Zebra® 105SLPlus™ User Guide P1056468-002 Rev.
© 2013 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH Corp. and Zebra’s licensors. Unauthorized reproduction of this manual or the software and/or firmware in the 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.
Declaration of Conformity Declaration of Conformity We have determined that the Zebra printers identified as the 105SLPlus™ 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.
Declaration of Conformity Compliance Information Compliance Information FCC Compliance Statement This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation.
Contents Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________________________________________
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Document Who Should Use This Document Who Should Use This Document This User Guide is intended for use by any person who needs to perform routine maintenance, upgrade, or troubleshoot problems with the printer. How This Document Is Organized The User Guide is set up as follows: P1056468-002 Section Description Introduction on page 13 This section provides a high-level overview of the printer and its components.
About This Document Document Conventions Document Conventions Table 1 shows the way that certain information is conveyed in this document. Table 1 • Document Conventions Alternate Color If you are viewing this guide online, you can click the blue text used for cross-references or hyperlinks to jump directly to other sections in the guide or to web sites on the internet. LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in Arial font.
About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________
1 Introduction This section provides a high-level overview of the printer and its components. Contents Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Media. . . . . . .
Introduction Printer Components Printer Components Figure 1 shows the components inside the media compartment of your printer. Depending on printer model and the installed options, your printer may look slightly different. Familiarize yourself with these components before continuing with the printer setup procedure.
Introduction Control Panel Control Panel All controls and indicators for the printer are located on the control panel (Figure 2). Figure 2 • Control Panel 1 2 3 4 5 9 6 10 7 11 8 12 13 14 1 POWER light On when the printer is on. 2 PAUSE light On when the printer is paused. 3 ERROR light Off Normal operation—no printer errors. On A printer error exists. Check the display for more information. Off Normal operation. No data being received or processed.
Introduction Control Panel 10 The NEXT/SAVE button • When in Setup Mode, the NEXT/SAVE button navigates to the next parameter in the menus. • When exiting Setup Mode, the NEXT/SAVE button initiates various options. (See Exit Setup Mode on page 19.
Introduction Control Panel Display Control Panel Display The control panel includes a display, where you can view the printer’s status or change its operating parameters. In this section, you will learn how to navigate through the menu system and change values for menu items. After the printer completes the power-up sequence, it moves to the Idle Display (Figure 3).
Introduction Control Panel Display Table 2 • Navigation (Continued) Perform an action + indicates that an action can be performed. Press PLUS (+) to perform the specified action. Change Parameter Values - and + indicate that a value can be changed. Press PLUS (+) or MINUS (-) to scroll through the accepted values.
Introduction Control Panel Display Table 2 • Navigation (Continued) Exit Setup Mode 1. At the Idle Display (Figure 3), press SETUP to enter Setup Mode. The printer displays the first parameter. 2. While in Setup Mode, press SETUP/EXIT to exit the operating parameters. The LCD displays SAVE CHANGES. 3. To return to the parameters, plus PREVIOUS. OR Press PLUS (+) or MINUS (-) to scroll through the exit options: • PERMANENT—Stores values in the printer even when power is turned off.
Introduction Control Panel Display Changing Password-Protected Parameters Certain parameters, including the communication parameters, are password-protected by factory default. Caution • Do not change password-protected parameters unless you have a complete understanding of the parameters’ functions. If the parameters are set incorrectly, the printer may function unpredictably. The first time that you attempt to change a password-protected parameter, the printer displays ENTER PASSWORD.
Introduction Control Panel Display Operating Parameters on the Control Panel Items in this menu are shown in the order in which they appear when you press the RIGHT ARROW. For more information about these settings, see Print Settings on page 83. Adjust the Print Darkness Set the darkness to the lowest setting that provides good print quality.
Introduction Control Panel Display Set the Media Type Select the type of media that you are using. See Media Type on page 85 for more information. Select the Media Sensor Select the media sensor that is appropriate for the media that you are using. See Sensor Type on page 102 for more information. Select the Print Method Specify if ribbon is being used. Thermal Transfer media requires ribbon for printing while Direct Thermal media does not.
Introduction Control Panel Display Set Supplies Low Warning When this feature is enabled, the printer provides warnings when the media or ribbon is reaching near the end of the roll. See Supplies Low Warning on page 89 for more information. Set Early Warning for Maintenance When this feature is enabled, the printer provides warnings when the printhead needs to be cleaned. See Early Warning for Maintenance on page 89 for more information.
Introduction Control Panel Display Reset New Printhead Counter for Early Warning* • If you received the message WARNING REPLACE HEAD, replace the printhead, and then press PLUS (+) to select YES to reset the Early Warning for Maintenance printhead replacement counter. • If you have not replaced the printhead, press MINUS (-) to select NO. * This parameter appears only if Early Warning for Maintenance is enabled.
Introduction Control Panel Display Print Font List This option prints a label that lists the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory. See Print Information on page 91 for more information. Print Bar Code List This option prints a label that lists the available bar codes in the printer. Bar codes may be stored in RAM or Flash memory. See Print Information on page 91 for more information.
Introduction Control Panel Display Print Network Configuration Label This option prints a configuration label (see Figure 14 on page 149), which lists the settings for any print server that is installed. See Print Information on page 91 for more information. Print All Labels This option prints labels that list the available fonts, bar codes, images, formats, and the current printer and network configurations. See Print Information on page 91 for more information.
Introduction Control Panel Display Calibrate the Media and Ribbon Sensors Use this menu item to adjust the sensitivity of the media and ribbon sensors. See Media and Ribbon Sensor Calibration on page 94 for more information. For instructions on how to perform a calibration procedure, see Calibrate the Ribbon and Media Sensors Manually on page 106. Set Parallel Communications Select the communications port that matches the one being used by the host computer.
Introduction Control Panel Display Set the Parity Value Select the parity value that matches the one being used by the host computer. See Parity on page 104 for more information. Set the Host Handshake Protocol Value Select the handshake protocol that matches the one being used by the host computer. See Host Handshake on page 105 for more information. Set the Zebra Protocol Value Protocol is a type of error checking system.
Introduction Control Panel Display Set the Control Character Value Set the control prefix character to match what is used in your label formats. See Control Character on page 100 for more information. Set the Format Command Prefix Value Set the format command prefix character to match what is used in your label formats. See Command Character on page 101 for more information. Set the Delimiter Character Value Set the delimiter character to match what is used in your label formats.
Introduction Control Panel Display Set the Head-Close Action Set the action for the printer to take when you close the printhead. See Head-Close Action on page 92 for more information. Set the Backfeed Sequence This parameter sets when label backfeed occurs after a label is removed in some print modes. It has no effect in Rewind mode. This setting is superseded by ~JS when received as part of a label format. See Backfeed Sequence on page 87 for more information.
