alignment spindle.
12. Close the front housing assembly by slightly lifting and then hooking it onto the
pins on the tear-off/peel-off bar.
13. Loosen the thumbscrew and slide out the rewind media guide to the end of the
take-up spindle.
14. Wrap the backing around a core placed on the take-up spindle; then, turn the take-up
spindle counterclockwise to wind up the excess backing material.
15. Slide the rewind media guide against the backing material, and tighten the
thumbscrew to lock it into position.
16. Close the front housing assembly.
17. Close the printhead assembly.
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Media supply guide
Transmissive
sensor
Printhead
assembly
Front
housing
assembly
Label
Media
supply
hanger
Dancer
Ribbon
sensor
Media
guide
Take-up
spindle
Printhead
open lever
Rewind
media
guide
Media
alignment
spindle
Thumbscrew
Figure 17
Backing Removal
1. Cut the backing material prior to where it winds onto the take-up spindle.
2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock”
position.
3. Loosen the thumbscrew and slide out the rewind media guide to the end of the
take-up spindle.
4. Slide the core and backing material from the take-up spindle.
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Power Rewind Mode
(Power rewind option required)
Refer to Figure 18.
1. Press the printhead open lever. The printhead assembly springs up.
2. Flip down the media supply guide.
3. Slide out the media guide as far from the printer frame as possible.
4. Place the roll of media on the media supply hanger.
5. Flip up the media supply guide. Slide in the media supply guide so that it just
touches, but does not restrict, the edge of the roll.
6. Feed the media under the dancer, through the slot in the transmissive sensor, and
under the ribbon sensor.
7. Pull approximately 36” (1 m) of media through the front of the printer.
8. Ensure that the media is against the back of the transmissive sensor. Then, slide
in the media guide so that it just touches, but does not restrict, the edge of the
media.
9. Remove at least 12” (305 mm) of labels from the backing material.
10. Feed the backing material over the front housing assembly, through the rewind
base, and under the media alignment spindle.
11. Loosen the thumbscrew and slide out the rewind media guide to the end of the
take-up spindle.
12. Wrap the media around a core placed on the take-up spindle; then turn the spindle
counterclockwise to wind up the excess material.
13. Slide the rewind media guide against the media, and tighten the thumbscrew to
lock it into position.
14. Close the printhead assembly.
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Media supply guide
Transmissive
sensor
Printhead
assembly
Front
housing
assembly
Media
supply
hanger
Dancer
Ribbon
sensor
Media
guide
Take-up
spindle
Printhead
open lever
Rewind
media
guide
Media
alignment
spindle
Thumbscrew
Figure 18
Media Removal
1. Cut the media prior to where it winds onto the take-up spindle.
2. Rotate the take-up spindle until the rewind media guide is in the “12 o’clock”
position.
3. Loosen the thumbscrew and slide out the rewind media guide to the end of the
take-up spindle.
4. Slide the core and roll of media from the take-up spindle.
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Fanfold Media Loading
Fanfold media feeds through either the bottom or rear access slot.
Refer to Figure 19.
1. Press the printhead open lever. The printhead assembly springs up.
2. Flip down the media supply guide.
3. Slide out the media guide as far from the printer frame as possible.
4. Pass the fanfold media over the media supply hanger.
5. Flip up the media supply guide. Slide in the media supply guide so that it just
touches, but does not restrict, the edge of the media.
6. Thread the media under the dancer, through the slot in the transmissive sensor,
under the ribbon sensor, and out the front of the printer.
7. Ensure that the media is against the back of the transmissive sensor. Then, slide
in the media guide so that it just touches, but does not restrict, the edge of the
media.
8. Close the printhead assembly.
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Media supply guide
Printhead
assembly
Transmissive
sensor
Dancer
Media guide
Media
supply
hanger
Ribbon
sensor
Printhead open lever
Media supply guide
Printhead
assembly
Transmissive
sensor
Dancer
Media guide
Media
supply
hanger
Ribbon
sensor
Printhead open lever
Figure 19
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Ribbon Loading
NOTE: The ribbon supply spindle in your printer is a "dual tension"
variety. Most applications require the spindle to be in the "normal"
position. The "low tension" position is recommended only when wide
ribbon is used and normal tension hampers the ribbon movement.
To place this spindle in the "normal" position, firmly pull out the
spindle end cap until it clicks into place as shown in Figure 20. To
place the spindle in the "low tension" position, firmly push in the
spindle end cap until it clicks into place.
Spindle end cap
retracted
Spindle end cap
extended
Normal position
Low tension position
Figure 20
Loading the Ribbon
CAUTION: Always use ribbon that is wider than the media. The smooth
backing of the ribbon protects the printhead from wear. (For direct thermal
printing, do not load ribbon in the printer.)
Refer to Figure 21.
1. Press the printhead open lever. The printhead assembly springs up.
2. Push the ribbon roll completely onto the ribbon supply spindle.
3. Pull the end of the ribbon over the ribbon sensor, under the printhead assembly,
and out the front of the printer.
4. Close the printhead assembly, keeping the ribbon snug and free of wrinkles and
in line with the guide mark near the left edge of the ribbon guide plate.
5. Wind the ribbon clockwise onto the ribbon take-up spindle.
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Ribbon take-up spindle
Ribbon
guide plate
Printhead
assembly
Ribbon
supply spindle
Printhead open lever
Ribbon take-up spindle
Ribbon
guide plate
Printhead
assembly
Ribbon
supply spindle
Ribbon sensor
Printhead open lever
Figure 21
Ribbon Removal
To remove the ribbon:
1. Break the ribbon between the ribbon guide plate and the ribbon take-up spindle.
2. While turning the ribbon take-up spindle release knob counterclockwise, squeeze
the ribbon against the ribbon take-up spindle tension blades.
