Zebra Technologies Printer PA400 User Manual

PA400

User's

Guide

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Customer order #52600L

Manufacturer part #52600LB Rev. 1

User's

Guide

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Proprietary Statement

This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and

use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, repro-

duced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies

Corporation.

Product Improvements

Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are subject to

change without notice.

FCC Compliance Statement

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of

the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential

installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance

with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that the inter-

ference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television recep-

tion, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by

one or more of the following measures:

•

Reorient or relocate the receiving antenna.

Increase the separation between the equipment and the receiver.

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

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

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

sure compliance.

“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation could void

the user’s authority to operate the equipment.”

Canadian DOC Compliance Statement

This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus as set out in the radio

interference regulations of the Canadian Department of Communications.

Liability Disclaimer

Zebra Technologies Corporation takes steps to assure that its published Engineering Specifications and Manuals are correct;

however, errors do occur. Zebra Technologies Corporation reserves the right to correct any such errors and disclaims liability

resulting therefrom.

No Liability for Consequential Damage

In no event shall Zebra Technologies corporation or anyone else involved in the creation, production, or delivery of the accom-

panying product (including hardware and software) be liable for any damages whatsoever (including, without limitation, dam-

ages for loss of business profits, business interruption, loss of business information, or other pecuniary loss) arising out of the

use of or the results of use of or inability to use such product, even if Zebra Technologies Corporation has been advised of the

possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or inci-

dental damages, the above limitation may not apply to you.

Copyrights

This copyrighted manual and the label printer described herein are owned by Zebra Technologies Corporation. All rights are re-

served. 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.

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I have determined that the Zebra printers identified as the

Zebra^®Portable Line^™

PA400 and PT400

manufactured by:

Zebra Technologies Corporation

333 Corporate Woods Parkway

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

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

for Home, Office, Commercial, and Industrial use

if no unauthorized change is made in the equipment,

and if the equipment is properly maintained and operated.

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Contents

Introduction

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

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1

Reporting Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Getting Ready to Print

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . 3

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

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

Fanfold Media . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Loading the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Power Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Feed Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Error LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Battery Charging LED . . . . . . . . . . . . . . . . . . . . . . . 19

Printing a Test Label . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connecting the Printer and Computer . . . . . . . . . . . . . . . . . 20

Communicating with the Printer . . . . . . . . . . . . . . . . . . . . 22

Setting the Communication Parameters . . . . . . . . . . . . . . 22

Setting Up the Software . . . . . . . . . . . . . . . . . . . . . . . . 22

Adjusting the Print Width . . . . . . . . . . . . . . . . . . . . . . . 22

Adjusting the Print Darkness. . . . . . . . . . . . . . . . . . . . . . 22

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Adjusting the Printhead Pressure. . . . . . . . . . . . . . . . . . . . 23

Adjusting the Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Hand/Shoulder Strap . . . . . . . . . . . . . . . . . . . . . . . . 24

Adjustable Shoulder Strap . . . . . . . . . . . . . . . . . . . . . 26

Calibration

Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Manual Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Preventive Maintenance

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Extending Battery Life . . . . . . . . . . . . . . . . . . . . . . . . . 30

Battery Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting

Help! The LEDs are On/Off/Flashing! . . . . . . . . . . . . . . . . 33

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . 35

Troubleshooting Tests . . . . . . . . . . . . . . . . . . . . . . . . . 37

Printing a Configuration Label . . . . . . . . . . . . . . . . . . . 37

Recalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Resetting the Factory Default Values. . . . . . . . . . . . . . . . 37

Communications Diagnostics. . . . . . . . . . . . . . . . . . . . 37

Feed Button Modes . . . . . . . . . . . . . . . . . . . . . . . . . 39

Specifications

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

Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Memory/Communications . . . . . . . . . . . . . . . . . . . . . . . 42

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Font/Bar Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

Adapter Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . 45

RJ45 Connector Pin Identification . . . . . . . . . . . . . . . . . . . 45

Null Modem Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . 46

Index

iii

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Introduction

Hello!

Thank you for choosing our Zebra Portable Printer. Don’t let its size fool

you - this rugged little printer is sure to become a productive and efficient

addition to your workplace. And it’s no wonder, because it’s made by

Zebra Technologies Corporation - your number one source for bar code

printers, software, and supplies!

• This user’s guide gives you all the information you’ll need to operate the

printer.

• To create and print label formats, take a look at the ZPL II Programming

Guide (part #46530L) for information about Zebra’s label design

programming language, better known as “ZPL II.” If one was not

ordered with your printer, simply call your reseller or Zebra

Technologies Corporation or visit the Zebra web site . If you’d like to

use a different label preparation software, contact your reseller or Zebra

for advice and information.

• The PA400/PT400 Maintenance Manual (part #505142L) contains all

the information you’ll need to properly maintain the printer.

Unpacking and Inspection

Inspect the printer for possible shipping damage:

• Check all exterior surfaces for damage.

• Raise the media access door (refer to “Loading the Media” in Getting

Ready to Print) and inspect the media compartment for damage.

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

Reporting Damage

If you discover shipping damage:

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

Zebra Technologies Corporation is not responsible for any damage

incurred during shipment of the printer and will not cover the repair of

this damage under its warranty policy.

• Keep the carton and all packing material for inspection.

• Notify your authorized Zebra reseller.

