10PAX4™/R110PAX4™ Print Engine User Guide
© 2011 ZIH Corp. The copyrights in this manual and the software and/or firmware in the print engine described therein are owned by ZIH Corp. and Zebra’s licensors. Unauthorized reproduction of this manual or the software and/or firmware in the print engine 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 Incorporation DECLARATION OF INCORPORATION ZEBRA TECHNOLOGIES CORPORATION Declares that the following Information Technology Equipment Zebra PAX4 Series complies with the following applicable directives and standards for the ITE: Heavy Industry environment Applicable Directives and Supporting Standards: 89/336/EEC EMC Directive, EN55022:1998 Class A, EN61000-6-2, EN61000-3-2, EN61000-3-3 W/Amendment 12 73/23/EEC LVD Directive, EN60950-1:03, CB Scheme FCC Part 15, Subpart B, Class A, ICES
Compliance Information Compliance Information FCC Compliance Statement This device complies with Part 15 rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for Class A Digital Devices, pursuant to Part 15 of the FCC Rules.
Contents About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Ribbon Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 RFID Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Miscellaneous Print Engine Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 57512L-004 Rev.
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 operate or troubleshoot problems with the print engine. How This Document Is Organized The User Guide is set up as follows: 57512L-004 Rev. A Section Description Introduction on page 15 This chapter shows the operational controls and location of major components used when loading media and ribbon.
About This Document Contacts Contacts Technical Support via the Internet is available 24 hours per day, 365 days per year. Web Site: www.zebra.com E-mail Back Technical Library: E-mail address: emb@zebra.com Subject line: Emaillist Self Service Knowledge Base: www.zebra.com/knowledgebase Online Case Registration: www.zebra.com/techrequest Which Department Do You Need? Regional Headquarters Technical Support For questions on the operation of Zebra equipment and software, please call your distributor.
About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. LCD Display Examples Text from a print engine’s Liquid Crystal Display (LCD) appears in Bubbledot ICG font.
About This Document Document Conventions 1 1 2 3 6/29/11 2 1 3 Buttons Liquid Crystal Display (LCD) Lights/LEDs 110PAX4/R110PAX4 User Guide 57512L-004 Rev.
About This Document Document Conventions Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________
1 Introduction This chapter shows the operational controls and location of major components used when loading media and ribbon. Contents Print Engine Exterior View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction Print Engine Exterior View Print Engine Exterior View Print engines are available in a right-hand configuration (media moves from left to right, Figure 1) and a left-hand configuration (media moves from right to left, Figure 2). Figure 1 • Right-Hand (RH) Print Engine 1 2 4 3 Figure 2 • Left-Hand (LH) Print Engine 1 2 4 3 1 2 3 4 57512L-004 Rev.
Introduction Control Panel Control Panel All controls and indicators for the print engine are located on the control panel (Figure 3). The Liquid Crystal Display (LCD) shows print engine operating status and feature parameters. The buttons are used to control the print engine operations and change parameters. The lights (LEDs) indicate the print engine’s status.
Introduction Control Panel Table 1 • Control Panel Buttons (Continued) Button Description/Function CANCEL CANCEL functions only in Pause mode. Pressing CANCEL has these effects: • Cancels the label format that is currently printing. • If no label format is printing, the next one to be printed is canceled. • If no label formats are waiting to be printed, CANCEL is ignored. To clear the print engine’s entire label format memory, press and hold CANCEL until the DATA light turns off.
Introduction Control Panel Table 2 • Control Panel Lights (Continued) LED OFF Indicates ON Indicates FLASHING Indicates RIBBON (Yellow) Normal operation. Ribbon properly loaded. Ribbon in while print engine is in direct thermal mode, or no ribbon loaded while the print engine is in thermal transfer mode. The print engine is paused, LCD displays error message, and PAUSE light is ON. — ERROR (Orange) No print engine errors. — A print engine error exists. Check the LCD for status.
Introduction Power On/Off Switch Power On/Off Switch The print engine power switch is located above the control panel, as shown in Figure 4. When this switch is placed in the ON (I) position, the POWER light turns on, and the print engine automatically performs a Power-On Self Test (POST). For more information, see Power-On Self Test on page 119. Figure 4 • Power Switch Location (Right-Hand) 57512L-004 Rev.