Introduction Control Panel Display Set the Reprint Mode When reprint mode is enabled, you can reprint the last label printed either by issuing certain commands or by pressing the LEFT ARROW on the control panel. See Reprint Mode on page 88 for more information. View Sensor Settings The following parameters are automatically set during the calibration procedure and should be changed only by a qualified service technician. Select Format Conversion Scaling Factor Selects the bitmap scaling factor.
Introduction Control Panel Display Select the Idle Display Select the information shown on the printer’s display when the printer is idle. See Idle Display on page 95 for more information. Set the Real-Time Clock (RTC) Date This parameter allows you to set the date to display in the Idle Display. See RTC Date on page 95 for more information. Set the Real-Time Clock (RTC) Time This parameter allows you to set the date to display in the Idle Display. See RTC Time on page 95 for more information.
Introduction Control Panel Display View if IP Settings Are Loaded from the Printer or Print Server This parameter tells whether to use the printer’s or the print server’s LAN/WLAN settings at power-up. The default is to use the printer’s settings. See Load from External Device on page 96 for more information. View the Active Print Server* This menu item displays which print server is being used.
Introduction Control Panel Display Set the Subnet Mask* View and, if necessary, change the subnet mask. Changes are saved only if IP PROTOCOL is set to PERMANENT. To allow any saved changes to take effect, use RESET NETWORK on page 35 to reset the print server. See Subnet Mask on page 98 for more information. * This menu item appears only if a wired or wireless print server is installed in your printer. Set the Default Gateway* View and, if necessary, change the default gateway.
Introduction Control Panel Display Reset the Network Settings* This option resets the wired or wireless print server. You must reset the print server to allow any changes to the network settings to take effect. See Reset Network on page 99 for more information. * This menu item appears only if a wired or wireless print server is installed in your printer. Specify the Password Level This parameter allows you to select whether certain factoryselected menu items or all menu items are password protected.
Introduction Control Panel Display Select the Display Language If necessary, change the language that the printer displays. See Language on page 100 for more information. Note • The selections for this parameter are displayed in the actual languages to make it easier for you to find one that you are able to read.
2 Printer Setup and Operation This section assists the technician with initial setup and operation of the printer. Contents Handling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To Ship the Printer .
Printer Setup and Operation Handling the Printer Handling the Printer This section describes how to handle your printer. Unpack and Inspect the Printer Important • Zebra Technologies is not responsible for any damage incurred during the shipment of the equipment and will not repair this damage under warranty. When you receive the printer, do the following: 1. Immediately unpack the printer. 2. Check all exterior surfaces for damage. 3.
Printer Setup and Operation Select a Location for the Printer Select a Location for the Printer Select a location for the printer that meets these conditions: • Surface: The surface where the printer will be located must be solid, level, and of sufficient size and strength to hold the printer. • Space: The area where the printer will be located must include enough space for ventilation and for accessing the printer components and connectors.
Printer Setup and Operation Select a Data Communication Interface Select a Data Communication Interface You may connect your printer to a computer using one or more of the available connections. The standard connections are shown in Figure 4. A ZebraNet wired or wireless print server option or a parallel port may also be present on your printer.
Printer Setup and Operation Select a Data Communication Interface Table 4 • Data Communication Interfaces Interface Standard or Option RS-232 Serial Standard Description Limitations and Requirements • Maximum cable length of 50 ft (15.24 m). • You may need to change printer parameters to match the host computer. • You need to use a null-modem adaptor to connect to the printer if using a standard modem cable.
Printer Setup and Operation Select a Data Communication Interface Table 4 • Data Communication Interfaces (Continued) Interface Standard or Option Wireless print server Option Description Limitations and Requirements • Can print to the printer from any computer on your Wireless Local Area Network (WLAN). • Can communicate with the printer through the printer’s web pages. • The printer must be configured to use your WLAN.
Printer Setup and Operation Connect the Printer to a Power Source Connect the Printer to a Power Source The AC power cord must have a three-prong female connector on one end that plugs into the mating AC power connector at the rear of the printer. If a power cable was not included with your printer, refer to Power Cord Specifications on page 44. Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation.
Printer Setup and Operation Connect the Printer to a Power Source 3. Turn on (I) the printer. The printer boots up and performs a self-test. Power Cord Specifications Caution • For personnel and equipment safety, always use an approved three-conductor power cord specific to the region or country intended for installation. This cord must use an IEC 320 female connector and the appropriate region-specific, three-conductor grounded plug configuration.
Printer Setup and Operation Connect the Printer to a Power Source Figure 5 • Power Cord Specifications 2 3 1 4 1 2 3 4 AC power plug for your country—This should bear the certification mark of at least one of the known international safety organizations (Figure 6). 3-conductor HAR cable or other cable approved for your country. IEC 320 connector—This should bear the certification mark of at least one of the known international safety organizations (Figure 6). Length ≤ 9.8 ft. (3 m).
Printer Setup Install the Control Panel Keypad Cover Install the Control Panel Keypad Cover A protective cover for the control panel keypad is provided with your printer (Figure 7). Install this optional cover if your printer will operate in a moist or dirty environment. This will help to protect the keypad from damage. Figure 7 • Control Panel Keypad Cover To install the control panel keypad cover, complete these steps: 1.
Printer Setup and Operation Types of Media Types of Media Important • Zebra strongly recommends the use of Zebra-brand supplies for continuous high-quality printing. A wide range of paper, polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the printing capabilities of the printer and to prevent premature printhead wear. To purchase supplies, go to http://www.zebra.com/howtobuy.
Printer Setup and Operation Types of Media Table 5 • Roll and Fanfold Media (Continued) Media Type How It Looks Description Non-Continuous Fanfold Media Fanfold media is folded in a zigzag pattern. Fanfold media can have the same label separations as non-continuous roll media. The separations would fall on or near the folds. Continuous Roll Media Roll media is wound on a 3-in. (76-mm) core. Continuous roll media does not have gaps, holes, notches, or black marks to indicate label separations.
Printer Setup and Operation Ribbon Overview Ribbon Overview Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
Printer Setup and Operation Ribbon Overview Adhesive Test If you have labels available, perform the adhesive test to determine which side of a ribbon is coated. This method works well for ribbon that is already installed. To perform an adhesive test, complete these steps: 1. Peel a label from its liner. 2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon. 3. Peel the label off of the ribbon. 4. Observe the results.
Printer Setup and Operation Select a Print Mode Select a Print Mode Use a print mode that matches the media being used and the printer options available (Table 6). Table 6 • Print Modes and Printer Options Print Mode When to Use/Printer Options Required Printer Actions Tear-Off (default setting) Use for most applications. This mode can be used with any printer options and most media types. The printer prints label formats as it receives them.