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1 Top Cover

Error LED

Power LED

Printhead Pressure Adjuster

Power Button

Feed Button

7 Ribbon Cartridge

Printhead

Platen Roller

Media Guides

Media Hangers

1 Media Access Door

2 Battery Compartment

3 Media Compartment

4 Strap

5 Communications Port

6 Battery Charging Receptacle

7 Battery Charging LED

8 Charging Station Connector

19 Peel Bar

Figure 1

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Getting Ready to Print

Battery

Installing the Battery

NOTE: Batteries are shipped uncharged.

1. Slide up the battery compartment door.

2. Insert the battery into the printer as shown in Figure 2, with the

silver-colored battery contacts facing up.

3. After the battery is completely inserted, slide down the battery

compartment door.

When the battery is first installed, the Power and Error LEDs will light for

approximately two seconds and then go off. If these lights do not go on, the

battery is not fully charged (see “Charging the Battery”).

Battery

Compartment

Door

Silver-colored

Battery

Contacts

Battery

Figure 2

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Charging the Battery

Refer to Figure 3 (your battery charger may look slightly different than the

ones illustrated).

If you are using a 120 VAC battery charger:

1. With the battery installed in the printer, insert the connector of the

battery charger into the receptacle on the side of the printer.

2. Plug the battery charger into an appropriate 120 VAC electrical outlet.

3. The battery charging LED will briefly flash and then stay on. When

the battery is fully charged (approximately one hour for the standard

battery; two hours for the extended life battery), the light will go off.

4. You may either remove the battery charger from the printer or leave it

connected for a continuous maintenance charge.

If you are using a universal battery charger:

1. With the battery installed in the printer, insert the connector of the

battery charger into the receptacle on the side of the printer.

2. Make sure the supplied power cord is inserted in the battery charger.

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

Power

Cord Plug

Varies by

Country

120 VAC

Charger

Universal

Charger

Figure 3

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4. The battery charging LED will briefly flash and then stay on. When

the battery is fully charged (approximately one hour for the standard

battery; two hours for the extended life battery), the light will go off.

5. You may either remove the battery charger from the printer or leave it

connected for a continuous maintenance charge.

Loading the Media

You can operate this printer in one of two different modes: Tear-Off or

Peel-Off. Tear-Off mode allows you to tear off each label (or a strip of

labels) after it is printed. In Peel-Off mode, the backing material is peeled

away from the label as it is printed. After you remove this label, the next

one is printed.

Tear-Off Mode

NOTE: If ribbon is loaded (PT400 only), remove the ribbon

cartridge before loading the media.

1. Refer to Figure 4. Raise the media access door by lifting at the notch

until it unhooks from the top cover.

Top Cover

Notch

Media

Access

Door

Figure 4

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2. Refer to Figure 5. Swing the media access door open to expose the

media compartment.

3. Pivot the top cover to reveal the printhead.

4. Lift the printhead until you feel it “lock” into place. Be careful not to

force the printhead past this position!

WARNING: NEVER touch the thermal print elements on the

underside of the printhead. Under certain conditions, they

can be very hot! Also, dirt or moisture from your hands can

damage the printhead!

Media

Compartment

Printhead

Media

Guides

Media

Hangers

Figure 5

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5. Refer to Figures 5 and 6. Thread the media into the printer until it

extends approximately 1” (25.4 mm) past the printhead.

6. Separate and hold open the media hangers.

7. Place the media roll onto the media hangers, making sure it is tightly

wound.

8. Release the media hangers so the media locks into the correct position.

Make sure the media is threaded under both media guides.

Media

Guides

1“ Past Printhead

Media

Hangers

Unwind this direction

Media

Roll

Figure 6

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9. Refer to Figure 7. If it’s not already in place, install the tear bar in the

media access door. Gently lift the tab on the bar to move it over the

protrusion on the door. Make sure the lip of the bar (inset, Figure 7)

faces out of the printer.

If you’re using direct thermal media, continue on with step 10.

However, if you’re using thermal transfer media, you must also install

a ribbon cartridge. Proceed to “Loading the Ribbon” in this chapter.

10. Close the printhead and the top cover.

Tab

Protrusion

Lip

Figure 7

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11. Swing up the media access door, ensuring that the media extends over

the tear bar (refer to Figure 8).

12. Lift to hook the top of the media access door over the top cover.

13. Push in the bottom of the media access door to close.

14. Turn on the printer or press the Feed button if the printer is already on.

Tear Bar

Figure 8

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Peel-Off Mode

NOTES: Your authorized Zebra reseller can recommend the

correct ribbon and peel-off media for your application.

If ribbon is loaded (PT400 only), remove the ribbon cartridge

before loading the media.

1. Refer to Figure 4. Raise the media access door by lifting at the notch

until it unhooks from the top cover.

2. Refer to Figure 5. Swing the media access door open to expose the

media compartment.

3. Pivot the top cover to reveal the printhead.

4. Lift the printhead until you feel it “lock” into place. Use caution not to

force the printhead past this position!

WARNING: NEVER touch the thermal print elements on the

underside of the printhead. Under certain conditions, they

can be very hot! Also, dirt or moisture from your hands can

damage the printhead!

5. Refer to Figures 5 and 6. Remove approximately 6” (152.4 mm) of

labels from the media roll. Then, thread the media into the printer until

it extends approximately 1” (25.4 mm) past the printhead.