2 Print Engine Setup This section provides the tasks that you must complete and the issues that you must consider before you load and configure your print engine. Contents Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Engine Setup Before You Begin Before You Begin Review this checklist, and resolve any issues before you set up or use your print engine. Unpack and Inspect the Print Engine Have you unpacked the print engine and inspected it for damage? If you have not, see Unpack and Inspect the Print Engine on page 23.
Print Engine Setup Handling the Print Engine Handling the Print Engine This section describes how to handle your print engine. Unpack and Inspect the Print Engine When you receive the print engine, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage. • Raise the media door, and inspect the media compartment for damage to components.
Print Engine Setup Handling the Print Engine Recycle the Print Engine This print engine is recyclable. If you must dispose of the print engine, do not do so in unsorted municipal waste. Please recycle according to your local standards. For more information, see http://www.zebra.com/environment.
Print Engine Setup Print Engine Installation Print Engine Installation This section provides basic information for mounting the print engine into an applicator. The illustrations in this section show the print engine from different angles and include dimensions and clearance needs. Requirements Stability When the print engine is mounted, the complete assembly must be physically stable. When the print engine is loaded with ribbon and media, the equipment must not become physically unstable.
Print Engine Setup Print Engine Installation Dimensions and Clearance Needs Figure 5 • Front View of Right-Hand Print Engine 5 mounting screws - 0.218 in. (5.5 mm) through - counterbore 0.350 in. x 0.197 in. (8.9 x 5 mm) deep - socket head cap screw (M5 or 10-3) 57512L-004 Rev.
Print Engine Setup Print Engine Installation Figure 6 • Right Side View of Right-Hand Print Engine 6/29/11 110PAX4/R110PAX4 User Guide 57512L-004 Rev.
Print Engine Setup Print Engine Installation Figure 7 • Rear View of Right-Hand Print Engine 57512L-004 Rev.
Print Engine Setup Print Engine Installation Figure 8 • Top View of Right-Hand Print Engine Install the Print Engine in an Applicator This section provides the basic instructions for installing the print engine into an applicator. Caution • If the print engine is installed improperly, it could fall out of the applicator and cause injury. The center mounting bolt and four mounting screws must be installed and secured. See Figure 9 for the location of the bolt and screws.
Print Engine Setup Print Engine Installation 3. Install the four corner mounting screws to secure the print engine to the applicator. Figure 9 • Front View of Print Engine in Applicator 1 2 3 4 1 1 2 3 4 57512L-004 Rev.
Print Engine Setup Select a Data Communication Interface Select a Data Communication Interface Table 4 provides basic information about data communication interfaces that you can use to connect your print engine to a computer. You may send label formats to the print engine through any data communication interface that is available. Select an interface that is supported by both your print engine and your computer or your Local Area Network (LAN).
Print Engine Setup Select a Data Communication Interface Data Cables and Wireless Cards You must supply all data cables or removeable radio cards for your application. (Some wireless print servers come with an integrated radio card.) Data Cables Ethernet cables do not require shielding, but all other data cables must be fully shielded and fitted with metal or metallized connector shells. Unshielded data cables may increase radiated emissions above the regulated limits.
Print Engine Setup Connect the Print Engine to a Power Source Connect the Print Engine to a Power Source The power supply in the print engine automatically detects the applied line voltage and works in the 90 to 264 VAC, 47 to 63 Hz range. 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 print engine. If a power cable was not included with your print engine, refer to Power Cord Specifications on page 34.
Print Engine Setup Connect the Print Engine to a Power Source 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. Depending on how your print engine was ordered, a power cord may or may not be included.
Print Engine Setup 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 print engine and to prevent premature printhead wear. To purchase supplies, go to http://www.zebra.com/howtobuy.
Print Engine Setup Types of Media Table 5 • Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description Roll media is wound on a 3-in. (76-mm) core. Individual labels are separated by one or more of the following methods: • Web media separates labels by gaps, holes, or notches. • Black mark media uses pre-printed black marks on the back side of the media to indicate label separations.
Print Engine Setup 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.
Print Engine Setup 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.
3 Operations If you have completed the tasks and resolved the issues in Print Engine Setup on page 21, follow the instructions in this chapter to load and calibrate your print engine. Contents Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Used Ribbon . . . . . . . . . . . . . . . . . . . .