Printer Setup and Operation Select a Print Mode Table 6 • Print Modes and Printer Options Print Mode When to Use/Printer Options Required Printer Actions Peel-Off Use when the printer has the Rewind option if you want to remove the labels from the liner one label at a time. The printer peels the label from the liner during printing and then pauses until the label is removed. The liner winds onto the rewind spindle.
Printer Setup and Operation Select a Print Mode Table 6 • Print Modes and Printer Options Print Mode When to Use/Printer Options Required Printer Actions Cutter Use when the printer has a cutter option if you want the labels to be cut apart. The printer prints a label and then cuts it free.
Printer Setup and Operation Load the Ribbon Load the Ribbon Use the instructions in this section to load ribbon (if used) in your printer. Ribbon is used only with thermal transfer labels. For direct thermal labels, do not load ribbon in the printer. To determine if ribbon must be used with a particular media, see When to Use Ribbon on page 49.
Printer Setup and Operation Load the Ribbon 3. Align the segments of the ribbon supply spindle. 4. Position the ribbon with the loose end unrolling clockwise. 5. Place the roll of ribbon on the ribbon supply spindle. Push the roll back as far as it will go. 6. A ribbon leader makes ribbon loading and unloading easier. Does your roll of ribbon have paper or something else attached to the end to serve as a ribbon leader? If… Then… Yes Continue with the next step. No a.
Printer Setup and Operation Load the Ribbon 7. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Rotate the printhead-open lever (1) to the open position. 1 8. Thread the ribbon over the media dancer assembly (1) and under the ribbon guide roller (2).
Printer Setup and Operation Load the Ribbon 9. Push the ribbon leader forward until it passes under the printhead assembly (1), over the snap plate (2), and then over the platen roller (3). 1 2 3 10. Bring the ribbon leader over the upper ribbon roller (1) and then toward the ribbon take-up spindle (2). 1 2 11. Wind the ribbon leader and attached ribbon counterclockwise around the ribbon take-up spindle.
Printer Setup and Operation Load the Ribbon 12. Rotate the spindle counterclockwise several turns to wind the ribbon and remove any slack. 13. Is media already loaded? If… Then… No a. Continue with Load the Media on page 59. Yes a. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) until it locks into place. 2 1 b. Close the media door.
Printer Setup and Operation Load the Media Load the Media 1. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Open the printhead assembly by rotating the printhead-open lever (1). 1 2. Loosen the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1).
Printer Setup and Operation Load the Media 3. Slide the outer media guide (1) all the way out.
Printer Setup and Operation Load the Media 4. Insert media into the printer. Follow the instructions for roll or fanfold media, as appropriate. Fanfold Media Roll Media a. Remove and discard any tags or labels that are dirty or that are held by adhesives or tape. a. Thread the fanfold media through the bottom or rear slot. Bottom Feed Rear Feed b. Pull out the media supply guide as far as it goes. 7/3/13 b. Pull out the media supply guide as far as it goes.
Printer Setup and Operation Load the Media Roll Media (Continued) c. Place the roll of media on the media supply hanger. Push the roll back as far as it will go. d. Slide in the media supply guide until it touches the edge of the roll. Fanfold Media (Continued) c. Drape the media over the media supply hanger. d. Slide in the media supply guide until it touches the edge of the media. 5.
Printer Setup and Operation Load the Media 6. Push the media forward until it passes under the printhead assembly (1), under the snap plate (2), and then over the platen roller (3). 1 2 3 7. In which print mode will your printer be operating? (For more information on print modes, see Select a Print Mode on page 51.) 7/3/13 If using… Then… Tear-Off mode Continue with Final Steps for Tear-Off Mode on page 65. Peel-Off mode Continue with Final Steps for PeelOff Mode on page 67.
Printer Setup and Operation Load the Media P1056468-002 If using… Then… Rewind mode Continue with Final Steps for Rewind Mode on page 72. Cutter mode Continue with Final Steps for Cutter Mode on page 77.
Printer Setup and Operation Load the Media 7. Final Steps for Tear-Off Mode 8. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media. 1 2 9. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1).
Printer Setup and Operation Load the Media 10. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) until it locks into place. 2 1 11. Close the media door. 12. Set the printer to Tear-Off mode (for more information, see Print Mode on page 84). 13. If desired, perform the CANCEL Self Test on page 149 to verify that your printer is able to print.
Printer Setup and Operation Load the Media 7. Final Steps for Peel-Off Mode 8. Remove the rewind plate (if installed) from the front of the printer. Store it on the two mounting screws on the inside of the printer base.
Printer Setup and Operation Load the Media 9. Extend approximately 36 in. (920 mm) of media out of the printer. Remove and discard the labels from this exposed media. 10. Remove the hook from the rewind spindle. 11. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate. Note • A core is not required.
Printer Setup and Operation Load the Media 12. Wind the media liner counterclockwise around the rewind spindle. a. Reinstall the hook. Insert the short end of the hook into the hole in the center of the adjusting nut (1). Insert the long end of the hook into the small hole on the guide plate (2). 2 1 b. Rotate the spindle counterclockwise several turns to wind the media liner over the hook and remove any slack. 13. Align the media with the inner media guide (1).
Printer Setup and Operation Load the Media 14. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 15. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) until it locks into place. 2 1 The backing winds on the rewind spindle or core.
Printer Setup and Operation Load the Media 16. Close the media door. 17. Set the printer to Peel-Off mode (for more information, see Print Mode on page 84). 18. If desired, perform the CANCEL Self Test on page 149 to verify that your printer is able to print.
Printer Setup and Operation Load the Media 7. Final Steps for Rewind Mode 8. Remove the rewind plate from its storage location inside the printer. 9. Position the rewind plate so that the lip on the attached hook plate points down. 3 1 2 4 5 1 2 3 4 5 Upper slot Lower slot Rewind plate Lip Adjustable hook plate 10. Insert the hook plate lip 1/2 in. (13 mm) into the lower slot in the side plate. 11. Align the upper end of the rewind plate with the matching upper slot in the side plate. 12.
Printer Setup and Operation Load the Media 13. Extend approximately 36 in. (920 mm) of media out of the printer. Remove and discard the labels from this exposed media. 14. Remove the hook from the rewind spindle. 15. If you are using a core, slide it onto the rewind spindle until it is flush against the guide plate. Note • A core is not required.
Printer Setup and Operation Load the Media 16. Wind the media liner counterclockwise around the rewind spindle. a. Reinstall the hook. Insert the short end of the hook into the hole in the center of the adjusting nut (1). Insert the long end of the hook into the small hole on the guide plate (2). 2 1 b. Rotate the spindle counterclockwise several turns to wind the media liner over the hook and remove any slack. 17. Align the media with the inner media guide (1).