6. Separate and hold open the media hangers.

7. Place the media roll onto the media hangers, making sure it is tightly

wound.

8. Release the media hangers to lock the media into the correct position.

Ensure that the media is threaded under both media guides.

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9. The tear bar should not be installed in the printer. If it is, gently lift the

tab on the bar to get it over the protrusion on the door (reverse the

procedure shown in Figure 7). Then, pull the bar out of the printer.

NOTE: When not in use, the tear bar may be stored on the inside

of the media access door. Refer to Figure 9. With the lip of the bar

facing the inside of the door, simply align the notches of the bar

with the tabs on the door. Press and slide the bar toward the

door’s hinged end.

If you’re using direct thermal media, continue on with step 10.

However, if you’re using thermal transfer media, you must also install

a ribbon cartridge. Proceed to “Loading the Ribbon” in this chapter.

Door

Tab

Door

Tab

Tear Bar

Notch

Tear Bar

Notch

Figure 9

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10. Close the printhead and the top cover.

11. Swing up the media access door, ensuring that the media liner is

threaded through the wide slot in the media access door (refer to

Figure 10).

12. Lift to hook the top of the media access door over the top cover.

13. Push in the bottom of the media access door to close.

14. Turn on the printer or press the Feed button if the printer is already on.

NOTES: To ensure optimal print quality, make sure that the

backing material is flush against the peel bar (as shown in

Figure 10). If it starts to “loop” away from the peel bar, gently

pull down on the backing material.

With certain types of media, it may be necessary to reduce the

print speed to 1.5” (38.1 mm) per second to produce consistent

peel operation. Consult your authorized Zebra reseller for advice

and information.

Label

Backing

Material

Wide Slot

Figure 10

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Fanfold Media (optional vibration mount required)

NOTE: If ribbon is loaded (PT400 only), remove the ribbon

cartridge before loading the media.

1. Raise the media access door by lifting at the notch until it unhooks

from the top cover (refer to Figure 4).

2. Swing the media access door open to expose the media compartment

(refer to Figure 5).

3. Pivot the top cover to reveal the printhead.

4. Lift the printhead until you feel it “lock” into place. Be careful not to

force the printhead past this position!

WARNING: NEVER touch the thermal print elements on the

underside of the printhead. Under certain conditions, they

can be very hot! Also, dirt or moisture from your hands can

damage the printhead!

5. Separate and hold open the media hangers (refer to Figure 11).

6. Place the plastic media core (refer to Figure 11) onto the media

hangers.

Media

Guides

Media

Hangers

Plastic

Media

Core

Figure 11

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NOTE: The plastic media core can be obtained from an

authorized Zebra supplies reseller.

7. Release the media hangers so the plastic media core locks into the

correct position.

8. Place the fanfold media in the fanfold media tray.

9. Swing up the media access door. Thread the fanfold media through the

slot beneath the notch on the media access door (refer to Figure 12).

10. Swing open the media access door. Continue to insert the media into

the printer and under the plastic media core until it appears beneath the

printhead. Make sure the media is threaded under both media guides.

If you’re using direct thermal media, continue on with step 11.

However, if you’re using thermal transfer media, you must also install

a ribbon cartridge. Proceed to “Loading the Ribbon” in this chapter.

11. Swing up the media access door, ensuring that the media extends over

the tear bar (refer to Figure 13).

12. Lift to hook the top of the media access door over the top cover.

13. Push in the bottom of the media access door to close.

14. Turn on the printer or press the Feed button if the printer is already on.

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Notch

Fanfold

Media

Slot

Figure 12

Media

Figure 13

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Loading the Ribbon (PT400 only)

1. If the printhead is not already open, lift it until you feel it “lock” into

place.

WARNING: NEVER touch the thermal print elements on the

underside of the printhead. Under certain conditions, they

can be very hot! Also, dirt or moisture from your hands can

damage the printhead!

2. Hold the ribbon cartridge as shown in Figure 14. The placement

arrows should be visible and pointing toward the back of the printer.

3. Align the lower protrusions on both sides of the ribbon cartridge with

the channels in the left and right frames (refer to Figure 14).

4. Slide the ribbon cartridge past the printhead (refer to Figure 15). It will

automatically move into the correct operating position.

5. Close the printhead (refer to Figure 16) and the top cover. Swing up

the media access door, ensuring that the media is properly extending

out of the printer (see Figure 8 for Tear-Off, or Figure 10 for Peel-Off).

6. Lift to hook the top of the media access door over the top cover. Push

in the bottom of the media access door to close.

7. Turn on the printer or press the Feed button if the printer is already on.

Channel

Printhead

Arrows

Ribbon

Cartridge

Lower

Protrusion

Figure 14

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To remove the ribbon cartridge, simply lift the printhead and pull the ribbon

cartridge from the printer.

Printhead

Ribbon

Cartridge

Figure 15

Printhead

Ribbon

Figure 16

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Operator Controls

Refer to Figure 17.

Power Button

• Press to turn on the printer.

• To turn off the printer, press and hold until the Power LED flashes once.

(Holding the button for approximately two seconds acts as a safeguard.

That way, no data will be lost if the button is accidentally pressed or

bumped.)

CAUTION: The power should be turned off before connecting

or disconnecting the communications cable.

Feed Button

• Forces the printer to feed one blank label.