Operations Load Media Load Media Important • If the print engine power is Off (O), rollers in the print engine can turn if you pull on the media. This could cause loaded ribbon to become slack and possibly wrap around the auxiliary roller. If you load or unload media with the power off, inspect the auxiliary roller to make sure that no ribbon is wrapped around it before turning On (I) the power. Figure 13 identifies the media-handling components.
Operations Load Media Figure 14 • Loaded Media Left-Hand Right-Hand 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. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution.
Operations Load Media 4. Slide the outer media guide (1) all the way out. 1 5. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Open the printhead assembly by unlatching the printhead latch (1) from the locking pin (2). 1 2 57512L-004 Rev.
Operations Load Media 6. Thread the media under the upper guide post (1), below the pinch roller assembly (2), and under the printhead assembly (3). 2 1 3 7. Extend approximately 30 in. (75 cm) of media past the peel bar (1). Remove and discard the labels (2) from this exposed media. 2 1 8. Position the media (1) so that it is aligned with and just touching the inner media guide (2). 2 1 6/29/11 110PAX4/R110PAX4 User Guide 57512L-004 Rev.
Operations Load Media 9. Position the outer media guide (1) so that it just touches the outer edge of the media (2). 1 2 10. Press down on the pinch roller assembly (1) until it locks closed. 1 11. Close the printhead assembly by rotating the printhead latch (1) until it latches onto the locking pin (2). 1 2 12. Raise the peel roller latch (1) so that the peel roller assembly (2) pivots down. 1 2 57512L-004 Rev.
Operations Load Media 13. Thread the media liner around the peel bar (1), under the media liner roller (2), and through the peel roller assembly (3). Note • If the applicator has an air tube, route the media liner between the air tube and the peel bar. Do not thread the media liner over the air tube. 3 2 1 14. Rotate the peel roller assembly (1) up until it locks into the closed position. 1 15.
Operations Load Ribbon Load Ribbon Use ribbon with thermal transfer media. The ribbon must be coated on the outside and wider than the media. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear. Figure 15 identifies the ribbon system components inside the media compartment of a right-hand print engine. A left-hand unit contains a mirror image of these components. Figure 16 on page 47 shows the print engine with ribbon loaded.
Operations Load Ribbon Figure 16 • Loaded Ribbon Left-Hand Right-Hand 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. You are not required to turn off the printer power when working near an open printhead, but Zebra recommends it as a precaution.
Operations Load Ribbon 2. On the lower dancer assembly, squeeze the opening tabs (1) to pivot open the dancer arm (2). 1 2 3. Carefully thread the ribbon (1) through the lower dancer assembly, and then slowly release the dancer arm (2). 1 2 4. Thread the ribbon between the ribbon sensor (1) and the ribbon sensor reflector (2). 2 57512L-004 Rev.
Operations Load Ribbon 5. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Open the printhead assembly by unlatching the printhead latch (1) from the locking pin (2). 1 2 6. Thread the ribbon under the printhead assembly (1) and then up toward the auxiliary roller (2). 2 1 7. Thread the ribbon over the auxiliary roller (1), around the idler roller (2), and then up toward the upper dancer assembly.
Operations Load Ribbon 8. On the upper dancer assembly, squeeze the opening tabs (1) to pivot open the dancer arm (2). 1 2 9. Carefully thread the ribbon (1) through the upper dancer assembly, and then slowly release the dancer arm (2). 1 2 10. Place an empty ribbon core (1) onto the ribbon take-up spindle (2). Push the core toward the print engine frame until it is fully seated. Left-Hand 1 57512L-004 Rev.
Operations Load Ribbon 11. Attach the end of the ribbon to the empty ribbon core with adhesive tape or a label, and wind for several turns in the direction shown. Ensure that the ribbon winds evenly on the spindle. Left-Hand Right-Hand 12. Close the printhead assembly by rotating the printhead latch (1) until it latches onto the locking pin (2). 1 2 13. Close the media door. 6/29/11 110PAX4/R110PAX4 User Guide 57512L-004 Rev.
Operations Remove Used Ribbon Remove Used Ribbon To remove used ribbon, complete these steps: 1. Open the media door. 2. Examine the ribbon. Did the ribbon run out? 57512L-004 Rev. A If... Then... Yes a. No a. Cut the ribbon near the ribbon take-up spindle. b. Remove the used ribbon and core from the ribbon take-up spindle. c. Locate an empty ribbon core. If necessary, remove and discard the used ribbon from the core removed in the previous step. d.