3. When the tension blades collapse into the ribbon take-up spindle, hold the release
knob and rotate the spent ribbon toward the rear of the printer. Then, slide off
the ribbon.
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Configuration
After you have installed the media and ribbon and the power-on self test (POST) is
complete, the front panel display will show “PRINTER READY.” (If the printer fails
its POST, refer to page 73.) You may now set printer parameters for your application
using the front panel display and the four keys directly below it.
NOTE: Printers that are operating on an IP network can be quickly
configured via ZebraNet WebView™ (optional ZebraNet PrintServer II
required). For information, refer to ZebraNet Networking:
PrintServer II Installation and User’s Guide.
NOTE: Unless otherwise noted, all parameters are listed in the order
they are displayed, starting with “DARKNESS.”
Entering the Setup Mode
To enter the programming mode, press the SETUP/EXIT key.
�
Press the INCREMENT (+) or DECREMENT (-) key to scroll to the setting you
wish to change.
�
Press the SELECT key to toggle the functionality of the INCREMENT (+) and
DECREMENT (-) keys.
�
Press the INCREMENT (+) or DECREMENT (-) keys to increase or decrease the
value; answer “yes” or “no”; print a label; or, select the digit you wish to change.
�
Press the SELECT key again to use the INCREMENT (+) and DECREMENT (-)
keys to scroll to the desired menu item.
An asterisk (*) in the upper left-hand corner of the display indicates that the value
displayed is different than the currently stored value.
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Changing Password-Protected Parameters
Certain parameters are password protected by factory default.
NOTE: You have the option of making ALL parameters password
protected. See “PASSWORD LEVEL” on page 52.
CAUTION: Do not change password-protected parameters unless you are
sure you know what you are doing! If they are set incorrectly, these
parameters could cause the printer to function in an unpredictable way.
The first attempt to change one of these parameters will require you to enter a
four-digit password. This is done via the “ENTER PASSWORD” display. The
DECREMENT (-) key changes the selected digit position. The INCREMENT (+)
key increases the selected digit value. After entering the password, press the
SELECT key. The parameter you wish to change will be displayed. If the password
was entered correctly, you can now change the value.
The default password value is 1234. The password can be changed using the ^KP
(Define Password) ZPL II instruction.
NOTE: Once the password has been entered correctly, it will not
have to be entered again unless you leave and re-enter the
programming mode using the SETUP/EXIT key.
NOTE: You can disable the password protection feature so that it no
longer prompts you for a password by setting the password to ØØØØ
via the ^KPØ ZPL/ZPL II command. To re-enable the
password-protection feature, send the ZPL/ZPL II command ^KPx,
where “x” can be any number, one to four digits in length, except Ø.
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Leaving the Setup Mode
You can leave the program mode at any time by pressing the SETUP/EXIT key. The
“SAVE CHANGES” display will appear. There are five choices, described below.
Pressing the INCREMENT (+) or DECREMENT (-) key displays other choices and
pressing the SELECT key selects the displayed choice.
�
PERMANENT -- Permanently saves the changes. Values are stored in the printer
even when power is turned off.
�
TEMPORARY -- Saves the changes until changed again or until power is turned
off.
�
CANCEL -- Cancels all changes since pressing the SETUP/EXIT key except the
darkness and tear-off settings (if they were changed).
�
LOAD DEFAULTS -- Loads factory defaults.
�
LOAD LAST SAVE -- Loads values from the last permanent save.
Configuration and Calibration Sequence
Display Shows
Action/Explanation
PRINTER READY
Normal printer operation.
Setting Print Parameters
Adjusting Print Darkness Press the INCREMENT (+) key to increase darkness.
Press the DECREMENT (-) key to decrease darkness.
Default: +10
Range: 0 to +30
Darkness settings are dependent upon a variety of factors, including ribbon
type, media, and the condition of the printhead. You may adjust the darkness
for consistent high-quality printing.
If printing is too light, or if there are voids in printed areas, you should increase
the darkness. If printing is too dark, or if there is spreading or bleeding of
printed areas, you should decrease the darkness.
DARKNESS
The FEED key self test on page 76 can also be used to determine the best
darkness setting. Since the darkness setting takes effect immediately, you can
see the results on labels that are currently printing.
CAUTION: Set the darkness to the lowest setting that provides good print
quality. Darkness set too high may cause ink smearing and/or it
may burn through the ribbon.
Darkness settings also may be changed by the driver or software settings.
Adjusting the Tear-Off Position Press the INCREMENT (+) key to increase the
value, press the DECREMENT (-) key to decrease the value. Each press of the
key adjusts the tear-off position by four dot rows.
Default: +0
TEAR OFF
Range: -120 to +120
This parameter establishes the position of the media over the tear-off/peel-off
bar after printing. The label and backing can be torn off or cut between labels.
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Display Shows
Action/Explanation
Selecting Print Mode Press the INCREMENT (+) or DECREMENT (-) key to
display other choices.
Default: Tear-off
PRINT MODE
Selections: Tear-off, peel-off, cutter, rewind
Print mode settings tell the printer the method of media delivery that you wish
to use. Be sure to select a print mode that your hardware configuration
supports since some selections displayed are for optional printer features.
Setting Media Type Press the INCREMENT (+) or DECREMENT (-) key to
display other choices.
Default: Continuous
Selections: Continuous, non-continuous
This parameter tells the printer the type of media you are using. Selecting
continuous media requires that you include a label length instruction in your
label format (^LLxxxx if you are using ZPL or ZPL II).
MEDIA TYPE
SENSOR TYPE
SENSOR SELECT
When non-continuous media is selected, the printer feeds media to calculate
label length (the distance between two detections of the inter-label gap,
webbing, or alignment notch or hole).
Setting the Sensor Type Press the INCREMENT (+) or DECREMENT (-) key to
display other choices.