Printer Setup and Operation Load the Media 18. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 19. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) until it locks into place. 2 1 The media winds on the rewind spindle or core.
Printer Setup and Operation Load the Media 20. Close the media door. 21. Set the printer to Rewind mode (for more information, see Print Mode on page 84). 22. If desired, perform the CANCEL Self Test on page 149 to verify that your printer is able to print.
Printer Setup and Operation Load the Media 7. Final Steps for Cutter Mode 8. Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers. Thread the media forward until it passes under the printhead assembly (1), under the snap plate (2), and through the cutter assembly (3). 1 2 3 9. Align the media with the inner media guide (1). Slide in the outer media guide (2) until it just touches the edge of the media.
Printer Setup and Operation Load the Media 10. Tighten the thumb screw (not visible from this angle) that is located on the bottom of the outer media guide (1). 1 11. Push down the printhead assembly (1), and then rotate the printhead-open lever (2) until it locks into place. 2 1 The media winds on the rewind spindle or core.
Printer Setup and Operation Load the Media 12. Close the media door. 13. Set the printer to Cutter mode (for more information, see Print Mode on page 84). 14. If desired, perform the CANCEL Self Test on page 149 to verify that your printer is able to print.
Printer Setup and Operation Load the Media Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ____________
3 Printer Configuration and Adjustment This section assists you with configuration of and adjustments to the printer. Contents Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Print Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Maintenance and Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Configuration and Adjustment Changing Printer Settings Changing Printer Settings This section presents the printer settings that you can change and identifies the tools for changing them. These tools include the following: • ZPL and Set/Get/Do (SGD) commands (See the Zebra® Programming Guide for more information.) • The printer’s control panel display (See Control Panel Display on page 17 for more information.
Printer Configuration and Adjustment Changing Printer Settings Print Settings Table 7 • Print Settings Print Darkness Set the darkness to the lowest setting that provides good print quality. If you set the darkness too high, the label image may print unclearly, bar codes may not scan correctly, the ribbon may burn through, or the printhead may wear prematurely. If desired, use the FEED Self Test on page 151 to determine the best darkness setting. Accepted values: 0.0 – 30.
Printer Configuration and Adjustment Changing Printer Settings Table 7 • Print Settings (Continued) Tear-Off Position If necessary, adjust the position of the media over the tear-off bar after printing. • Higher numbers move the media out (the tear line moves closer to the leading edge of the next label). • Lower numbers move the media in (the tear line moves closer to the edge of the label just printed).
Printer Configuration and Adjustment Changing Printer Settings Table 7 • Print Settings (Continued) Media Type Select the type of media that you are using. • If you select CONTINUOUS, you must include a label length in your label format (^LL if you are using ZPL). • If you select NON-CONTINUOUS for various non-continuous media, the printer feeds media to calculate the label length. See Types of Media on page 47 for more information.
Printer Configuration and Adjustment Changing Printer Settings Table 7 • Print Settings (Continued) Maximum Label Length Set the maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length plus the interlabel gap. If you set the value to one that is smaller than the label length, the printer assumes that continuous media is loaded, and the printer cannot calibrate. For example, if the label length is 6.
Printer Configuration and Adjustment Changing Printer Settings Table 7 • Print Settings (Continued) Backfeed Sequence This parameter sets when label backfeed occurs after a label is removed in some print modes. It has no effect in Rewind mode. This setting is superseded by ~JS when received as part of a label format.
Printer Configuration and Adjustment Changing Printer Settings Table 7 • Print Settings (Continued) Reprint Mode When reprint mode is enabled, you can reprint the last label printed by pressing and holding PAUSE + CANCEL on the printer’s control panel.
Printer Configuration and Adjustment Changing Printer Settings Maintenance and Diagnostic Tools Table 8 • Maintenance and Diagnostic Tools Supplies Low Warning When this feature is enabled, the printer provides warnings when the media or ribbon is reaching near the end of the roll.
Printer Configuration and Adjustment Changing Printer Settings Table 8 • Maintenance and Diagnostic Tools (Continued) Non-Resettable Counter The non-resettable counter gives the total length of media that the printer has printed. You can use firmware commands to change the unit of measure for this counter.
Printer Configuration and Adjustment Changing Printer Settings Table 8 • Maintenance and Diagnostic Tools (Continued) Print Information Print the specified information on one or more labels. • FONTS—Prints the available fonts in the printer, including standard printer fonts plus any optional fonts. Fonts may be stored in RAM or Flash memory. • BAR CODES—Prints the available bar codes in the printer. Bar codes may be stored in RAM or Flash memory.
Printer Configuration and Adjustment Changing Printer Settings Table 8 • Maintenance and Diagnostic Tools (Continued) Power-Up Action Set the Power-Up Action Set the action for the printer to take during the power-up sequence. • CALIBRATE adjusts sensor levels and thresholds, determines the label length, and feeds the media to the next web. • FEED—feeds the labels to the first registration point. • LENGTH determines the label length using current sensor values, and feeds the media to the next web.
Printer Configuration and Adjustment Changing Printer Settings Table 8 • Maintenance and Diagnostic Tools (Continued) Load Defaults Load Printer or Print Server Defaults • FACTORY—Restores all printer settings other than the network settings back to the factory defaults. Use care when loading defaults because you will need to reload all settings that you changed manually. • NETWORK—Reinitializes the printer’s wired or wireless print server.
Printer Configuration and Adjustment Changing Printer Settings Table 8 • Maintenance and Diagnostic Tools (Continued) Media and Ribbon Sensor Calibration Calibrate the printer to adjust the sensitivity of the media and ribbon sensors. For complete instructions on how to perform a calibration procedure, see Calibrate the Ribbon and Media Sensors Manually on page 106.
Printer Configuration and Adjustment Changing Printer Settings Table 8 • Maintenance and Diagnostic Tools (Continued) Idle Display Select the information shown on the printer’s display when the printer is idle.
Printer Configuration and Adjustment Changing Printer Settings Network Settings Table 9 • Network Settings Primary Network Select the Primary Network Device This parameter determines which device should be considered primary in the active device selection. Accepted values: • • WIRED WIRELESS Related ZPL command(s): ^NC SGD command used: ip.
Printer Configuration and Adjustment Changing Printer Settings Table 9 • Network Settings (Continued) IP Protocol Set the IP Resolution Method This parameter tells if the user (permanent) or the server (dynamic) selects the IP address. If a dynamic option is chosen, this parameter tells the method(s) by which the wired or wireless print server receives the IP address from the server.
Printer Configuration and Adjustment Changing Printer Settings Table 9 • Network Settings (Continued) Subnet Mask View or Set the Subnet Mask View and, if necessary, change the subnet mask. This menu item appears only if a wired or wireless print server is installed on your printer. To save changes to this setting, set IP PROTOCOL to PERMANENT, and then reset the print server (see Reset Network on page 99).