Operations Calibrate the Print Engine Calibrate the Print Engine Calibrate the print engine when it is first put into service. Calibration allows the print engine to establish the proper settings for the specific media and ribbon used in your application. You may calibrate the print engine at other times as needed. Table 6 shows the different methods for calibration.
Operations Calibrate the Print Engine Table 6 • Types of Calibration (Continued) Type of Calibration Description When/How It Occurs Sensor Profile Calibration The print engine auto-calibrates and prints a media sensor profile. See Sensor Profile on page 130. Select the SENSOR PROFILE option on the control panel. See Print Sensor Profile on page 76 for instructions.
Operations Adjust Ribbon and Media Sensors Adjust Ribbon and Media Sensors This section describes how to adjust the sensors. Ribbon Sensor The ribbon sensor (Figure 17) is mounted in a fixed position, and no adjustment is required. Figure 17 • Ribbon Sensor Location 1 1 2 2 Ribbon sensor reflector Ribbon sensor Reflective Media Sensor Some types of media have black marks printed on the underside of the media liner, which act as “start of label” indicators.
Operations Adjust Ribbon and Media Sensors 2. How does the current media indicate the start of labels? If the media... Then... Has notches or holes between labels Align the sensor with the notch or hole in the media. Uses interlabel gaps Position the sensor approximately at the center of the media width. Figure 18 • Media Sensor Adjustment (Right-Hand Unit Shown) 1 2 1 2 57512L-004 Rev.
4 Configuration This section describes the control panel parameters that are used to configure the print engine for operation. Contents Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter and Use Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Setup Mode Setup Mode After you have installed the media and ribbon and the Power-On Self Test (POST) is complete, the control panel displays PRINTER READY. You may now set print engine parameters for your application using the control panel display and the buttons directly below it. If it becomes necessary to restore the initial print engine defaults, see FEED and PAUSE Self Test on page 126.
Configuration Setup Mode Exit Setup Mode When you exit setup mode, you have several options for saving, changing, or not changing parameters. To leave Setup mode, complete these steps: 1. While in Setup mode, press SETUP/EXIT. The LCD displays SAVE CHANGES. 2. Press the left or right oval to display the save options: LCD Description PERMANENT Stores values in the print engine even when power is turned off. TEMPORARY Saves the changes until power is turned off.
Configuration Change Password-Protected Parameters Change 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 print engine may function unpredictably.
Configuration Print a Configuration Label Print a Configuration Label A configuration label lists the print engine settings that are stored in configuration memory. After you load the media and ribbon (if necessary), print a configuration label as a record of your print engine’s current settings. Keep the label to use when troubleshooting printing problems. To print a configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2.
Configuration Print a Network Configuration Label Print a Network Configuration Label If you are using a print server, you can print a network configuration label after the print engine is connected to the network. To print a network configuration label, complete these steps: 1. On the control panel, press SETUP/EXIT. 2. Press NEXT or PREVIOUS to scroll through the parameters until you reach LIST NETWORK. 3. Press the right oval to confirm printing. A network configuration label prints (Figure 20).
Configuration Control Panel Parameters Control Panel Parameters Use the LCD on the control panel to view and adjust print engine settings. How to View or Modify Parameters While viewing parameters, press NEXT to continue to the next parameter, or press PREVIOUS to return to the previous parameter in the cycle. When a parameter is changed, an asterisk (*) appears in the upper left corner of the display to indicate that the value is different from the one currently active in the print engine.