Default: Web
Selections: Web, mark
This parameter tells the printer whether you are using media with a web
(gap/space between labels, notch, or hole) to indicate the separation between
labels or if you are using media with a black mark printed on the back. If your
media does not have black marks on the back, leave your printer at the default
setting (web).
Setting the Sensor Select Press the INCREMENT (+) or DECREMENT (-) key
to display other choices.
Default: Auto select
Selections: Auto select, reflective, transmissive
This parameter tells the printer the sensor you wish to use. “Auto select” is
compatible with most types of media. However, if you encounter difficulties
with calibration, refer to “Types of Media” on page 6 to help you choose the
appropriate sensor for your media. (Select the reflective sensor with either
continuous or non-continuous black mark media: choose the transmissive
sensor if you are using non-continuous web media.)
Selecting Print Method Press the INCREMENT (+) key for the next value;
press the DECREMENT (-) key for the previous value.
Default: Thermal transfer
Selections: Thermal transfer, direct thermal
PRINT METHOD
The print method parameter tells the printer the method of printing you wish
to use: direct thermal (no ribbon) or thermal transfer (using thermal transfer
media and ribbon).
NOTE: Selecting direct thermal when using thermal transfer media and
ribbon creates a warning condition, but printing will continue.
Setting Print Width Press the INCREMENT (+) key to increase the value,
press the DECREMENT (-) key to decrease the value. To change the unit of
measurement, press the DECREMENT (-) key until the unit of measurement is
active, then press the INCREMENT (+) key to toggle to a different unit of
measure (inches, mm, or dots).
PRINT WIDTH
Default:, Range: The default and range of acceptable values may vary
depending on what printer you have. Refer to “Printing Specifications” on
page 80 for further information about the ranges available for your model.
Print width determines the printable area across the width of the label.
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Display Shows
Action/Explanation
Initialize Memory Card
CAUTION: Perform this operation only when it is necessary to erase all
previously stored information from the optional memory card. Press the
SETUP/EXIT key to bypass this function.
1. Press the INCREMENT (+) key to select “YES.”
If your printer is set to require a password, you will now be
prompted to enter the password. Enter the password and then
press the SELECT key.
2. The display will ask “INITIALIZE CARD?”. Press the INCREMENT (+)
key “YES.”
3. The front panel LCD will ask “ARE YOU SURE?”.
INITIALIZE CARD
4. Press the INCREMENT (+) key “YES” to begin initialization.
or
Press the DECREMENT (-) key “NO” to cancel the request and return to
the “INITIALIZE CARD” prompt.
5. Press the SETUP/EXIT key followed by the SELECT key. If initialization
is still in process, the front panel display will flash back and forth between
the two phrases “CHECKING B: MEMORY” and “PRINTER IDLE.”
When initialization is complete, the printer will automatically exit the
configuration mode and the front panel will display “PRINTER READY.”
NOTE: Depending on the amount of memory in the memory card,
initialization may take up to five minutes to complete.
Initialize Flash Memory
CAUTION: Perform this operation only when it is necessary to erase all
previously stored information from the FLASH memory. Press the
SETUP/EXIT key to bypass this function.
1. Press the INCREMENT (+) key to select “YES.”
If your printer is set to require a password, you will now be prompted
to enter the password. Enter the password and then press the
SELECT key.
2. The display will ask “INITIALIZE FLASH?”. Press the INCREMENT (+)
key “YES.”
3. The front panel LCD will ask “ARE YOU SURE?”.
INIT FLASH MEM
4. Press the INCREMENT (+) key “YES” to begin initialization.
or
Press the DECREMENT (-) key “NO” to cancel the request and return to
the “INITIALIZE FLASH” prompt.
5. Press the SETUP/EXIT key followed by the SELECT key. If initialization
is still in process, the front panel display will flash back and forth between
the two phrases “CHECKING E: MEMORY” and “PRINTER IDLE.”
When initialization is complete, the printer will automatically exit the
configuration mode and the front panel will display “PRINTER READY.”
NOTE: Depending on the amount of free FLASH memory, initialization may
take up to one minute to complete.
Media and Ribbon Sensor Calibration
Performing the manual calibration procedure first resets the sensitivity of the sensors to better
detect the media and ribbon you are using. With the sensors at their new sensitivity, the printer
then performs the manual calibration. Changing the type of ribbon and/or media may require
resetting the sensitivity of the media and ribbon sensors.
Display Shows
Action/Explanation
Sensor Profile Press the INCREMENT (+) key to print a media sensor profile.
See Figure 22. The media sensor profile may be used to troubleshoot
registration problems that may be caused when the media sensor detects
preprinted areas on the media or experiences difficulty in determining web
location. If the sensitivity of the media and/or ribbon sensors MUST be
adjusted, use the manual calibration procedure.
SENSOR PROFILE
Manual Calibration Press the INCREMENT (+) key to start the calibration
procedure.
MANUAL
CALIBRATION
This procedure is used to reset the sensitivity of the media and ribbon
sensors. Then, the manual calibration is performed.
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Figure 22
Setting Communication Parameters
Communication parameters must be set correctly for the printer to communicate with the host.
These parameters make sure that the printer and host are “speaking the same language.” All
communication parameters are password protected.
Display Shows
Action/Explanation
Setting Parallel Communications Press the INCREMENT (+) or
DECREMENT (-) key to display other choices.
Default: Parallel
PARALLEL COMM
Selections: Parallel, twinax/coax
Select the communications port that matches the one being used by the host
computer.
Setting Serial Communications Press the INCREMENT (+) or
DECREMENT (-) key to display other choices.
Default: RS232
SERIAL COMM
Selections: RS232, RS422/485, RS485 multidrop
Select the communications port that matches the one being used by the host
computer.
Setting Baud
other choices.
Press the INCREMENT (+) or DECREMENT (-) key to display
Default: 9600
BAUD
Selections: 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400
The baud setting of the printer must match the baud setting of the host for
accurate communications to take place. Select the value that matches the one
being used by the host.