• Takes the printer out of a “pause” condition. (The printer is put into

“pause” by either a software command or an error condition.) See

Troubleshooting.

• Used for printer setup and status (see “Feed Button Modes” in

Troubleshooting).

Feed

Button

Error

LED

Power

LED

Power

Button

Figure 17

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Indicator LEDs

Refer to Figures 17 and 18.

Power LED (Green)

• “On” during normal printer operation.

• Functions as a printer operational/battery status indicator (see “Help!

The LEDs are On/Off/Flashing!” in Troubleshooting).

Error LED (Orange)

• “Off” during normal printer operation.

• Functions as a printer operational status indicator (see “Help! The LEDs

are On/Off/Flashing!” in Troubleshooting).

Battery Charging LED (Yellow)

• Functions as a battery charging status indicator.

• “On” while the battery is fast charging.

• “Flashing” when the printer is preparing the battery for fast charging or

the battery overheats while charging.

• “Off” if the battery is fully charged or the battery charger is not plugged

in.

Receptacle

Battery Charging LED

Figure 18

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Printing a Test Label

Before you connect the printer to your computer or portable data terminal,

make sure that the printer is in proper working order. You can do this by

printing a configuration label (refer to “Feed Button Modes” in

Troubleshooting). If you can’t get this label to print, refer to

Troubleshooting.

Connecting the Printer and Computer

CAUTION: The power should be turned off before connecting

or disconnecting the communications cable.

This printer is configured as Data Terminal Equipment (DTE). There are

two types of cables available for the printer.

The straight through printer adapter cable connects to a null modem cable,

which connects to the computer or a portable data terminal (PDT). Consult

your computer/PDT reseller for the appropriate DB-9 null modem cable for

your device.

Refer to Figure 19.

1. Plug the null modem cable into the serial data port of the computer.

2. Plug the other end of the null modem cable into the connector of the

printer adapter cable.

NOTE: The adapter cable maintains interface compatability with

the full line of Zebra printers.

3. Plug the adapter cable into the printer’s communications port (see

Figure 1).

Null modem cables are also available for many popular portable data

terminal models. Consult your authorized Zebra reseller for available data

cables.

Refer to Figure 20.

1. Turn off the portable data terminal and the printer.

2. Plug the communications cable into the communications port of both

the portable data terminal and the printer. A ferrite is built into the

cable near the connector that plugs into the printer.

3. Turn on the portable data terminal and the printer.

For pinout and cabling information, refer to Specifications.

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Computer

Communications

Ports

Adapter

Cable

10101

Null Modem

Cable

Figure 19

Ferrite

Communications

Cable

Figure 20

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Communicating with the Printer

Setting the Communication Parameters

When using the printer’s serial port to transfer data, you will need to make

sure that the printer and the computer have identical communication

parameter settings. To initialize the communication parameters for the

printer:

• Press and hold the Feed button until the Error LED flashes once, then

twice, then three times. Release the button. The baud rate for the

printer will be reset to 9600 baud, 8 bits per character, no parity, and 1

stop bit using software handshaking (XON/XOFF). Then, set the

communication parameters on your computer to match this.

• Some computer programs use different settings than the default modes

(for example, computers operating in MS-DOS use hardware

handshaking instead of XON/XOFF). To use different settings than the

defaults and save these settings permanently, refer to your label

preparation software user’s manual.

Setting Up the Software

In order to create labels, you must decide whether you will use ZPL II or a

commercial label preparation system. To use ZPL II, refer to the ZPL II

Programming Guide. If you choose to use a label preparation system,

follow the installation instructions included in the package.

Adjusting the Print Width

Print width must be calibrated when you are using the printer for the first

time and whenever there is a change in the width of the media you are

using. Print width can be set via the software (consult your label

preparation software user’s manual) or refer to “Feed Button Modes” in

Troubleshooting.

Adjusting the Print Darkness

The relative darkness setting is software controlled. Follow the instructions

in your label preparation software user’s manual.

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Adjusting the Printhead Pressure

Adjust printhead pressure if print darkness is inconsistent across the label.

NOTE: In general, use a higher setting for wide labels and a

lower setting for narrow labels.

There are four printhead pressure settings (see Figure 21). Depending on

whether you want to increase or decrease the printhead pressure, slide the

printhead pressure adjuster toward the back or front of the printer. Then,

print another test label. Repeat this procedure until you achieve the desired

results.

WARNING: NEVER tighten or loosen the two screws that

secure the printhead to the bracket! They are not used to

adjust printhead pressure!

Printhead Pressure Adjuster

Screws

Securing

Highest

Pressure

Setting

Lowest

Pressure

Setting

Printhead

to the

Bracket

Figure 21

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Adjusting the Strap

Hand/Shoulder Strap

To lengthen the strap:

Refer to Figure 22.

1. With the printer in front of you, unwrap the padded handle by lifting up

the loose end of the handle.

2. Unlatch the buckle by squeezing both sides of the fastener.

3. Let the loose end of the strap fall to the side.

4. Pull up the handle.

Handle

(Pull Up)

Fastener

Buckle

Figure 22

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To shorten the strap:

Refer to Figure 23.

1. Pull the buckle until the strap is taut.

2. Latch by inserting the fastener into the buckle.

3. Wrap and secure the padded handle around the strap.

Handle

Buckle

Fastener

Figure 23

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Adjustable Shoulder Strap

Refer to Figure 24.