Configuration Control Panel Parameters Standard Print Engine Parameters Table 7 shows parameters in the order in which they are displayed when you press NEXT after entering Setup mode. Table 7 • Print Engine Parameters (Page 1 of 25) Parameter DARKNESS - Action/Explanation +04.0 + Adjust Print Darkness Darkness (burn duration) settings depend on a variety of factors, including ribbon type, media type, and the condition of the printhead.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 2 of 25) Parameter Action/Explanation BACKFEED SPEED 2 IPS + Adjust Backfeed Speed If backfeed is on, adjusts the speed at which the label backs up before printing (given in inches per second). Default: 2 IPS Range: 1 to 12 IPS To change the value shown: 1. Press the right oval to increase the value. 2. Press the left oval to decrease the value.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 3 of 25) Parameter PRINT MODE -APPLICATOR Action/Explanation + Select Print Mode Print mode settings tell the print engine the method of media delivery that you wish to use. Make sure that your print engine can support the selected option. Default: APPLICATOR Selections: TEAR-OFF, REWIND, APPLICATOR To change the value shown: 1. Press the left or right oval to scroll through the options.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 4 of 25) Parameter PRINT WIDTH - 168 0/8 MM Action/Explanation + Set Print Width Determines the printable area across the width of the label given the resolution of the print engine. Default: 168 0/8 MM for 203 dpi print engines; 168 0/12 MM for 300 dpi print engines Note • Setting the width too narrow can result in portions of the label not being printed on the media.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 5 of 25) Parameter MAXIMUM LENGTH 39.0IN 988MM Action/Explanation Set Maximum Label Length This parameter is used during the media portion of the calibration process. Always set maximum label length to a value that is at least 1.0 in. (25.4 mm) greater than the actual label length (Figure 22).
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 6 of 25) Parameter Action/Explanation Set Early Warning for Media When this parameter is enabled, the print engine provides warnings when labels are running low. Note • Update the number of labels per roll when beginning use of the Early Warning System. The print engine does not make any adjustments when power is turned off and on.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 7 of 25) Parameter Action/Explanation MEDIA REPLACED? NO YES Reset Media Counter for Early Warning This parameter appears only when Early Warning for Media is enabled. To reset the media counter: 1. Did you replace the media? a. If you replaced the media, press the right oval to select YES. b. If you did not replace the media, press the left oval to select NO.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 8 of 25) Parameter Action/Explanation Set Early Warning for Maintenance When this parameter is enabled, the print engine provides warnings when the printhead needs to be cleaned. Note • If necessary, update the number of labels per roll when beginning use of the Early Warning System for Maintenance. The print engine does not make any adjustments when power is turned off and on. Default: MAINT. OFF Selections: MAINT.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 9 of 25) Parameter HEAD LIFE 1000000 IN Action/Explanation + Set Printhead Life for Early Warning This parameter appears only when Early Warning for Maintenance is enabled. Set this value to the number of inches of media that the printhead is expected to print. Default: 1,000,000 inches Range: 100 to 1,000,000 inches To change the value shown: 1. Press the left oval to move the cursor. 2.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 10 of 25) Parameter LIST IMAGES PRINT Action/Explanation List Images This option prints a label that lists the available images stored in the print engine’s RAM, Flash memory, optional memory card, PCMCIA cards, or Compact Flash cards. To print a list of the available images: 1. Press the right oval to select PRINT.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 11 of 25) Parameter FORMAT CARD: A: Action/Explanation B: Format Memory Card This option erases all previously stored information from the optional PCMCIA card or Compact Flash card. Caution • This option completely erases the selected card. To format a memory card: 1. Press the left oval to select A: or the right oval to select B:.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 12 of 25) Parameter INIT FLASH MEM. YES Action/Explanation Initialize Flash Memory This option erases all previously stored information from Flash memory. Caution • This option completely erases the Flash memory. To initialize Flash memory: 1. Press the right oval to select YES. 2. Enter the password. For instructions, see Change Password-Protected Parameters on page 60. The display shows INITIALIZE FLASH? 3.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 13 of 25) Parameter SENSOR PROFILE PRINT Action/Explanation Print Sensor Profile A sensor profile shows sensor settings compared to actual sensor readings. This label (which will extend across several actual labels or tags) can be used to troubleshoot printing problems. To interpret the results of the sensor profile, see Sensor Profile on page 130. Figure 23 • Sensor Profile To print a sensor profile: 1.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 14 of 25) Parameter MEDIA AND RIBBON CALIBRATE Action/Explanation Calibrate Media and Ribbon Sensor Sensitivity Use this procedure to adjust sensitivity of media and ribbon sensors. Important • Follow this procedure exactly as presented. All of the steps must be performed even if only one of the sensors requires adjustment. You may press the left oval at any step in this procedure to cancel the process.