DA402 Stripe® Series Direct Thermal Printer User's Guide Rev.
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the information and use of parties operating and maintaining the equipment described herein. Such proprietary information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed written permission of Zebra Technologies Corporation.
I have determined that the Zebra printers identified as the ® Stripe Series DA402 and T402 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.
Contents Introduction Hello! . . . . . . . . . . . . . What’s in the Box . . . . . . . Unpacking and Inspection . . . Reporting Damage . . . . . DC Power Supply . . . . . . . Printer Overview (illustration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting What the Status LED is Telling You . . . Print Quality Problems . . . . . . . . . . Manual Calibration . . . . . . . . . . . . Troubleshooting Tests . . . . . . . . . . Printing a Configuration Label . . . . Recalibration . . . . . . . . . . . . . Resetting the Factory Default Values. Communications Diagnostics . . . . . Feed Button Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Hello! Thank you for choosing the Zebra DA402 Printer. This rugged little printer is certain to become a productive and efficient addition to your workplace! n n This user’s guide provides the information you will need to operate and maintain the printer. To create and print label formats, take a look at the ZPL II Programming Guide. If one was not ordered with your printer, simply call your distributor or visit our web site at www.zebra.com.
Unpacking and Inspection Inspect the printer for possible shipping damage: Check all exterior surfaces for damage. n Raise the top cover (refer to “Loading the Media” on page 5) and inspect the media compartment for damage. In case shipping is required, save the carton and all packing material. n Reporting Damage If you discover shipping damage: n Immediately notify and file a damage report with the shipping company.
WARNING: NEVER OPERATE THE PRINTER AND POWER SUPPLY IN AN AREA WHERE THEY CAN GET WET. SERIOUS PERSONAL INJURY COULD RESULT! DC Power Supply Refer to Figure 1. 1. 2. 3. The DC power supply has a barrel connector on one end that must be inserted into the power supply receptacle on the back of the printer. Insert the separate AC power cord into the power supply. Plug the other end of the cord into an appropriate AC electrical outlet.
Printer Overview Feed Button Status LED Tear Bar Printhead Release Lever Release Lever Lock-down Screw Media Guide Adjuster Media Hangers Platen Roller Media Guides Peel-Off Option Cutter Option Peel Bar Peel Roller Cutter Unit Figure 2 4
Getting Ready to Print Loading the Media You can operate this printer in three different modes: tear-off, peel-off, or with a cutter. n n n 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 this label is removed, the next one is printed. In cutter mode, the printer automatically cuts the label after it is printed. Tear-Off Mode 1.
2. 3. Separate and hold open the media hangers (refer to Figure 4). Place the media roll onto the media hangers, ensuring that it is tightly wound (refer to Figure 5). NOTE: Refer to Figure 6. If you are using labels, make sure the media unwinds from the top of the roll. Tags unwind from the bottom of the roll.
Figure 5 Tags Labels Figure 6 7
4. Refer to Figure 7. Thread the media through the media guides. NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 7). The media guides should just touch, but not restrict, the edges of the media. 5. Close the top cover and turn on the printer or press the feed button if the printer is already on (see “Auto Calibration” on page 18 for more information).
Peel-Off Mode (optional) 1. Unlatch the top cover by pulling the two green release levers toward you (refer to Figure 8). Then, lift the top cover to expose the media compartment.
2. 3. 4. 5. Separate and hold open the media hangers (refer to Figure 9). Place the media roll onto the media hangers, making sure it is tightly wound (refer to Figure 10). Open the peel-off unit by pulling down on its textured top surface (refer to Figure 11). Activate the peel-off unit by moving the peel-off switch to the left (refer to Figure 11 inset). NOTE: When not operating the printer in peel-off mode, always deactivate the peel-off unit by moving the peel-off switch to the right. 6.
Figure 10 Peel-off Switch ON OFF Figure 11 11
7. Refer to Figure 12. Thread the label backing through the media guides and over the peel bar. NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 12). The media guides should just touch, but not restrict, the edges of the media.
8. Thread the label backing between the black platen roller and white peel roller until it comes out of the slot beneath the peel-off unit (refer to Figure 13). 9. Close the peel-off unit by pushing in on its smooth side surface. 10. To remove any slack, rewind media onto the roll. 11. Close the top cover and turn on the printer or press the feed button if the printer is already on (see “Auto Calibration” on page 18 for more information).