Slide the two buckles toward either the printer or shoulder pad until you

achieve the desired length.

Grip

Buckle

Here

Shoulder

Pad

Pull Strap

Here to

Lengthen

Pull Strap

Here to

Shorten

Figure 24

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Calibration

Auto Calibration

NOTE: The printer will not auto calibrate when you are using

pre-printed labels or pre-printed label backing. If you are using

this type of media, see “Manual Calibration.”

By default, this printer automatically sets the sensor levels for, and

determines the length of, the label you are using. To auto calibrate:

1. Load the media according to the instructions in “Loading the Media” in

Getting Ready to Print.

2. Turn on the printer or press the Feed button if the printer is already on.

3. Some blank labels will feed, completing auto calibration.

4. If the Error LED begins flashing, refer to “Manual Calibration.”

Hints:

• Auto calibration only works when you are using non-continuous media

(a gap, notch, or black mark separates each label).

• When auto calibration is selected, it occurs when the printer is turned on

(if the printhead has been opened), whenever an error is cleared, or if the

battery (or other power source) has been removed.

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Manual Calibration

A manual calibration should be performed whenever you are using

pre-printed labels (or label backing) or if the printer will not auto calibrate.

1. Turn on the printer power.

2. Remove 4-6” (102-152 mm) of labels from a section of backing

material. Load the media so that only the backing material is threaded

through the printer and under the printhead.

3. Press and hold the Feed button until the Error LED flashes once, then

twice. Release the button.

4. The printer will set the media sensor for the label backing you are

using. After it is done making this adjustment, the roll will

automatically feed until a label is positioned at the printhead.

5. A profile of the media sensor settings will print (similar to the example

in Figure 25). Upon completion, the printer will save the new settings

in memory and the printer is ready for normal operation.

6. Press the Feed button. One entire blank label should feed. If this

doesn’t happen, try defaulting (refer to “Feed Button Modes” in

Troubleshooting) and recalibrating the printer.

NOTE: Performing a manual calibration disables the auto

calibration function. To return to auto calibration, either default

the printer (see “Feed Button Modes” in Troubleshooting) or

refer to your label preparation software user’s manual.

NOTE: When using non-continuous media, set the appropriate

software command (see your label preparation software user’s

manual) before you perform a manual calibration.

Figure 25

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Preventive Maintenance

WARNING: To avoid possible personal injury or damage to

the printer, never insert any pointed or sharp objects into the

printer.

Cleaning

CAUTION: Use only the cleaning agents indicated. Zebra

Technologies Corporation will not be responsible for damage

caused by any other cleaning materials used on this printer.

Area

Method

Interval

Use 70% isopropyl alcohol on a cotton swab

to clean the print elements from end to end

(the print elements are located in the thin

gray line on the printhead). Note: You do

not have to turn off the printer to do this.

Printhead

(Figure 1)

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.

After every

five rolls of

media or

three ribbon

cartridges

(or more

With the printer turned off, rotate the platen

roller and clean it thoroughly with 70%

isopropyl alcohol and a cotton swab or

lint-free cloth.

often, if

needed)

Platen roller

(Figure 1)

With the printer power turned off and battery

removed, press down on the top of the

printhead. Then, clean the area beneath the

screw with 70% isopropyl alcohol and a

cotton swab. Caution: Do not turn the screw.

Head open

sensor plate

(Figure 26)

Peel bar

(Figure 1)

Clean it thoroughly with 70% isopropyl

alcohol and a cotton swab.

As needed

Tear bar

(Figure 8)

Clean it thoroughly with 70% isopropyl

alcohol and a cotton swab.

Exterior

Interior

Water-dampened cloth

Brush/air blow

As needed

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PRESS

DOWN

Head Open Sensor Plate

Clean under screw

Figure 26

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.

Extending Battery Life

• Never expose the battery to direct sunlight or temperatures over 104° F

(40° C).

• Choose the media or ribbon that is easiest to “burn.” An authorized

Zebra reseller can help you determine this.

• Make sure you’re using the optimal ribbon/media combination for your

application. An authorized Zebra reseller can help you determine this.

• If you print the same text or graphic on every label, consider using a

pre-printed label.

• Choose the correct print darkness, print speed, and printhead pressure

for your media and ribbon.

• Use software handshaking (XON/XOFF) whenever possible.

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• Select Tear-Off mode whenever possible (Peel-Off mode uses more

power).

• Pull the battery out of the printer if the printer won’t be used for a day or

more and you’re not performing a maintenance charge.

• Completely discharge the battery before recharging. Wait until you get

a “battery under voltage - level 1” indication (Error LED off and Power

LED flashing) before you recharge.

• Consider purchasing an extended life battery, which offers double the

life of a standard battery.

Battery Disposal

The EPA certified RBRC Battery Recycling Seal on the nickel-cadmium

(Ni-Cd) battery indicates Zebra Technologies Corporation is voluntarily

participating in an industry program to collect and recycle these batteries at

the end of their useful life, when taken out of service in the United States or

Canada. The RBRC program provides a convenient alternative to placing

used Ni-Cd batteries into the trash or the municipal waste stream, which

may be illegal in your area. Please call 1-800-8-BATTERY for

information on Ni-Cd battery recycling and disposal bans/restrictions in

your area. Zebra Technologies Corporation’s involvement in this program

is part of our commitment to preserving our environment and conserving

our natural resources.