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 15 of 25) Parameter PARALLEL COMM. -BIDIRECTIONAL Action/Explanation + Set Parallel Communications Select the communications port that matches the one being used by the host computer. Default: BIDIRECTIONAL Selections: BIDIRECTIONAL, UNIDIRECTIONAL To change the value shown: 1. Press the left or right oval to scroll through the options.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 16 of 25) Parameter PARITY NONE Action/Explanation + Set Parity This setting applies only when the serial port is used. The parity of the print engine must match the parity of the host computer for accurate communications to take place. Select the parity that matches the one being used by the host computer. Default: NONE Selections: EVEN, ODD, NONE To change the value shown: 1.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 17 of 25) Parameter COMMUNICATIONS - NORMAL MODE Action/Explanation + Set Communications Mode The communication diagnostics mode is a troubleshooting tool for checking the interconnection between the print engine and the host computer. For more information, see Communications Diagnostics Test on page 129. Default: NORMAL MODE Selections: NORMAL MODE, DIAGNOSTICS To select communication diagnostics mode: 1.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 18 of 25) Parameter DELIMITER CHAR <,>2CH Action/Explanation + Set Delimiter Character The delimiter character is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. See the ZPL II Programming Guide for more information. Note • Do not use the same hex value for the control, format, and delimiter character. The print engine must see different characters to work properly.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 19 of 25) Parameter Action/Explanation Select Head Close Option This parameter sets the action of the media when you close the printhead. Default: CALIBRATION Selections: FEED, CALIBRATION, LENGTH, SHORT CAL, and NO MOTION • Feed—feeds the labels to the first registration point. • Calibration—determines the length of the label and adjusts the sensor settings. • Length—In continuous mode, feeds the last stored label length.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 20 of 25) Parameter LEFT POSITION ±0000 Action/Explanation + Adjust Left Position This parameter establishes how far from the left edge of a label the format begins to print by adjusting horizontal positioning on the label. Positive numbers adjust the printing away from the main frame by the number of dots selected; negative numbers shift printing toward the main frame. The displayed value represents dots.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 21 of 25) Parameter APPLICATOR PORT OFF Action/Explanation + Set Applicator Port Mode Determines the action of the applicator port. Note • Set this value as suggested by the applicator manufacturer. Default: OFF Selections: OFF, MODE 1, MODE 2, MODE 3, MODE 4 • OFF: The applicator port is off. • MODE 1: Asserts the ~END_PRINT signal low while the print engine is moving the label forward.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 22 of 25) Parameter START PRINT SIG - PULSE MODE Action/Explanation + Select Start Print Signal This parameter determines how the print engine reacts to the Start Print Signal input on pin 3 of the applicator interface connector at the rear of the print engine. Caution • Start Print Signal is set by the applicator manufacturer and should not be changed unless the factory defaults have been reloaded. Please make a note of it.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 23 of 25) Parameter RIBBON LOW MODE 25M Action/Explanation + Set Ribbon Low Mode When the Ribbon Low feature is off, the output signal (Pin 9) does not function, the LOW RIBBON warning is not displayed, and the print engine continues to print until it runs out of ribbon. When the Ribbon Low feature is set to any of the lengths, output signal (Pin 9) on the applicator port is functional.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 24 of 25) Parameter Action/Explanation WEB S. - 073 MEDIA S. - 075 RIBBON S. - 071 MARK S. - + To skip these parameters: + 000 + + MEDIA LED - 082 + RIBBON LED - 008 MARK LED - 005 +10 1. Press NEXT/SAVE repeatedly. + MARK MED S. 000 - LCD ADJUST - These parameters are automatically set during the calibration procedure and should be changed only by a qualified service technician.
Configuration Control Panel Parameters Table 7 • Print Engine Parameters (Page 25 of 25) Parameter Action/Explanation Set RTS Supply Dancer Arm Calibration Value This parameter is used as a diagnostic tool to monitor the voltage supplied to the Ribbon Tensioning System Supply Dancer Arm. Refer to the Maintenance Manual for information. RTS SUPPLY ARM XXX IDLE DISPLAY - FW VERSION + Select Idle Display This parameter selects the LCD options for the real-time clock.
5 Routine Maintenance This chapter provides routine cleaning and maintenance procedures. Contents Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance Lubrication Lubrication Caution • This print engine does not require lubrication. Applying lubricants may damage your print engine’s finish and decrease the performance of its electromechanical parts. Cleaning Schedule Cleaning your print engine regularly maintains print quality and may extend the life of the print engine. The recommended cleaning schedule is shown in Table 8. See the following pages for specific procedures. Caution • Use only the cleaning agents indicated.