Cutter Mode (optional) NOTE: The cutter is designed to cut through paper labels or the backing between labels, not the adhesive backing of the label. Adhesive build-up on the cutter blade may cause the cutter to jam. 1. 2. 3. Unlatch the top cover by pulling the two green release levers toward you (refer to Figure 14). Then, lift the top cover to expose the media compartment. Separate and hold open the media hangers (refer to Figure 15).
Media Hanger Media Hanger Figure 15 Figure 16 15
4. Refer to Figure 17. Thread the media through the media guides. NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 17). The media guides should just touch, but not restrict, the edges of the media. 5. 6. Refer to Figure 17. Thread the media through the cutter unit. Close the top cover and turn on the printer or press the feed button if the printer is already on (see “Auto Calibration” on page 18 for more information).
Fanfold Media Fanfold media loads from the outside of the printer. Refer to Figure 18. 1. 2. 3. Thread the media through the access slot in the back of the printer. Separate and hold open the media hangers. Lock the media hangers in position by tightening the screw located on the right media hanger. CAUTION: Do not overtighten the screw! Overtightening could pierce the case and damage the printer’s electronics! 4. Thread the media through the media guides.
Auto Calibration NOTE: If you are using pre-printed labels, pre-printed label backing, or continuous media, see “Manual Calibration” on page 28. An auto calibration is performed when the printer is turned on (if media is loaded) or after a media error is cleared. When it is auto calibrating, the printer sets the sensor levels for, and determines the length of, the label you are using. If the status LED flashes red, refer to “Manual Calibration” on page 28.
Operator Controls Refer to Figure 19. Power Switch n Press to turn on and turn off the printer. CAUTION: The power should be turned off before connecting or disconnecting the communications and power cables. Feed Button n Forces the printer to feed one blank label. n Takes the printer out of a “pause” condition. (The printer is put into “pause” by either a ZPL II command or an error condition.) See “What the Status LED is Telling You” on page 25.
Printing a Test Label Before you connect the printer to your computer, make sure that the printer is in proper working order. You can do this by printing a configuration label: 1. 2. 3. Make sure the media is properly loaded and the top cover of the printer is closed. Then, turn the printer power on if you have not already done so. When the status LED is solid green, press and hold the feed button until the status LED flashes once. Release the feed button. A configuration label will print.
Parallel Interface Requirements The required cable (IEEE 1284-compliant is recommended) must have a standard 36-pin parallel connector on one end, which is plugged into the parallel port located on the back of the printer (refer to Figure 20). The other end of the parallel interface cable connects to the printer connector at the host computer. For pinout information, refer to page 48.
Communicating with the Printer Via the Serial Port Serial communications between the printer and the host computer can be set by either autobaud synchronization or the ^SC command. Autobaud Autobaud synchronization allows the printer to automatically match the communication parameters of the host computer. To autobaud: 1. 2. 3. Press and hold the feed button until the green status LED flashes once, twice, and then three times. While the status LED flashes, send a ZPL II format to the printer.
Using ZPL II For detailed information about creating labels using ZPL II, refer to the ZPL II Programming Guide or visit our web site at www.zebra.com. Adjusting the Print Width Print width must be calibrated when: You are using the printer for the first time. There is a change in the width of the media. Print width may be set by way of the five-flash sequence in “Feed Button Modes” (see page 31) or refer to the Print Width (^PW) command (consult your ZPL II Programming Guide).
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Troubleshooting What the Status LED is Telling You Status LED Condition and Color Printer Status For a Resolution, Refer to: 1 Off Off Solid Green On 2 Flashing Yellow Stopped 3 Flashing Green Normal Operation 4 Flashing Red Stopped 5 Double Flashing Green Paused 6 Solid Yellow Various 7 Alternately Flashing Green and Red Needs Service 8 RESOLUTIONS: 1. The printer is not receiving power.
5. The media is out. n Load a roll of media, following the instructions in “Loading the Media” on page 5. Then, press the feed button to resume printing. The printhead is open. n Close the top cover. Then, press the feed button to resume printing. The cutter is jammed. n Turn off the printer and remove any jammed labels from the cutter unit. Then, turn on the printer to resume printing. 6. The printer is paused. n Press the feed button to resume printing. 7. The printhead is under temperature.
n n Adjust the print darkness and/or print speed. Refer to the six-flash sequence in “Feed Button Modes” on page 31, or the ^PR and ~SD commands in the ZPL II Programming Guide. The media being used is incompatible with the printer. Be sure to use the recommended media for your application, and always use Zebra-approved labels and tags. There are long tracks of missing print (blank vertical lines) on several labels. n n The printhead is dirty.