Setting Data Bits
display other choices.
Press the INCREMENT (+) or DECREMENT (-) key to
Default: 7-bits
Selections: 7-bits, 8-bits
DATA BITS
The data bits of the printer must match the data bits of the host for accurate
communications to take place. Set the data bits to match the setting being
used by the host.
NOTE: Must be set to 8 data bits to use Code Page 850.
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Display Shows
Action/Explanation
Setting Parity
other choices.
Press the INCREMENT (+) or DECREMENT (-) key to display
Default: Even
PARITY
Selections: Even, odd, none
The parity of the printer must match the parity of the host for accurate
communications to take place. Select the parity that matches the one being
used by the host.
Setting Host Handshake
key to display other choices.
Press the INCREMENT (+) or DECREMENT (-)
Default: XON/XOFF
HOST HANDSHAKE
Selections: XON/XOFF, DTR/DSR
The handshake protocol of the printer must match the handshake protocol of
the host for communications to take place. Select the handshake protocol that
matches the one being used by the host.
Setting Protocol Press the INCREMENT (+) or DECREMENT (-) key to
display other choices.
Default: None
Selections: None, Zebra, ACK_NACK
Protocol is a type of error checking system. Depending on the selection, an
indicator may be sent from the printer to the host signifying that data has been
received. Select the protocol that is requested by the host. Further details on
protocol can be found in the ZPL II Programming Guide Volume I.
PROTOCOL
NOTE: Zebra is the same as ACK_NACK except that with Zebra the response
messages are sequenced.
NOTE: If Zebra is selected, printer must use DTR/DSR host handshake
protocol.
Display Shows
Action/Explanation
Setting Network ID Press the DECREMENT (-) key to move to the next
digit position, press the INCREMENT (+) key to increase the value of the digit.
Default: 000
Range: 000 - 999
NETWORK ID
Network ID is used to assign a unique number to a printer used in an
RS-422/RS-485 network. This gives the host the means to address a specific
printer. If the printer is used in a network, you must select a network ID
number. This does not affect TCP/IP or IPX networks.
Setting Communications Mode Press the INCREMENT (+) or
DECREMENT (-) key to display other choices.
Default: Normal mode
Selections: Normal mode, diagnostics
The communication diagnostics mode is a troubleshooting tool for checking
the interconnection between the printer and the host. When “diagnostics” is
selected, all data sent from the host to the printer will be printed as straight
ASCII hex characters. The printer prints all characters received including
control codes, like CR (carriage return). A sample printout is shown in
Figure 32 on page 77.
COMMUNICATIONS
NOTES on diagnostic printouts:
• An FE indicates a framing error.
• An OE indicates an overrun error.
• A PE indicates a parity error.
• An NE indicates noise.
For any errors, check that your communication parameters are correct. Set
the print width equal to or less than the label width used for the test. See
page 42 for more information.
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Selecting Prefix and Delimiter Characters
Prefix and delimiter characters are 2-digit hex values used within the ZPL/ZPL II formats sent to the
printer. The printer uses the last prefix and delimiter characters sent to it, whether from a ZPL II
instruction or from the front panel.
NOTE: DO NOT use the same hex value for the control, format, and delimiter character. The
printer needs to see different characters to function properly.
Display Shows
Action/Explanation
Control Prefix Character
Press the DECREMENT (-) key to move to the
next digit position, press the INCREMENT (+) key to increase the value of the
digit.
Default: 7E (tilde - displayed as a black square)
Range: 00-FF
CONTROL PREFIX
The printer looks for this 2-digit hex character to indicate the start of a
ZPL/ZPL II control instruction.
Format Prefix Character
Press the DECREMENT (-) key to move to the
next digit position, press the INCREMENT (+) key to increase the value of the
digit.
Default: 5E (caret)
Range: 00 - FF
FORMAT PREFIX
The printer looks for this 2-digit hex character to indicate the start of a
ZPL/ZPL II format instruction.
Delimiter Character Press the DECREMENT (-) key to move to the next
digit position, press the INCREMENT (+) key to increase the value of the digit.
Default: 2C (comma)
Range: 00 - FF
DELIMITER CHAR
The delimiter character is a 2-digit hex value used as a parameter place marker
in ZPL/ZPL II format instructions. Refer to the ZPL II Programming Guide
Volume I for more information.
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Selecting ZPL Mode
Display Shows
Action/Explanation
Selecting ZPL Mode
display other choices.
Press the INCREMENT (+) or DECREMENT (-) key to
Default: ZPL II
Selections: ZPL II, ZPL
ZPL MODE
The printer will remain in the selected mode until it is changed by this front panel
instruction or by using a ZPL/ZPL II command. The printer accepts label formats
written in either ZPL or ZPL II. This eliminates the need to rewrite any ZPL formats
you already have. Refer to the ZPL II Programming Guide Volume II for more
information on the differences between ZPL and ZPL II .
Power-Up and Head Close Parameters
Media Power-Up
display other choices.
Press the INCREMENT (+) or DECREMENT (-) key to
Default: Feed
Selections: Feed, calibration, length, and no motion
This parameter establishes the action of the media when the printer is turned
on.
MEDIA POWER UP
• Calibration: Recalibrates the media and ribbon sensors.
• Feed: Feeds the label to the first web.
• Length: Determines the length of the label.
• No Motion: Media does not move.
Head Close
other choices.
Press the INCREMENT (+) or DECREMENT (-) key to display
Default: Feed
Selections: Feed, calibration, length, no motion
Determines the action of the media after the printhead has been opened and
then closed.
HEAD CLOSE
• Calibration: Recalibrates the media and ribbon sensors.
• Feed: Feeds the label to the first web.
• Length: Determines the length of the label.
• No Motion: Media does not move.
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Label Positioning Parameters
Display Shows
Action/Explanation
Backfeed Sequence
display other choices.