Routine Maintenance Clean the Media Compartment Clean the Media Compartment Remove any accumulated dirt and lint from the interior of the print engine using a soft bristle brush and/or vacuum cleaner. This area should be inspected every time a new ribbon is loaded. Clean the Sensors To ensure proper operation of the print engine, all sensors should be cleaned on a regular basis. The sensors are shown in the following: • See Figure 24 for the media sensors.
Routine Maintenance Clean the Sensors Figure 25 • Door-Open Sensor Location (Right-Hand Unit Shown) 1 1 Door-open sensor Figure 26 • Ribbon Sensor Location (Right-Hand Unit Shown) 1 1 2 57512L-004 Rev.
Routine Maintenance Clean the Printhead and Platen Roller Clean the Printhead and Platen Roller Clean the printhead and platen roller according to the schedule in Table 8 on page 90. Clean the printhead more often if you see inconsistent print quality, such as voids or light print. Clean the platen roller if you see media movement problems.
Routine Maintenance Clean the Printhead and Platen Roller 4. Using Preventative Maintenance kit (part number 47362) or a solution of 90% isopropyl alcohol and 10% deionized water on a cotton swab, wipe the print elements from end to end. Allow the solvent to evaporate. 1 2 3 1 2 3 Printhead elements (gray strip) Cotton swab Platen Roller 5. Use a lint-free cloth moistened with alcohol to clean the platen roller and other rollers. Rotate the rollers while cleaning. 6.
Routine Maintenance Toggle Positioning Toggle Positioning Proper toggle positioning is important for proper print quality. The toggle should be positioned approximately midway across the width of the media. Caution • Observe proper electrostatic safety precautions when handling any static-sensitive components such as circuit boards and printheads. To adjust the toggle, complete these steps: 1. Print some labels at 2.4 in.
Routine Maintenance Toggle Positioning 5. Tighten the locking nut. 6. Print additional labels at 2.4 in.(61 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? 57512L-004 Rev. A 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 Printhead Pressure Adjustment Printhead Pressure Adjustment Before adjusting the printhead pressure, check that the toggles are positioned correctly. See Toggle Positioning on page 95. Printhead life and drive system life (belts and bearings) can be maximized by using the lowest pressure that produces the desired print quality without allowing the ribbon or media to slip.
Routine Maintenance Printhead Pressure Adjustment 4. Loosen the locking nut on the toggle assembly. 5. 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. 6. To lock the toggle pressure, tighten the locking nut against the adjusting nut. 57512L-004 Rev.
Routine Maintenance Power Fuse Replacement Power Fuse Replacement The print engine uses a metric-style fuse (5 × 20 mm IEC) rated for 5 Amps at 250 Volts that bears the certification mark of a known international safety organization (see Figure 11 on page 34). The power entry module comes with two approved fuses in the fuse holder: one is in-circuit, and the other is a spare. Caution • Turn Off (O) the print engine and disconnect it from the power source before performing the following maintenance.
Routine Maintenance Power Fuse Replacement Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___________
6 Troubleshooting This section provides information about errors that you might need to troubleshoot. Assorted diagnostic tests are included. Contents Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Checklists Troubleshooting Checklists If an error condition exists with the print engine, review this checklist: Is there an error message on the LCD? If yes, see LCD Error Messages on page 103. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 77. Is the CHECK RIBBON light on when ribbon is loaded properly? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 77.
LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 9 for LCD errors, the possible causes, and the recommended solutions. Table 9 • LCD Error Messages LCD Display/ Print Engine Condition ERROR CONDITION RIBBON OUT The print engine 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.
LCD Error Messages Table 9 • LCD Error Messages (Continued) LCD Display/ Print Engine Condition WARNING RIBBON IN Possible Cause Recommended Solution Ribbon is loaded, but the print engine is set for direct thermal mode. Ribbon is not required with direct thermal media. If you are using direct thermal media, remove the ribbon. This error message will not affect printing. The RIBBON light is on; the ERROR light flashes.
LCD Error Messages Table 9 • LCD Error Messages (Continued) LCD Display/ Print Engine Condition WARNING HEAD COLD The print engine prints while the ERROR light flashes. Possible Cause Recommended Solution 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 printhead temperature is approaching its lower operating limit.