Printer Configuration and Adjustment Changing Printer Settings Table 9 • Network Settings (Continued) ESSID View the ESSID Value The Extended Service Set Identification (ESSID) is an identifier for your wireless network. This setting, which cannot be modified from the control panel, gives the ESSID for the current wireless configuration. Accepted values: 32-character alphanumeric string (default 125) Related ZPL command(s): none SGD command used: wlan.
Printer Configuration and Adjustment Changing Printer Settings Language Settings Table 10 • Language Settings Language If necessary, change the language that the printer displays.
Printer Configuration and Adjustment Changing Printer Settings Table 10 • Language Settings (Continued) Command Character Set the Format Command Prefix Value The format command prefix is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. The printer looks for this hex character to indicate the start of a ZPL/ZPL II format instruction. Set the format command prefix character to match what is used in your label formats.
Printer Configuration and Adjustment Changing Printer Settings Sensor Settings Table 11 • Sensor Settings Sensor Type Select the Media Sensor Select the media sensor that is appropriate for the media that you are using.
Printer Configuration and Adjustment Changing Printer Settings Port Settings Table 12 • Port Settings Parallel Communications Set Parallel Communications Select the communications port that matches the one being used by the host computer. Accepted values: • • BIDIRECTIONAL UNIDIRECTIONAL Related ZPL command(s): none SGD command used: none Control panel menu item: PARRALEL COMM.
Printer Configuration and Adjustment Changing Printer Settings Table 12 • Port Settings (Continued) Baud Rate Set the Baud Rate Select the baud value that matches the one being used by the host computer. Accepted values: • • • • • • • • • • • • 115200 57600 38400 28800 19200 14400 9600 4800 2400 1200 600 300 Related ZPL command(s): ^SC SGD command used: comm.
Printer Configuration and Adjustment Changing Printer Settings Table 12 • Port Settings (Continued) Host Handshake Set the Host Handshake Protocol Value Select the handshake protocol that matches the one being used by the host computer.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Sensors Manually Calibrate the Ribbon and Media Sensors Manually Use the calibration procedure in this section when necessary to calibrate the printer based on the media and ribbon that you are currently using. Manual calibration is recommended whenever you are using pre-printed labels (or label backing) or if the printer will not correctly auto calibrate.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Sensors Manually 2. Raise the media door. 3. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Rotate the printhead-open lever (1) to the open position.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Sensors Manually 4. What type of media are you using? For more information, see Types of Media on page 47. If you are using… Then… Media where labels are separated by gaps a. Set the sensor type to WEB. (See Sensor Type on page 102.) b. Extend approximately 8in. (203 mm) of media out of the printer. c. Remove and discard the labels from this exposed media. d. Pull the backing into the printer.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Sensors Manually If you are using… Then… Black mark media a. Set the sensor type to MARK. (See Sensor Type on page 102.) b. Position a black mark over the red light from the black mark media sensor. Media where labels are separated by holes or notches a. Remove the media from between the media sensors. 5. Press PLUS (+) to continue. The control panel displays: REMOVE RIBBON 6. Remove the ribbon (if used). 7.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Sensors Manually 8. Press PAUSE to begin the media calibration process. The control panel displays: CALIBRATING PLEASE WAIT When the process is complete, the control panel displays: RELOAD ALL 9. Rotate the printhead-open lever (1) to the open position. 1 10. Reload the media and ribbon (if used). With preprinted or black mark media, make sure that an area without preprinting or without a black mark is over the media sensor. 11.
Printer Configuration and Adjustment Calibrate the Ribbon and Media Sensors Manually 12. Close the media door. The printer completes calibration and feeds labels until they come to rest in the appropriate spot for printing. 13. Press PAUSE to enable printing.
Printer Configuration and Adjustment Remove Used Ribbon Remove Used Ribbon Remove used ribbon from the ribbon take-up spindle each time you change the roll of ribbon. To remove used ribbon, complete these steps: 1. Has the ribbon run out? If the ribbon... Then Ran out Continue with the next step. Did not run out Cut or break the ribbon before the ribbon take-up spindle. 2. While holding the ribbon take-up spindle, turn the ribbon release knob clockwise until it stops.
Printer Configuration and Adjustment Remove Media or Liner from the Rewind Spindle Remove Media or Liner from the Rewind Spindle Rewind mode uses the rewind spindle to wind media, while Peel-Off mode uses the rewind spindle to wind used liner. Remove the media or the liner from the rewind spindle each time that you change media. Important • It is not necessary to turn off the power to remove media or liner from the rewind spindle.
Printer Configuration and Adjustment Remove Media or Liner from the Rewind Spindle 2. Pull out the spindle hook. 3. Slide the media or liner off of the rewind spindle.
Routine Maintenance Adjust Transmissive Media Sensors Adjust Transmissive Media Sensors The transmissive media sensor assembly consists of two parts: a light source and a light sensor. The lower media sensor is the light source, and the upper media sensor is the light sensor. The media passes between the two parts. Adjust these sensors only when the printer cannot detect the top of the labels.
Routine Maintenance Adjust Transmissive Media Sensors 3. Using a thin, flat-blade screwdriver, loosen the upper media sensor adjustment screw. Z X Y 4. Slide the upper media sensor along the slot to the desired position.
Routine Maintenance Adjust Transmissive Media Sensors 5. Tighten the adjustment screw to secure the upper media sensor in its new position. Z X Y 6. Adjust the lower media sensor to match the new position of the upper media sensor. See Lower Media Sensor on page 118.
Routine Maintenance Adjust Transmissive Media Sensors Lower Media Sensor After you adjust the upper media sensor, adjust the lower media sensor to match its new position. To adjust the lower media sensor, complete these steps: 1. Locate the lower media sensor assembly under the rear roller. The sensor is a spring clip holding a circuit board. 2. Slide the lower sensor until it is under the upper media sensor. Use the light that shines from the lower sensor to help align it with the upper sensor.
Routine Maintenance Adjust Printhead Pressure and Toggle Position Adjust Printhead Pressure and Toggle Position Print quality depends on the labels and ribbon used as well as the toggle pressure and position. Make sure that your labels and ribbon are acceptable for your application. If they are, check the toggle position and then the printhead pressure. Toggle Position Adjustment You may need to adjust the toggles if printing is too light on one side or if thick labels are used.
Routine Maintenance Adjust Printhead Pressure and Toggle Position 5. Tighten the locking nuts. 6. Print additional labels at 2 in. (51 mm) per second by again running the PAUSE Self Test. (Press and hold PAUSE while turning on (I) the printer.) 7. Do both sides of the label print at the same level of gray? If… Then… Yes The toggles are positioned correctly. Increase the darkness setting to the optimum level for the media being used. No a.