Press the INCREMENT (+) or DECREMENT (-) key to
Default: Default (90%)
Selections: Default, after, before, 10%, 20%, 30%, 40%, 50%, 60%, 70%,
80%, off
This parameter establishes when and how much label backfeed occurs after a
label is removed or cut in the peel-off or cutter modes. It has no effect in
rewind or tear-off modes. This parameter setting can be superseded by the
~JS instruction when received as part of a label format (refer to the
ZPL II Programming Guide Volume I).
BACKFEED
NOTE: The difference between the value entered and 100% establishes how
much backfeed occurs before the next label is printed. For example,
a value of 40 means that 40% of the backfeed takes place after the
label is removed or cut. The remaining 60% takes place before the
next label is printed. A value of “before” means that all backfeed will
take place before the next label is printed.
Adjusting Label Top Position Press the INCREMENT (+) key to increase the
value, press the DECREMENT (-) key to decrease the value. The displayed
value represents dots.
Default: +0
LABEL TOP
Range: -120 to +120 dot rows
The label top position adjusts the print position vertically on the label. Positive
numbers adjust the label top position further down the label (away from the
printhead), negative numbers adjust the position up the label (toward the
printhead).
Adjusting Left Position Press the DECREMENT (-) key to move to the next
position, press the INCREMENT (+) key to change between + and - and to
increase the value of the digit. The displayed value represents dots.
Default: 0000
Range: -9999 to +9999
LEFT POSITION
NOTE: For a negative value, enter the value before changing to the minus
sign.
This parameter establishes how far from the left edge of a label the format will
begin to print by adjusting horizontal positioning on the label. Positive
numbers adjust the printing to the left by the number of dots selected,
negative numbers shift printing to the right.
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Display Shows
WEB S.
Action/Explanation
MEDIA S.
These parameters are automatically set during the calibration procedure. They
should only be changed by a qualified service technician. Refer to the
maintenance manual for more information on these parameters.
RIBBON S.
TAKE LABEL S.
MEDIA LED
RIBBON LED
Press the SELECT key repeatedly to skip these parameters.
LCD Display Adjustment Press the DECREMENT (-) key to decrease the value
(reduce brightness), press the INCREMENT (+) key to increase the value
(increase brightness).
LCD ADJUST
Range: 00 to 19
This parameter allows you to adjust the brightness of your display if your
display is difficult to read.
Format Convert Press the INCREMENT (+) or DECREMENT (-) key to display
other choices.
Default: None
FORMAT CONVERT
PASSWORD LEVEL
Selections: None, 150 � 300, 150 � 600, 200 � 600, 300 � 600
Selects the bitmap scaling factor. The first number is the original dots per inch
(dpi) value; the second, the dpi to which you would like to scale.
Password Level Press the INCREMENT (+) or DECREMENT (-) key to display
other choices.
Default: Selected items
Selections: Selected items, all items
This parameter allows you to select whether certain Zebra-selected menu
items (”selected items”) or all menu items (”all items”) are password protected.
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Display Shows
Action/Explanation
IP Resolution
other choices.
Press the INCREMENT (+) or DECREMENT (-) key to display
Default: Dynamic
IP RESOLUTION*
Selections: Dynamic, permanent
Depending on the selection, allows either the user (”permanent”) or the server
(”dynamic”) to select the IP address. For more information, refer to ZebraNet
Networking: PrintServer II Installation and User’s Guide.
IP Protocols
other choices.
Press the INCREMENT (+) or DECREMENT (-) key to display
Default: All
Selections: All, gleaning only, RARP, BOOTP, DHCP, DHCP/BOOTP
IP PROTOCOLS*
If “dynamic” was chosen in the previous parameter, this selection determines
the method(s) by which the PrintServer II will receive the IP address from the
server. For more information, refer to ZebraNet Networking: PrintServer II
Installation and User’s Guide.
IP Address Press the DECREMENT (-) key to move to the next digit
position, press the INCREMENT (+) key to increase the value of the digit.
This parameter allows you to select the IP address if “permanent” was chosen
in “IP RESOLUTION.” (If “dynamic” was chosen, the user cannot select the
address.) For more information, refer to ZebraNet Networking: PrintServer II
Installation and User’s Guide.
IP ADDRESS*
Subnet Mask
other choices.
Press the INCREMENT (+) or DECREMENT (-) key to display
Default: Permanent (user must set)
SUBNET MASK*
Selections: Dynamic (user may set, but server can assign), permanent
This parameter selects the part of the IP address that is considered to be part
of the local network. It can be reached without going through the default
gateway.
Default Gateway Press the DECREMENT (-) key to move to the next digit
position, press the INCREMENT (+) key to increase the value of the digit.
DEFAULT
GATEWAY*
This parameter allows you to select the IP address that the network traffic is
routed through if the destination address is not part of the local network.
* Option required
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Listing Printer Information
Display Shows
Action/Explanation
List Fonts Press the INCREMENT (+) key to print a label listing all of the
available fonts.
LIST FONTS
LIST BAR CODES
LIST IMAGES
This selection is used to print a label that lists all of the fonts currently available
in the printer, including standard printer fonts plus any optional fonts. Fonts
may be stored in RAM, FLASH memory, font EPROMs, or font cards.
List Bar Codes Press the INCREMENT (+) key to print a label listing all of the
available bar codes.
This selection is used to print a label that lists all of the bar codes currently
available in the printer.
List Images Press the INCREMENT (+) key to print a label listing all of the
available images.
This selection is used to print a label that lists all of the images currently stored
in the printer’s RAM, FLASH memory, optional EPROM, or optional memory
card.
List Formats Press the INCREMENT (+) key to print a label listing all of the
available formats.
LIST FORMATS
This selection is used to print a label that lists all of the formats currently
stored in the printer’s RAM, FLASH memory, optional EPROM, or optional
memory card.