Outside North America, please follow local battery recycling guidelines.

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Troubleshooting

Try as you may, you can’t seem to get the label to look right. Or, the LEDs

are on or flashing when they’re normally off. This is the section of the

User’s Guide that can help you solve your printer’s problems! If, after

reading this section, you’re still having difficulty getting your printer to

print, contact a qualified Zebra service technician.

Help! The LEDs are On/Off/Flashing!

Error LED

(Orange)

Power LED

(Green)

Printer

Status

For a Resolution,

Refer to:

Off

Stopped

Paused

Flashing

Double Flashing

Off

Stopped

Flashing

Stopped

Needs Service

Various

Alternate Flashing

Simultaneous Flashing

2 and 6

4 and 6

5 and 6

3 and 7

Flashing

Various

Yes

Double Flashing

Resolutions:

1. The printer is not receiving power.

• Have you turned on the printer power?

• Ensure that the battery is fully charged. Follow the instructions in

“Charging the Battery” in Getting Ready to Print.

• Make sure the battery is properly installed. Refer to “Installing the

Battery” in Getting Ready to Print.

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2. The printhead is open.

• Close the top cover and media access door. Then, press the Feed button

to resume printing.

The media is out.

• Load a roll of media, following the instructions in “Loading the Media”

in Getting Ready to Print. Then, press the Feed button to resume

priting.

The ribbon is out (PT400 only).

• Load the ribbon, following the instructions in “Loading the Ribbon” in

Getting Ready to Print. Then, press the Feed button to resume printing.

The head open sensor plate is dirty.

• Clean the head open sensor plate according to the instructions in

Preventive Maintenance.

3. The printer is paused.

• Press the Feed button to resume printing.

4. The printhead is under temperature.

• Continue printing while the printhead reaches the correct operating

temperature.

5. The printhead is over temperature.

• Printing automatically stops until the printhead cools to an acceptable

printing temperature; then, the printer automatically resumes operation.

The battery is over temperature.

• Printing automatically stops until the printer and battery cool to an

acceptable operating temperature; then, the printer automatically

resumes operation.

6. The battery is under voltage (level 1).

• Wait until the current label finishes printing, then plug the battery

charger into the printer (you don’t have to turn off the printer to do this).

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7. The battery is under voltage (level 2).

• The battery may not have enough power to print the next label and can

reset the printer, losing formats in the printer. Plug the battery charger

into the printer (you don’t have to turn off the printer to do this). After

the battery is charged, press the Feed button.

8. FLASH memory is not programmed.

• Return the printer to an authorized Zebra reseller.

Print Quality Problems

No print on the label.

• If you aren’t using ribbon, make sure the correct media (direct thermal)

is loaded. Try this: Quickly rub your nail or a blunt object over the

label surface. If it doesn’t produce dark marks, the wrong media

(thermal transfer) is loaded.

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

“Loading the Media” and “Loading the Ribbon” in Getting Ready to

Print.

• You may be trying to use the printer outside of its environmental limits.

The correct operating temperature range for this printer is between 32° F

and 104° F (0° to 40° C).

The printed image doesn’t look right.

• The printhead is dirty. Clean the printhead according to the instructions

in Preventive Maintenance.

• Printhead pressure needs to be adjusted. Follow the steps in “Adjusting

the Printhead Pressure” in Getting Ready to Print.

• The print darkness needs to be adjusted. See “Adjusting the Print

Darkness” in Getting Ready to Print.

• The print mode may be incompatible with the media you are using. If

your printer is set for thermal transfer mode, you must use thermal

transfer, rather than direct thermal, media and a ribbon cartridge.

• The media being used is incompatible with the printer. Be sure to use

the Zebra-recommended media for your application.

• Battery voltage is low. See “Charging the Battery” in Getting Ready to

Print.

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

several labels.

• The printhead is dirty. Clean the printhead according to the instructions

in Preventive Maintenance.

• The printhead elements are damaged. Call a qualified service technician

to replace the printhead.

Misregistration of labels (the printing does not start at the top of

the label) and misprinting of 1 to 3 labels.

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

“Loading the Media” in Getting Ready to Print.

• The printer needs to be calibrated. Refer to Calibration.

• Printhead pressure needs to be adjusted. Follow the instructions in

“Adjusting the Printhead Pressure” in Getting Ready to Print.

• The correct media sensor may not be activated. In manual calibration,

select the media sensing method for the labels you are using (refer to

your label preparation software user’s manual).

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

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

• If the LEDs are on or flashing, refer to “Help! The LEDs are

On/Off/Flashing!” in Troubleshooting.

• Make sure the data cable is installed correctly. Also, make sure you are

using a null modem cable between the printer’s adapter cable and the

computer (see Figure 19), or the appropriate null modem cable.

• A communications problem has occurred. First, make sure that the

correct communications port on the computer is selected. Next, verify

that the same handshaking is in use by both the printer and the computer.

Then, ensure that the communication parameters of the printer and the

computer match. Refer to “Communicating with the Printer” in Getting

Ready to Print.

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Troubleshooting Tests

Printing a Configuration Label

To print out a listing of the printer’s current configuration (a sample is

shown in Figure 27), refer to “Feed Button Modes” in this chapter.

Recalibration

Recalibrate the printer if it starts to display unusual symptoms, such as

skipping labels. See Calibration.