Routine Maintenance Adjust Printhead Pressure and Toggle Position Printhead Pressure Adjustment If positioning the toggles properly does not solve a print quality problem, try adjusting the printhead pressure. Maximize printhead life by using the lowest pressure that produces the desired print quality. Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads.
Routine Maintenance Adjust Printhead Pressure and Toggle Position 4. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Move the adjusting nut until the print quality is acceptable. Use the lowest pressure that provides the desired print quality. • To increase printhead pressure, move the adjusting nut downward. • To decrease printhead pressure, move the adjusting nut upward. 5.
4 Routine Maintenance This section provides routine cleaning and maintenance procedures. Contents Replacing Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recycling Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance Replacing Printer Components Replacing Printer Components Some printer components, such as the printhead and platen roller, may wear out over time and can be replaced easily. Regular cleaning may extend the life of some of these components. See Cleaning Schedule and Procedures on page 125 for the recommended cleaning intervals.
Routine Maintenance Cleaning Schedule and Procedures Cleaning Schedule and Procedures Cleaning your printer regularly maintains print quality and may extend the life of the printer. The recommended cleaning schedule is shown in Table 13. See the following pages for specific procedures. Caution • While performing any tasks near an open printhead, remove all rings, watches, hanging necklaces, identification badges, or other metallic objects that could touch the printhead.
Routine Maintenance Cleaning Schedule and Procedures Clean the Media Compartment After every four rolls of media, inspect the media compartment. Use a soft bristle brush or a vacuum cleaner to remove any dirt and lint from the interior of the printer. Clean the Printhead and Platen Roller If print quality does not improve after you perform this procedure, clean the printhead with Save-a-Printhead cleaning film.
Routine Maintenance Cleaning Schedule and Procedures 2. Remove the media and ribbon (if loaded). 3. Using the swab from the Preventive Maintenance Kit (part number 47362), wipe along the brown strip on the printhead assembly from end to end. In place of the Preventive Maintenance Kit, you may use a clean swab dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate.
Routine Maintenance Cleaning Schedule and Procedures Clean the Sensors Brush or vacuum any accumulated paper lint and dust off the sensors. Clean the sensors according to the recommendations in Cleaning Schedule and Procedures on page 125. Ribbon and Label-Available Sensor Locations The ribbon sensor and optional label-available sensor are shown in Figure 9.
Routine Maintenance Cleaning Schedule and Procedures Transmissive Media Sensor The upper and lower transmissive media sensors are show in Figure 10 and Figure 11.
Routine Maintenance Cleaning Schedule and Procedures Clean the Snap Plate Clean the snap plate when label adhesive or a label is stuck to the underside. Figure 12 shows the location of the snap plate. Figure 12 • Snap Plate Location Important • Be careful not to bend or twist the metal snap plate as you remove it from or insert it into the printer. To clean the snap plate, complete these steps: 1.
Routine Maintenance Cleaning Schedule and Procedures 3. Insert a small-blade screwdriver or similar tool into the loop on the left side of the snap plate. Gently lift the left side of the snap plate slightly and, if necessary, support it with your left hand. Important • Take care not to bend, twist, or otherwise deform the loops. If the snap plate is damaged in any way, you may need a new plate for proper ribbon sensing. 4.
Routine Maintenance Cleaning Schedule and Procedures 5. Remove the snap plate from the printer. 6. Using the swab from the Preventive Maintenance Kit (part number 47362), clean the back of the snap plate. In place of the Preventive Maintenance Kit, you may use a clean swab or soft cloth dipped in a solution of isopropyl alcohol (minimum 90%) and deionized water (maximum 10%). Allow the solvent to evaporate. 7.
Routine Maintenance Cleaning Schedule and Procedures 8. Press down on the loops to lock the snap plate into place. 9. Reinstall the media and ribbon (if used). 10. Reconnect the data cables and AC power cord, and turn on (l) the printer.
Routine Maintenance Cleaning Schedule and Procedures Clean the Cutter If the cutter is not cutting the labels cleanly or if it jams with labels, clean the cutter. Caution • The cutter blade is sharp. Do not touch or rub the blade with your fingers. To clean the cutter, complete these steps: 1. Caution • Turn off (O) the printer and disconnect it from the power source before performing the following procedure. Turn off (O) the printer, and disconnect the AC power cord and all data cables. 2.
5 Troubleshooting This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Printing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Printing Issues Printing Issues Table 14 identifies possible issues with printing or print quality, the possible causes, and the recommended solutions. Table 14 • Printing Issues Issue Possible Cause Recommended Solution General print quality issues The printer is set at an incorrect print speed. For optimal print quality, set the print speed to the lowest possible setting for your application via control panel, the driver, or the software.
Troubleshooting Printing Issues Table 14 • Printing Issues (Continued) Issue Possible Cause Recommended Solution Long tracks of missing print on several labels Print element damaged. Call a service technician. Wrinkled ribbon. See wrinkled ribbon causes and solutions in Ribbon Problems on page 146. Fine, angular gray lines on blank labels Wrinkled ribbon. See wrinkled ribbon causes and solutions in Ribbon Problems on page 146.
Troubleshooting Printing Issues Table 14 • Printing Issues (Continued) Issue Possible Cause Vertical image or label drift The printer is using Set the printer for the correct media type non-continuous labels but is (gap/notch, continuous, or mark—see Media configured in continuous mode. Type on page 85) and calibrate the printer, if necessary (see Calibrate the Ribbon and Media Sensors Manually on page 106). The bar code printed on a label does not scan. The media sensor is calibrated improperly.
Troubleshooting Error Messages Error Messages The control panel displays messages when there is an error. See Table 15 for LCD errors, the possible causes, and the recommended solutions. Table 15 • Error Messages Display/ Printer Condition Possible Cause Recommended Solution The printhead was replaced with one that is not a genuine Zebra™ printhead. Install a genuine Zebra™ printhead.
Troubleshooting Error Messages Table 15 • Error Messages (Continued) Display/ Printer Condition The printer stops; the RIBBON light is on; the ERROR light flashes. Possible Cause Recommended Solution In thermal transfer mode, ribbon is not loaded or incorrectly loaded. Load ribbon correctly. See Load the Ribbon on page 54. In thermal transfer mode, the ribbon sensor is not detecting ribbon. 1. In thermal transfer mode, media is blocking the ribbon sensor. 1.
Troubleshooting Error Messages Table 15 • Error Messages (Continued) Display/ Printer Condition Possible Cause Recommended Solution The printhead has a faulty thermistor. Call a service technician. The ERROR light flashes. Caution • An improperly connected printhead data or power cable can cause this error message. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printer prints while the ERROR light flashes.