List Setup Press the INCREMENT (+) key to print a label listing the current
printer configuration.
LIST SETUP
LIST ALL
This selection is used to print a label that lists the current printer configuration
information. (Same as the CANCEL key self test.)
List All Press the INCREMENT (+) key to print a label listing all of the available
fonts, bar codes, images, formats, and the current printer configuration.
This selection is used to print a label that lists the five previous selections, as
described.
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Display Shows
Action/Explanation
Selecting the Display Language Press the INCREMENT (+) or DECREMENT (-)
key to display other choices.
Default: English
LANGUAGE
Selections: English, Spanish, French, German, Italian, Norwegian,
Portuguese, Swedish, Danish, Spanish 2, Dutch, Finnish, Japan
This parameter allows you to change the language used on the front panel
display.
You have now completed the entire configuration and calibration sequence. You may either press
the SELECT key or the SETUP/EXIT key.
You are now back at the first parameter in the configuration sequence.
DARKNESS
NOTE: If you pressed the SELECT key but are through programming the
printer configuration, you may press the SETUP/EXIT key and continue
with the “SAVE SETTINGS” function.
Save Settings Press the INCREMENT (+) or DECREMENT (-) key to display
other choices.
Default: Permanent
Selections: Permanent, temporary, cancel, load defaults, load last save.
This display appears when you attempt to exit the configuration mode.
• Permanent: Permanently saves the changes, even when printer power is
turned off.
SAVE SETTINGS
• Temporary: Saves the changes until changed again or until power is turned
off.
• Cancel: Cancels all changes since you entered the configuration mode
except for darkness and tear-off position (if they were changed).
• Load defaults: Loads factory defaults.
• Load last save: Loads the values from the last permanent save.
Press the SETUP/EXIT key to activate the displayed choice.
PRINTER READY
You have exited the configuration and calibration sequence and are now ready
for normal printer operation.
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Routine Care and Adjustments
Cleaning
This table provides a recommended cleaning schedule. Specific cleaning procedures
are provided on the following pages.
Area
Method
Interval
Printhead
Solvent*
After every roll of media (or 500 feet of
fanfold media) when printing in the direct
thermal mode.
Platen roller
Media sensors
Ribbon sensor
Media path
Ribbon path
Solvent*
Air blow
Air blow
Solvent*
Solvent*
After every roll of ribbon or three rolls of
media when printing in the thermal
transfer mode.
These intervals are intended as guidelines
only. You may have to clean more often,
depending upon your application and
media.
Pinch roller (Optional value peel-off
option required. See Figure 25.)
Solvent*
Citrus-based
adhesive
remover
After every roll of media (or more often,
depending upon your application and
media).
If cutting continuous,
pressure-sensitive media
Cutter
module
If cutting tag stock or label Solvent* and
After every two or three rolls of media.
backing material
Tear-off/peel-off bar
Take label sensor
air blow
Solvent*
Air blow
Once a month.
Once every six months.
*Zebra recommends using a solvent containing 90% isopropyl alcohol.
CAUTION: Use only the cleaning agents indicated. Zebra Technologies
Corporation will not be responsible for damage caused by any other
cleaning fluids used on this printer.
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Cleaning the Exterior
The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use
harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent or
desktop cleaner may be used sparingly.
Cleaning the Interior
Remove any accumulated dirt and lint from the interior of the printer using a soft
bristle brush and/or vacuum cleaner.
Cleaning the Printhead and Platen Roller
Inconsistent print quality, such as voids in the bar code or graphics, may indicate a
dirty printhead. For best results, perform the following cleaning procedure after
every roll of ribbon.
NOTE: The printer can remain on while you are cleaning the
printhead. In this way all label formats, images, and all temporary
parameter settings stored in the printer's internal memory will be
saved.
To clean the printhead, refer to Figure 23 and follow these steps:
1. Open the printhead assembly.
2. Remove the media and ribbon (if loaded).
3. Using a swab soaked in the Zebra-recommended solvent, wipe along the print
elements from end to end. (The print elements are on the brown strip just behind
the chrome strip on the printhead.) Allow sufficient time for the solvent to
evaporate.
4. Manually rotate the platen roller and clean thoroughly with solvent and a swab.
5. Brush/vacuum any accumulated paper lint and dust away from the media and
ribbon paths.
6. Reload media and/or ribbon, and close the printhead assembly.
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NOTE: If print quality has not improved after performing this
procedure, try cleaning the printhead with Save-a-Printhead cleaning
film. This specially coated material removes contamination buildup
without damaging the printhead. Call your authorized Zebra reseller
for more information.
Printhead
assembly
Take label
sensor
Transmissive
sensor
Ribbon
sensor
Reflective
sensor
Platen roller
Figure 23
Cleaning the Sensors
Brush or vacuum any accumulated paper lint and dust away from the printer sensors.
Refer to Figure 23. The reflective sensor, transmissive sensor, and ribbon sensor
should be cleaned on a regular basis to ensure proper operation of the printer. For
printers with the value peel-off, power peel-off, and/or power rewind option(s)
installed, clean the take label sensor.
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Cleaning the Power Peel-Off Module
(Power peel-off option required)
Perform the following procedure if adhesive buildup begins to affect peel
performance.
Refer to Figure 24.
1. Open the printhead assembly.
2. Open the front housing assembly by lifting the two handles; then, pivot down the
front housing assembly.
3. Remove the accumulated adhesive by rolling the sticky side of a blank label
against the peel rollers and lifting it away. (Do this step repeatedly until a
majority of the adhesive is gone.)
4. Use a swab soaked with the Zebra-recommended solvent to remove adhesive
from the tear-off/peel-off bar and reflective surface.
5. Close the front housing assembly.
6. Close the printhead assembly.
Printhead
assembly
Tear-off/
peel-off
bar
Peel
rollers
Reflective
surface
Front
housing
assembly
Handles
Figure 24
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Cleaning the Value Peel-Off Module
(Value peel-off option required)
Perform the following procedure if adhesive buildup begins to affect peel-off
performance.