Manual Calibration Manual calibration is recommended whenever you are using pre-printed labels (or label backing) or if the printer will not correctly auto calibrate. 1. 2. 3. 4. 5. 6. Turn on the printer power. Remove approximately 4” (102 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. Press and hold the feed button until the green status LED flashes once, then twice. Release the feed button.
Troubleshooting Tests Printing a Configuration Label To print out a listing of the printer’s current configuration (an example is shown in Figure 22), refer to the one-flash sequence in “Feed Button Modes” on page 31. Recalibration Recalibrate the printer if it starts to display unusual symptoms, such as skipping labels. See “Auto Calibration” on page 18.
Resetting the Factory Default Values Sometimes, resetting the printer to the factory defaults solves some of the problems. Follow the four-flash sequence instructions in “Feed Button Modes” on page 31. Communications Diagnostics If there is a problem transferring data between the computer and printer, try putting the printer in the communications diagnostics mode.
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 22). After printing the label, the printer will automatically enter a diagnostic mode in which the printer prints out a literal representation (see Figure 23) of all data subsequently received. To exit the diagnostic mode and resume printing, turn off and then turn on the printer.
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Maintenance 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. If necessary, refer to Figure 2 for part locations. Area Printhead Method After allowing the printhead to cool for approximately one minute, use 70% isopropyl alcohol on a cotton swab to clean the print elements from end to end (the print elements are located in the thin gray line on the printhead).
1 2 3 4 5 6 9 7 8 Figure 24 34
Parts List Refer to Figure 24.
Replacing the Printhead Removing the Printhead 1. Turn printer power off and unplug the printer. 2. Refer to Figure 25. Remove the four screws that secure the printhead and latch assembly to the top cover. 3. Refer to Figure 26. Slide the tension bar all the way to the right in its mounting bracket (1). Then, while gently pressing on the opposite mounting bracket (2), lift and remove the tension bar (3). 4. Refer to Figure 27. Remove both printhead wire harness connectors from their receptacles. 5.
Tension Bar Tension Bar Mounting Bracket 3 Tension Bar Mounting Bracket 1 2 Figure 26 Screw and Washer Screw and Washer Connector Connector Receptacle (shown hidden) Receptacle (shown hidden) Printhead Bracket Lip Printhead Figure 27 37
Installing the Printhead 1. Ensure that the printer is turned off and unplugged. 2. Refer to Figure 28. Route the two printhead wire harness connectors as shown. Then, insert the connectors into their receptacles. 3. Insert the printhead into the printhead bracket. 4. Refer to Figure 29. Reinstall the two screws and washers that secure the printhead to the printhead bracket. NOTE: The green grounding cable, which attaches to the feed switch assembly PC board, must also be secured by one of the screws. 5.
Green Grounding Cable Screw and Washer Screw and Washer Printhead Printhead Bracket Figure 29 Tension Bar 2 1 “V” of Tension Bar Printhead Bracket Notch Figure 30 39
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Specifications NOTE: Printer specifications are subject to change without notice. Printing Specifications Print Density 203 dots/inch (8 dots/mm) Print Speed 1.5” (38 mm), 2” (51 mm), and 2.5” (64 mm) per second Print Width 1” to 4.09” (25.4 mm to 104 mm) 1” to 2.25” (25.4 mm to 57 mm) for tag stock Print Length .005” to 22” (.125 mm to 559 mm) with standard memory Registration Tolerance Horizontal: +/- 0.0591” (1.5 mm) Vertical: +/- 0.
Label/Tag Specifications Label/Tag Width 1” to 4.25” (25.4 mm to 108 mm) 1” to 2.25” (25.4 mm to 57 mm) for tag stock Label/Tag Length 0.5” to 22” (13 mm to 559 mm) with standard memory Interlabel Gap 0.08” to 0.16” (2 mm to 4 mm) 0.118” (3 mm) recommended Label/Tag Thickness .003” to .007” (.08 mm to .18 mm) .003” to .0053” (.08 mm to .135 mm) for cutter option Label Roll Size Max. Outer Diameter 5” (127 mm) Inner Core 1” (25.4 mm) or 1.