Troubleshooting Error Messages Table 15 • Error Messages (Continued) Display/ Printer Condition Possible Cause Recommended Solution Caution • An improperly connected printhead data or power cable can cause these error messages. The printhead may be hot enough to cause severe burns. Allow the printhead to cool. The printhead data cable is not properly connected. Caution • Turn off (O) the printer before performing this procedure. Failure to do so can damage the printhead.
Troubleshooting Error Messages Table 15 • Error Messages (Continued) Display/ Printer Condition Possible Cause Recommended Solution There is not enough memory to perform the function specified on the second line of the error message. Free up some of the printer’s memory by adjusting the label format or printer parameters. One way to free up memory is to adjust the print width to the actual width of the label instead of leaving the print width set to the default. See Print Width on page 85.
Troubleshooting Calibration Problems Calibration Problems Table 16 identifies problems with calibration, the possible causes, and the recommended solutions. Table 16 • Calibration Problems Problem Possible Cause Recommended Solution Loss of printing registration on labels. Excessive vertical drift in top-of-form registration. The platen roller is dirty. Clean the platen roller according to the instructions in Clean the Printhead and Platen Roller on page 126.
Troubleshooting Communications Problems Communications Problems Table 17 identifies problems with communications, the possible causes, and the recommended solutions. Table 17 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the printer but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the printer driver or software communications settings (if applicable).
Troubleshooting Ribbon Problems Ribbon Problems Table 18 identifies problems that may occur with ribbon, the possible causes, and the recommended solutions. Table 18 • Ribbon Problems Problem Possible Cause Recommended Solution Broken or melted ribbon Darkness setting too high. 1. The ribbon is coated on the wrong side and cannot be used in this printer. Replace the ribbon with one coated on the correct side. For more information, see Coated Side of Ribbon on page 49.
Troubleshooting Miscellaneous Issues Miscellaneous Issues Table 19 identifies miscellaneous issues with the printer, the possible causes, and the recommended solutions. Table 19 • Miscellaneous Printer Problems Problem Possible Cause Recommended Solution The control panel display shows a language that I cannot read The language parameter was changed through the control panel or a firmware command. 1. The display is missing characters or parts of characters The display may need replacing.
Troubleshooting Printer Diagnostics Printer Diagnostics Self tests and other diagnostics provide specific information about the condition of the printer. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the printer. Important • Use full-width media when performing self tests. If your media is not wide enough, the test labels may print on the platen roller.
Troubleshooting Printer Diagnostics CANCEL Self Test The CANCEL self test prints a printer configuration label and a network configuration label. For other ways to print these labels, see Print Information on page 91. To perform the CANCEL Self Test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold CANCEL while turning on (I) the printer. Hold CANCEL until the first control panel light turns off.
Troubleshooting Printer Diagnostics PAUSE Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies or to determine if any printhead elements are not working. Figure 15 shows a sample printout. To perform a PAUSE self test, complete these steps: 1. Turn off (O) the printer. 2. Press and hold PAUSE while turning on (I) the printer. Hold PAUSE until the first control panel light turns off.
Troubleshooting Printer Diagnostics FEED Self Test Different types of media may require different darkness settings. This section contains a simple but effective method for determining the ideal darkness for printing bar codes that are within specifications. During the FEED self test, labels are printed at different darkness settings at two different print speeds. The relative darkness and the print speed are printed on each label. The bar codes on these labels may be ANSI-graded to check print quality.
Troubleshooting Printer Diagnostics Figure 17 • Bar Code Darkness Comparison Table 20 • Judging Bar Code Quality P1056468-002 Print Quality Description Too dark Labels that are too dark are fairly obvious. They may be readable but not “in-spec.” • The normal bar code bars increase in size. • The openings in small alphanumeric characters may fill in with ink. • Rotated bar code bars and spaces run together. Slightly dark Slightly dark labels are not as obvious.
Troubleshooting Printer Diagnostics Table 20 • Judging Bar Code Quality (Continued) Print Quality Description “In-spec” The “in-spec” bar code can only be confirmed by a verifier, but it should exhibit some visible characteristics. • The normal bar code will have complete, even bars and clear, distinct spaces. • The rotated bar code will have complete, even bars and clear, distinct spaces. Although it may not look as good as a slightly dark bar code, the bar code will be “in-spec.
Troubleshooting Printer Diagnostics FEED + PAUSE Self Test Performing this self test temporarily resets the printer configuration to the factory default values. These values are active only until power is turned off unless you save them permanently in memory. If the factory default values are permanently saved, a sensor calibration procedure must be performed. (See Calibrate the Ribbon and Media Sensors Manually on page 106.) To perform a FEED and PAUSE self test, complete these steps: 1.
Troubleshooting Printer Diagnostics Communication Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the printer and the host computer. When the printer is in diagnostics mode, it prints all data received from the host computer as straight ASCII characters with the hex values below the ASCII text. The printer prints all characters received, including control codes such as CR (carriage return).
Troubleshooting Printer Diagnostics Sensor Profile Use the sensor profile image (which will extend across several actual labels or tags) to troubleshoot the following situations: • The printer experiences difficulty in determining gaps (web) between labels. • The printer incorrectly identifies preprinted areas on a label as gaps (web). • The printer cannot detect ribbon. With the printer in the Ready state, print a sensor profile in one of these ways: Using the buttons on the control panel a.
Troubleshooting Printer Diagnostics Figure 19 • Sensor Profile (Ribbon Section) 1 2 Media Sensor Profile (Figure 20) The media sensor readings are shown as bars and flat areas on the sensor profile (Figure 20). The bars (1) indicate gaps between labels (the web), and the low areas (2) indicate where labels are located. If you compare the sensor profile printout to a blank length of your media, the bars should be the same distance apart as the gaps on the media.
Troubleshooting Printer Diagnostics Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________
6 Specifications This section provides the features of and specifications for this printer. Contents Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zebra Programming Language (ZPL) . . .
Specifications Features Features This section lists the standard and optional features for the printer. Standard Features Note • Printer specifications are subject to change without notice. • Thermal transfer and direct thermal printing • 16 MB SDRAM (12 MB user-available) • ZebraNet 10/100 Print Server (internal) • USB 2.
Specifications Features Zebra Programming Language (ZPL) ZPL II features include: • Downloadable graphics, scalable and bitmap fonts, and label formats • Object copying between memory areas • • • • • • • (RAM, memory card, and internal Flash) Code page 850 character set Data compression Automatic virtual input buffer management Format inversion Mirror image printing Four-position field rotation (0°, 90°, 180°, 270°) • Controlled via mainframe, mini-computer, PC, portable data terminal • Programmable quan
Specifications General Specifications General Specifications Physical Specifications Dimensions Height 15.5 in (393.7 mm) Width 10.31 in. (262 mm) Depth 20.38 in. (517.5 mm) Weight without options 50 lb. (22.