Resetting the Factory Default Values

Sometimes, resetting the printer to the factory defaults solves some printer

problems. Follow the instructions in “Feed Button Modes” in this chapter.

Communications Diagnostics

If there’s a problem transferring data between the computer and printer, try

putting the printer in the Communications Diagnostics mode. The printer

will print the ASCII characters and their respective hexidecimal values for

any data received from the host computer (see Figure 28). To find out how,

refer to “Feed Button Modes” in this chapter.

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Figure 27

Figure 28

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Feed Button Modes

Power Off Mode (Communications Diagnostics Mode)

With the printer power off, press and hold the Feed button while you turn on the

power. The printer prints out a listing of its current configuration (see Figure 27).

After printing the label, the printer will automatically enter a diagnostic mode in

which the printer prints out a literal representation (see Figure 28) of all data

subsequently received.

Power On Modes

With the printer power on, printhead closed, and Error LED off, press and hold the

Feed button for several seconds. The Error LED will flash a number of times in

sequence. The explanation at the right (Action) shows what happens when you

release the key after the specific number of flashes.

Flash

Sequence

Action

A configuration label prints.

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

Calibration and Figure 25).

***

The serial communication parameters are reset to 9600 baud, 8 bits per

character, no parity, 1 stop bit, and XON/XOFF.

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

memory.

***

****

The print width is calibrating. While the Error LED rapidly flashes, a

series of stacking rectangles prints on the label. When the rectangle

prints to the outer edges of the label, press and release the Feed

button. The label width and current communication parameters will be

saved into memory.

***

****

*****

If the Feed button is held down for six flashes and quickly released, the printer will

ignore the button. For additional information, refer to the maintenance manual.

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Specifications

NOTE: Printer specifications are subject to change without

notice.

Printing Specifications

Print Density

Print Width

Print Speed

203 dots/inch (8 dots/mm)

Up to 4.1” (104 mm)

1.5” or 2” per second (38.1 mm or 50.8 mm per second)

+/- 0.059” (+/- 1.5 mm)

Horizontal

Vertical

ü +/- 0.0393” (+/- 1.0 mm) on media >2” (50.8 mm) in

height

Registration

Tolerance

ü +/- 0.1180” (+/- 3.0 mm) on media < 2” (50.8 mm) in

height unless they are run without backfeed

Distance from Center Print

Element to Center of Label

+/- 0.0393” (+/- 1.0 mm)

ü Up to 18% black per batch

ü Up to 60 linear inches of media per batch

ü Up to four batches per hour

Maximum Duty Cycle

Ribbon Cartridge Specifications (PT400)

Ribbon Width

4.33” (110 mm)

.66” (16.8 mm)

Ribbon Outer Diameter

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Label Specifications

Label/Tag Width

Fanfold Width

1” to 4.25” (25.4 mm to 108 mm)

3.5” to 4.25” (89 mm to 108 mm)

0.5” to 10” (12.7 mm to 254 mm)

Label/Tag Length

.08” to .16” (.12” preferred)

2 mm to 4 mm (3 mm preferred)

Interlabel Gap

Label/Tag Thickness

Max. Outer

.0030” to .0106” (.076 mm to .269 mm)

2.1” (53.3 mm)

Label Roll

Size

Diameter

Inner Core

1” (25.4 mm)

ü Use Zebra-brand direct thermal or thermal transfer roll

media that is outside wound. Media may be reflective

(black mark) sensing or transmissive sensing, die-cut,

notched, or continuous.

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

ü Notched media must have a 0.5” (12.7 mm) wide x 0.094”

(2.4 mm) long cutout located in the center of the roll. The

reflective media black marks must be located in the center

of the roll.

Media Requirements

Minimum Black Mark Dimensions:

ü Mark width: 0.5” (12.7 mm) perpendicular to the edge of

the media.

ü Mark length: 0.094” (2.4 mm) parallel to the edge of the

media.

Memory/Communications Specifications

ROM Memory

RAM Memory

Communications

8 megabit flash (512 kilobyte x 16 data bit width)

4 megabit DRAM (256 kilobyte x 16 data bit width)

RS-232 serial port (RJ45 connector)

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Font/Bar Code Specifications

ü CG Triumvirate Bold Condensed scalable smooth

Fonts Available

ü Zebra fonts A, B, C, D, E, H, GS

ü Codabar (supports ratios of ü Industrial 2 of 5

2:1 to 3:1)

ü Standard 2 of 5

ü Code 11

ü Interleaved 2 of 5 (supports

ratios of 2:1 to 3:1, Modulus

10 Check Digit)

ü Code 128/USD 8 (supports

serialization in all subsets

and UCC Case Codes)

Bar Codes

Available

ü LOGMARS

ü MSI

ü Code 39 (supports ratios of

2:1 to 3:1)

ü Plessey

ü Code 93

ü POSTNET

ü UPC E

ü EAN 8/JAN 8

ü EAN 13/JAN 13

ü EAN 14/UPCA

ü UPC/EAN Extensions

ü Codablock

ü Code 49

ü MicroPDF417

ü PDF 417

Bar Codes

Available

ü Data Matrix

ü MaxiCode

ü QRcode

Rotation Angles

0°, 90°, 180°, and 270°

Physical/Environmental/Electrical

Specifications

Physical Size (L x W x H)

Weight (without battery)

Operating

2.8” x 9.2” x 7.9”

3.5 lbs.