Font/Bar Code Specifications ü CG Triumvirate Bold Condensed scalable smooth (0) ü Zebra fonts A-H, GS, P-V Fonts Available ü IBM Code Page 850 International Symbols ü Codabar (supports ratios ü Industrial 2 of 5 of 2:1 to 3:1) ü Standard 2 of 5 ü Code 11 ü Code 128/USD 8 (supports serialization in all subsets and UCC Case Codes) Bar Codes Available (1D) ü Code 39 (supports ratios of 2:1 to 3:1) (supports ratios of 2:1 to 3:1, Modulus 10 Check Digit) ü LOGMARS ü MSI ü Code 93 ü Plessey ü EAN
Agency Approvals n n n n n n n n n n n n n UL 544 Medical Equipment Standard Part 42.5 CSA 22.2 No. 950-95 Canadian Safety Standard IEC 950/EN 60950 International Safety Standard FCC Class B UL 1950 Domestic Safety Standard, 3rd Ed.
Serial (RS-232) Connector Technical Information Pin No. Description 1 Not used 2 RXD (receive data) input to the printer 3 TXD (transmit data) output from the printer 4 DTR (data terminal ready) output from the printer -- controls when the host may send data 5 Chassis ground 6 DSR (data set ready) input to the printer 7 RTS (request to send) output from the printer -- always in the ACTIVE condition when the printer is turned on 8 Not used 9 +5 V @ 0.
Connecting the Printer to a DTE Device DB-25S Connector to DTE Device (PC) 2 3 4 5 6 7 8 20 22 DB-9P Connector to Printer TXD RXD RTS CTS DSR GND DCD DTR DCD RXD TXD DTR GND DSR RTS CTS DB-9S Connector to DTE Device (PC) 1 2 3 4 5 6 7 8 9 DB-9P Connector to Printer DCD RXD TXD DTR GND DSR RTS CTS DCD RXD TXD DTR GND DSR RTS CTS Figure 31 46 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Connecting the Printer to a DCE Device DB-25S Connector to DCE Device 2 3 4 5 6 7 8 20 22 DB-9P Connector to Printer RXD TXD CTS RTS DTR GND DCD DSR DCD RXD TXD DTR GND DSR RTS CTS DB-9S Connector to DCE Device 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 DB-9P Connector to Printer DCD RXD TXD DTR GND DSR RTS CTS DCD TXD RXD DSR GND DTR CTS RTS 1 2 3 4 5 6 7 8 9 Figure 32 47
Parallel Interface Technical Information Pin No. 1 Description nStrobe/Host Clk 2-9 Data Bits 1-8 10 nACK/PtrClk 11 Busy/Per Busy 12 PError/ACK Data Req. 13 Select/Xflag 14 nAuto Fd/Host Busy 15 Not Used 16 & 17 18 19-30 Ground +5 V @ 0.75 A Fused Ground 31 nInit 32 nFault/nData Avail. 33 & 34 Not Used 35 +5V through 1.8 KΩ Resistor 36 nSelectin/1284 active NOTE: The maximum current available through the serial and/or parallel port is not to exceed a total of 0.75 Amps.
Index A Adjustments Print darkness . Print speed . . Print width . . Agency approvals . Auto calibration . . Autobaud . . . . . D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23 23 44 18 22 F C Calibration Auto . . . . . . . . . . . . Manual . . . . . . . . . . Cleaning Cutter . . . . . . . . . . . Exterior . . . . . . . . . . Interior . . . . . . . . . . Peel bar . . . . . . . . . . Platen roller . . . . . . . . Printhead . . . . . . . . . Tear bar . . .
M S Maintenance parts. . . . . . . . 35 Manual calibration . . . . . . . 28 Media loading Cutter mode . . . . . . . . . 14 Fanfold . . . . . . . . . . . 17 Peel-off mode. . . . . . . . . 9 Tear-off mode . . . . . . . . 5 Serial connector pinouts . . Set communications (^SC) . Specifications Font/bar code . . . . . . Label/tag . . . . . . . . Physical/environmental/ electrical. . . . . . . . Printing . . . . . . . . . Status LED . . . . . . . . . O Operator controls . . . . . . . . 19 Options . . . . . .