Refer to Figure 25.
1. Open the printhead assembly.
2. Open the pivot bracket assembly by pivoting the module toward you.
3. Use a swab soaked with the Zebra-recommended solvent to remove adhesive
from the tear-off/peel-off bar.
4. Manually rotate the pinch roller and clean thoroughly with solvent and a swab.
5. Close the pivot bracket assembly.
6. Close the printhead assembly.
Printhead
assembly
Tear-off/
peel-off
bar
Pinch
roller
Pivot
bracket
assembly
Figure 25
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Cleaning the Cutter Module
(Cutter option required)
WARNING!!! For personnel safety, ALWAYS turn off and
unplug the printer before performing this procedure.
Refer to Figure 26.
To clean adhesive off of the upper and lower cutter blades:
1. Use a swab moistened with the Zebra-recommended solvent to wipe along the
upper cutter blade.
2. To expose the lower cutter blade, turn the cutter motor thumbnut
counterclockwise until you see the “V”-shaped lower cutter blade.
3. Clean the lower blade, following the instructions in step 1.
4. When you have finished cleaning the cutter module, plug in and turn on the
printer. The lower cutter blade will return to its correct operating positions.
If the cutter continues to perform unsatisfactorily, contact an authorized service
technician.
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Upper
cutter
blade
Lower
cutter
blade
Cutter
motor
thumbnut
Figure 26
Lubrication
CAUTION! No lubricating agents of any kind should be used on this
printer! Some commercially available lubricants will damage the finish
and the mechanical parts, if used.
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Printhead Pressure Adjustment
This adjustment may be necessary if printing is too light on one side or if thick media
is used.
Refer to Figure 27.
The pressure adjustment dials each have four possible settings designated by blocks of
increasing size embossed on the print mechanism. The smallest block (fully
counterclockwise) is considered “position 1” and the largest block (fully clockwise) is
considered “position 4.”
The following table will help you to select the initial dial settings for your media.
Media Width
1” (25.4 mm)
2” (51 mm)
Left Dial
Right Dial
3
4
3
1
1
2
3” (76 mm)
3.5” and up
(89 mm and up)
3
3
NOTE: Some media types require higher pressure to print well. For
these media, increase both dials one position. If the media tends to
shift to the left while printing, increase the right dial setting one
position or decrease the left dial setting one position. If the media
tends to shift to the right while printing, increase the left dial setting
one position or decrease the right dial setting one position.
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Pressure adjustment dials
Figure 27
Power Rewind Media Alignment
(Power rewind option required.)
NOTE: Under normal operating conditions, media alignment should
not be necessary if the media/backing was initially installed tightly
against the backplate of the take-up spindle.
Perform the following adjustment if the media does not track properly onto the
take-up spindle.
Refer to Figure 28.
1. With media and backing material loaded, open the printhead assembly.
2. Turn the adjustment dial clockwise to align the media/backing material more to
the right. (The image will move to the left.)
or
Turn the dial counterclockwise to align the media/backing material more to the
left. (The image will move to the right.)
3. Manually rotate the take-up spindle and ensure the media/backing tracks
properly.
4. Close the printhead assembly.
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Printhead
assembly
Take-up
spindle
Adjustment
dial
Figure 28
Fuse Replacement
A user-replaceable AC power fuse is located just below the AC power switch at the
rear of the printer. The replacement fuse is a 3AG fast blow style rated at
5 Amp/250 VAC.
Before replacing the fuse, turn off the AC power switch and unplug the AC power
cord.
To replace the fuse, insert the tip of a flat blade screwdriver into the slot in the end of
the fuse holder end cap. Press in slightly on the end cap and turn the screwdriver
slightly counterclockwise. This will disengage the end cap from the fuse holder and
permit removal of the fuse.
To install a new fuse, reverse the sequence.
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Troubleshooting
LCD Error Conditions and Warnings
Error condition RIBBON OUT
Problem
Solution
In thermal transfer mode, the ribbon is not Load the ribbon correctly. See “Ribbon Loading” on
loaded or loaded incorrectly.
page 34.
In thermal transfer mode, the ribbon
sensor is not sensing correctly loaded
ribbon.
Perform the media and ribbon sensor calibration (see
page 45).
Put the printer in direct thermal mode via the front panel
and remove ribbon (if loaded).
In direct thermal mode, when ribbon is not
used:
Ensure that the printer driver or software settings are
correctly set (if applicable).
Error condition PAPER OUT
Problem
Solution
The media is not loaded or loaded
incorrectly.
Reload the media. Refer to “Roll Media Loading” on
page 22.
The media sensor is not positioned
properly.
Check the position of the reflective sensor. See
“Positioning the Media Sensor” on page 10.
Either load the correct media or set the printer for the
correct media type via the front panel.
The printer is set for non-continuous
media, but continuous media is loaded.
Ensure that the printer driver or software settings are
correctly set (if applicable).
Calibrate the printer (see page 45).
Via the front panel, locate the “SENSOR SELECT” menu
The incorrect media sensor is being used. item (page 41) and manually select the correct sensing
method.
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Error condition HEAD OPEN
Problem
Solution
The printhead is not fully closed.
Close the printhead.
Correctly align the ribbon with the guide mark on the
ribbon guide plate before closing the printhead
assembly. See “Ribbon Loading” on page 34.
The ribbon is loaded incorrectly; it is
covering the head open sensor.
Error condition RIBBON IN
Problem
Solution
Via the front panel, locate the “PRINT METHOD” menu
item (page 42) and select thermal transfer mode.
Print method is incorrectly set.
The ribbon is loaded.
Ensure that the printer driver and/or software settings
are correctly set (if applicable).
Remove the ribbon and set the printer to direct thermal
mode. (See “PRINT METHOD” on page 42.)