72 mm x 233 mm x 200 mm

1.6 kg.

32° to 104° F

0° to 40° C

Storage

Temperature

(w/battery)

-22° to 122° F

-40° to 140° F

-30° to 50° C

-40° to 60° C

Range

Storage

(w/o battery)

Operation

Relative

Humidity

10% to 90% (non-condensing)

Storage

5% to 95% (non-condensing)

External 120 or 230 VAC battery charger, depending on

which model you order. Additional custom line cords

may also be available.

Electrical

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Agency Approvals

• UL 544 Medical Equipment Standard Part 42.5

• CSA 22.2 number 950 Canadian Safety Standard

• IEC 950/EN 60950 International Safety Standard

• FCC Part 15 Subpart B Class B Electromagnetic Radiation Standard

• UL 1950 Domestic Safety Standard

• Canadian DOC Class A

• SOR/88-475 Canadian Electromagnetic Radiation Standard

• EN50082-1 International Immunity Standard

• EN55022 Class B European Electromagnetic Radiation Standard

Options

• Hand/shoulder strap

• Adjustable shoulder strap

• Weather-resistant protective case

• Vibration mount, U-arm bracket, and media catch tray

• Standard battery

• Extended life battery

• 120 VAC battery charger

• Universal switching battery charger

• Battery eliminator

• Data cables

For details, call your authorized Zebra reseller.

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9-Pin D to RJ45 Connection Table

DB-9S

Connector to

Null Modem Cable

RJ45

Connector

to Printer

UNUSED

RXD

TXD

DTR

GND

DSR

RTS

UNUSED

Adapter Cable Pinouts

Pin 1

Pin 8

RJ45 Connector Pin Identification

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25-Pin D to 9-Pin D Null Modem Cable

DB-25S

Connector

to P.C.

DB-9P

Connector

to Adapter Cable

TXD

DCD

RXD

RTS

CTS

DSR

GND

DCD

DTR

RXD

TXD

DTR

GND

DSR

RTS

CTS

9-Pin D to 9-Pin D Null Modem Cable

DB-9S

Connector

to P.C.

DB-9P

Connector

to Adapter Cable

DCD

RXD

TXD

DTR

GND

DSR

RTS

CTS

RXD

TXD

DTR

GND

DSR

RTS

CTS

Null Modem Cable Pinouts

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Index

Communication parameters,

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

Adapter cable . . . . . . . . . . 20

Adapter cable pinouts. . . . . . 45

Adjusting the strap . . . . . . . 24

Adjustments

Communications diagnostics . . 37

Configuration label . . . . . . . 37

Print darkness . . . . . . . . 22

Print width . . . . . . . . . 22

Printhead pressure. . . . . . 23

Agency approvals . . . . . . . . 44

Damage, shipping . . . . . . . . 1

Darkness, adjusting . . . . . . . 22

Data Terminal Equipment

(DTE) . . . . . . . . . . . . . 20

Defaulting the printer . . . . . . 39

Battery charging LED. . . . . . 19

Battery disposal . . . . . . . . . 31

Battery life, tips . . . . . . . . . 30

Battery, charging . . . . . . . . . 4

Battery, installing . . . . . . . . 3

Error LED. . . . . . . . . . 19, 33

Factory defaults, resetting . . . 37

Fanfold media. . . . . . . . . . 13

Feed button . . . . . . . . . . . 18

Feed button modes . . . . . . . 39

Calibration, automatic . . . . . 27

Calibration, manual . . . . . . . 28

Cleaning

Exterior . . . . . . . . . . . 29

Head open sensor plate . . . 29

Interior . . . . . . . . . . . 29

Peel bar . . . . . . . . . . . 29

Platen roller . . . . . . . . . 29

Printhead . . . . . . . . . . 29

Tear bar . . . . . . . . . . . 29

Handshaking . . . . . . . . . . 22

Indicator LEDs . . . . . . . . . 19

Inspection . . . . . . . . . . . . 1

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Loading the media

Reporting damage, shipping . . . 1

Ribbon loading . . . . . . . . . 16

Fanfold media . . . . . . . . 13

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

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

Loading the ribbon . . . . . . . 16

Lubrication . . . . . . . . . . . 30

RJ45 connector pin

identification . . . . . . . . . 45

Software. . . . . . . . . . . . . 22

Specifications

Font/bar code . . . . . . . . 43

Label . . . . . . . . . . . . 42

Memory/communications. . 42

Maintenance manual . . . . . . . 1

Media loading

Fanfold media . . . . . . . . 13

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

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

Physical/environmenal/

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

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

Ribbon cartridge . . . . . . 41

Strap, adjusting

Null modem cable. . . . . . . . 20

Null modem cable pinouts . . . 46

Hand/shoulder strap. . . . . 24

Adjustable shoulder strap . . 26

Operator controls . . . . . . . . 18

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

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

Troubleshooting. . . . . . . . . 33

Troubleshooting tests . . . . . . 37

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

Power button . . . . . . . . . . 18

Power LED . . . . . . . . . 19, 33

Print darkness, adjusting . . . . 22

Print width, adjusting . . . . 22, 39

Printhead pressure, adjusting . . 23

Unpacking . . . . . . . . . . . . 1

ZPL II . . . . . . . . . . . . 1, 22

ZPL II Programming Guide,

ordering . . . . . . . . . . . . 1

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