Specifications Print Specifications Print Specifications Refer to the tables that follow for printer specifications. Print Specifications 203 dpi 300 dpi Printhead resolution 203 dots/inch (8 dots/mm) 300 dots/inch (12 dots/mm) Dot size (width×length) 0.0049×0.0049 in. (0.125×0.125 mm) 0.0033×0.0039 in. (0.084×0.099 mm) First dot location (measured from inside media edge) 0.10 ± 0.035 in. (2.5 ± 0.9 mm) 0.023 ± 0.035 in. (0.6 ± 0.9 mm) Maximum print width 4.09 in. (104 mm) 4.09 in.
Specifications Media Specifications Media Specifications Use the correct size and type of labels for best performance. Refer to the tables that follow for specifications. Important • Media registration and minimum label length are affected by label type and width, ribbon type, print speed, and printer mode of operation. Performance improves as these factors are optimized. Zebra recommends qualifying any application with thorough testing. 110 Media Specifications 203 dpi 300 dpi Tear-Off 0.7 in.
Specifications Ribbon Specifications Black Mark Sensing Media Specifications 203 dpi 300 dpi Mark length (measuring parallel to label/tag edge) Minimum 0.12 in. (3 mm) 0.12 in. (3 mm) Maximum 0.43 in. (11 mm) 0.43 in. (11 mm) Mark width (measuring to perpendicular label/tag edge) Minimum 0.43 in. (11 mm) 0.43 in. (11 mm) Maximum Full media width Full media width Mark location within 0.040 in. (1 mm) of the inside media edge within 0.040 in.
Specifications Ribbon Specifications Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _________________
Glossary alphanumeric Indicating letters, numerals, and characters such as punctuation marks. backfeed When the printer pulls the media and ribbon (if used) backward into the printer so that the beginning of the label to be printed is properly positioned behind the printhead. Backfeed occurs when operating the printer in Tear-Off and Applicator modes. bar code A code by which alphanumeric characters can be represented by a series of adjacent stripes of different widths.
Glossary die-cut media A type of label stock that has individual labels stuck to a media liner. The labels may be either lined up against each other or separated by a small distance. Typically the material surrounding the labels has been removed. (See non-continuous media.) direct thermal A printing method in which the printhead presses directly against the media. Heating the printhead elements causes a discoloration of the heat-sensitive coating on the media.
Glossary media Material onto which data is printed by the printer. Types of media include: tag stock, die-cut labels, continuous labels (with and without media liner), non-continuous media, fanfold media, and roll media. media sensor This sensor is located behind the printhead to detect the presence of media and, for non-continuous media, the position of the web, hole, or notch used to indicate the start of each label. media supply hanger The stationary arm that supports the media roll.
Glossary symbology The term generally used when referring to a bar code. tag A type of media having no adhesive backing but featuring a hole or notch by which the tag can be hung on something. Tags are usually made of cardboard or other durable material. tear-off A mode of operation in which the user tears the label or tag stock away from the remaining media by hand. thermal transfer A printing method in which the printhead presses an ink or resin coated ribbon against the media.
Index A active print server how to interpret, 96 user menu item, 33 adhesive test for ribbon coating, 50 adjustments label left position, 87 label top position, 87 lower media sensor, 118 maximum label length, 86 media sensors, 115 print darkness, 83 print width, 85 printhead toggle pressure, 119 tear-off position, 84 B backfeed sequence how to change, 87 user menu item, 30 backfeed speed selection, 89 backing removal, 113 bar codes bar code does not scan, 138 bar codes label, 91 darkness comparison durin
Index cleaning cutter, 134 exterior of printer, 125 media compartment, 126 printhead and platen roller, 126 recommended schedule, 125 sensors, 128 snap plate, 130 command character user menu item, 29 ways to set, 101 communication diagnostics mode how to initiate, 94 user menu item, 28 communication interfaces, 40 communications diagnostics mode overview, 155 communications problems, 145 configuration label network ways to print, 91 printer ways to print, 91 printing using CANCEL self test, 149 confor
Index E early warning maintenance how to enable or disable, 89 printhead life menu item, 23 reset new printhead counter, 24 reset printhead cleaning counter, 23 set printhead cleaning interval, 23 user menu item, 23 media and ribbon how to enable or disable, 89 user menu item, 23 electrical specifications, 162 environmental specifications, 162 error messages, 139 ESSID user menu item, 34 ways to view, 99 Ethernet characteristics of a wired connection, 41 characteristics of wireless connection, 42 exterior
Index L M label backing removal, 113 label left position how to adjust, 87 user menu item, 30 label length how to adjust maximum value, 86 user menu item, 22 label shift, 87 label specifications, 164 label top position how to adjust, 87 user menu item, 30 label width, 85 label-available sensor location, 128 when to clean, 125 labels did not print, 145 labels not printing, 145 language how to change from unfamiliar language, 147 user menu item, 36 ways to change display language, 100 last saved setti
Index network settings load defaults ways to initiate, 93 when exiting Setup mode, 19 reset network user menu item, 35 ways to reset, 99 NO MOTION how to set as head-close action, 92 how to set as power-up action, 92 non-continuous media described, 47 problem with labels, 147 selecting media type, 85 O odometers non-resettable counter description, 90 user menu item, 24 print readings how to print, 90 user menu item, 24 print user-controlled counters, 90 user-controlled counters counter 1 menu item, 24 cou
Index print server active print server how to interpret, 96 user menu item, 33 characteristics of wired connection, 41 characteristics of wireless connection, 42 default gateway user menu item, 34 ways to view or set, 98 ESSID user menu item, 34 ways to view, 99 IP address user menu item, 33 ways to view or set, 97 IP protocol how to change, 97 user menu item, 33 MAC address user menu item, 34 ways to view, 98 network configuration label sample label, 149 ways to print, 91 primary network user menu it
Index reset network settings user menu item, 35 ways to reset, 99 reset printer to default values, 93 restore factory default settings, 19 network settings, 19 printer or printer default values, 93 rewind spindle, 113 ribbon adhesive test, 50 broken or melted ribbon, 146 determining coated side, 49 removal, 112 ribbon not detected correctly, 146 scratch test, 50 setting print method to Thermal Transfer mode, 85 specifications, 165 when to use, 49 wrinkled ribbon, 146 ribbon sensor cleaning, 128 location, 1
Index tear-off position how to adjust, 84 user menu item, 21 temperature operating, 39 storing the printer, 38 Thermal Transfer mode how to specify, 85 media scratch test, 49 time setting, 32 toggle pressure adjustment, 119 transmissive (media) sensor adjustment, 115 when to clean, 125 transmissive sensor selecting through user menu, 22 ways to select, 102 troubleshooting communications problems, 145 diagnostic tests, 148 error messages, 139 print quality problems, 136 ribbon problems, 146 types of me
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