Ensure that the printer driver and/or software settings
are correctly set (if applicable).
Warning HEAD OVER TEMP
Problem
Solution
Allow the printer to cool. Printing automatically resumes
when the printhead elements cool to an acceptable
operating temperature.
The printhead is over temperature.
Warning HEAD UNDER TEMP
Problem
Solution
Continue printing while the printhead reaches the
correct operating temperature.
The printhead is under temperature.
The environment may be too cold for proper printing.
Relocate the printer to a warmer area.
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Error condition HEAD OPEN
Problem
Solution
The printhead is not fully closed.
Close the printhead.
Correctly align the ribbon with the guide mark on the
ribbon guide plate before closing the printhead
assembly. See “Ribbon Loading” on page 34.
The ribbon is loaded incorrectly; it is
covering the head open sensor.
Error condition RIBBON IN
Problem
Solution
Via the front panel, locate the “PRINT METHOD” menu
item (page 42) and select thermal transfer mode.
Print method is incorrectly set.
The ribbon is loaded.
Ensure that the printer driver and/or software settings
are correctly set (if applicable).
Remove the ribbon and set the printer to direct thermal
mode. (See “PRINT METHOD” on page 42.)
Ensure that the printer driver and/or software settings
are correctly set (if applicable).
Warning HEAD OVER TEMP
Problem
Solution
Allow the printer to cool. Printing automatically resumes
when the printhead elements cool to an acceptable
operating temperature.
The printhead is over temperature.
Warning HEAD UNDER TEMP
Problem
Solution
Continue printing while the printhead reaches the
correct operating temperature.
The printhead is under temperature.
The environment may be too cold for proper printing.
Relocate the printer to a warmer area.
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Warning CUTTER JAM
Problem
Solution
Turn off the printer power and unplug the printer.
Inspect the cutter module for debris and clean as
needed following the cleaning instructions on page 60.
Cutter blade is in the media path.
OUT OF MEMORY*
Problem
Solution
Insufficient DRAM for the label length, downloaded
fonts/graphics, and images.
*There is not enough memory to perform
the function shown on the second line of
the error message.
Ensure that the device, such as FLASH memory or
PCMCIA card, is installed and not write protected or full.
Ensure that the data is not directed to a device that is
not installed or available.
Print Quality Problems
General print quality issues
Problem
Solution
You are using an incorrect media and
ribbon combination for your application.
Consult your authorized Zebra reseller/distributor for
information and advice.
For optimal print quality, set the print speed to the
lowest possible setting via ZPL II, the driver, or the
software.
The printer is set at the incorrect print
speed.
For optimal print quality, set the darkness to the lowest
possible setting via the front panel, the driver, or the
software.
The printer is set at the incorrect darkness
level.
Clean the printhead according to the instructions on
page 56.
The printhead is dirty.
There is light printing (or no printing) on
the left or right side of the label or the
printed image is not sharp.
The pressure adjustment dials need to be adjusted.
Follow the printhead pressure adjustment instructions
on page 62.
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Gray lines on blank labels with no consistent pattern
Problem
Solution
Clean the printhead according to the instructions on
page 56.
The printhead is dirty.
Light, consistent vertical lines running through all of the labels
Problem
Solution
Clean the printhead, platen roller, or both according to
the instructions on page 56.
The printhead or platen roller is dirty.
Intermittent creases on the left and right edges of the label
Problem
Solution
There is too much pressure on the
printhead.
Reduce the printhead pressure. Refer to the printhead
pressure adjustment on page 62.
Wrinkled ribbon
Problem
Solution
Load the ribbon correctly. See “Ribbon Loading” on
page 34.
The ribbon is not loaded correctly.
Set the darkness to the lowest possible setting for good
print quality. See “Darkness” on page 40.
The darkness setting is incorrect.
Set the pressure to the minimum required for good print
quality. See “Printhead Pressure Adjustment” on
page 62.
Incorrect printhead pressure or balance.
The media is not feeding correctly. It is
“walking” from side to side.
Make sure that the media guide and media supply guide
touch the edge of the media.
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Calibration
Problem
Solution
Adjust the reflective sensor position. See page 11.
Set the printer for the correct media type. See page 41.
Ensure that the media guides are properly positioned.
Via the front panel, locate the “SENSOR SELECT” menu
item (page 41) and manually select the correct sensing
method.
Loss of printing registration on labels.
Excessive vertical drift in top-of-form
registration.
Reload the media. Check the reflective sensor position
(see page 11).
Clean the platen roller according to the instructions on
page 56.
Perform a manual calibration (see page 45).
“Auto Calibrate” failed.
Load the media. Ensure that the reflective sensor is
properly positioned (see page 11).
Communications Problems
A label format was sent to the printer but not recognized. The DATA
light does not flash.
Problem
Solution
Check the printer driver or software communications
settings (if applicable).
Verify the prefix and delimiter characters. See page 49.
Are you using the correct communication cable? See
page 18 for the requirements.
The printer does not respond to label
requests.
Via the front panel, check the protocol setting. It should
be set to “none.” See page 47.
Ensure that the correct driver is being used (if
applicable).
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A label format was sent to the printer. Several labels print, then the
printer skips, misplaces, misses, or distorts the image on the label.
Problem
Solution
The host is set to EPP parallel
communications.
Change the settings on the computer host to standard
parallel communications.
Check the communication cable length. See page 18
for requirements.
The serial communication settings are
incorrect.
Check the printer driver or software communications
settings (if applicable).
A label format was sent to the printer but not recognized. The DATA
light flashes but no printing occurs.
Problem
Solution
The prefix and delimeter characters set in
the printer do not match the ones in the
label format.
Verify the prefix and delimeter characters. See
page 49.
Check the communication settings on the computer.
Ensure that they match the printer settings.
Incorrect data is being sent to the printer.
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