LCD Error Messages Table 9 • LCD Error Messages (Continued) LCD Display/ Print Engine Condition DEFRAGMENTING Possible Cause The print engine is defragmenting memory. The print engine stops. OUT OF MEMORY (function) Recommended Solution Caution • Do NOT turn off the print engine power during defragmenting. Doing so can damage the print engine. Allow the print engine to finish defragmenting. If you get this error message frequently, check your label formats.
Memory Errors Memory Errors The memory errors in Table 10 indicate that the print engine does not have enough memory to perform the function shown on the second line of the LCD. Table 10 • Memory Errors Problem/LCD Display Possible Cause Recommended Solution OUT OF MEMORY CREATING BITMAP Creating Bitmap The bitmap size (label length/width) does not fit in available memory. OUT OF MEMORY STORING BITMAP Storing Bitmap Not enough memory is available to store the bitmap created.
Print Quality Problems Print Quality Problems Table 11 identifies problems with print quality, the possible causes, and the recommended solutions. Table 11 • Print Quality Problems Problem Possible Cause Recommended Solution General print quality issues The print engine is set at the 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. See Adjust Print Speed on page 64.
Print Quality Problems Table 11 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Wrinkled ribbon Ribbon was fed through the ribbon system incorrectly. Load the ribbon correctly. See Load Ribbon on page 46. Incorrect burn temperature. Set the darkness to the lowest possible setting for good print quality. See Adjust Print Darkness on page 64. Incorrect or uneven printhead pressure. Set the printhead pressure to the minimum needed for good print quality.
Print Quality Problems Table 11 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Printing too light or too dark over the entire label The media or ribbon is not designed for high-speed operation. Replace supplies with those recommended for high-speed operation. You are using an incorrect combination of media and ribbon for your application. 1. You are using ribbon with direct thermal media. Direct thermal media does not require ribbon.
Print Quality Problems Table 11 • Print Quality Problems (Continued) Problem Possible Cause Vertical image or label drift The print engine is using Configure the print engine for non-continuous non-continuous labels but is and run calibration routine, if necessary. configured in continuous mode. The bar code printed on a label does not scan. 6/29/11 Recommended Solution The media sensor is calibrated improperly. See Calibrate Media and Ribbon Sensor Sensitivity on page 77.
Communications Problems Communications Problems Table 12 identifies problems with communications, the possible causes, and the recommended solutions. Table 12 • Communications Problems Problem Possible Cause Recommended Solution A label format was sent to the print engine but was not recognized. The DATA light does not flash. The communication parameters are incorrect. Check the print engine driver or software communications settings (if applicable).
Ribbon Problems Ribbon Problems Table 13 identifies problems that may occur with ribbon, the possible causes, and the recommended solutions. Table 13 • 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 print engine. Replace the ribbon with one coated on the correct side. For more information, see Coated Side of Ribbon on page 37.
Troubleshooting RFID Problems RFID Problems Table 14 identifies problems that may occur with RFID print engines, the possible causes, and the recommended solutions. For more information about RFID, refer to the RFID Programming Guide. A copy of the manual is available at http://www.zebra.com/manuals or on the user CD that came with your print engine. Table 14 • RFID Problems Problem Possible Cause Recommended Solution The RFID-enabled print engine voids every label.
Troubleshooting RFID Problems Table 14 • RFID Problems (Continued) Problem Possible Cause The RFID-enabled print engine voids every label. (Continued from previous page.) Low yields. Too many RFID tags per roll are voided. 6/29/11 Recommended Solution You are using an incorrect programming position, particularly if the tags being used are within print engine specifications.
Troubleshooting RFID Problems Table 14 • RFID Problems (Continued) Problem Possible Cause Recommended Solution The print engine stops at the RFID inlay. The print engine calibrated the label length only to the RFID inlay instead of to the interlabel gap. 1. Select FEED for the MEDIA POWER UP and HEAD CLOSE parameters (see Select Media Power-Up Option on page 81 or Select Head Close Option on page 82) 2. Calibrate the print engine. See Calibrate Media and Ribbon Sensor Sensitivity on page 77.
Miscellaneous Print Engine Problems Miscellaneous Print Engine Problems Table 15 identifies miscellaneous problems with the print engine, the possible causes, and the recommended solutions. Table 15 • Miscellaneous Print Engine Problems Problem Possible Cause Recommended Solution The LCD displays a language that I cannot read The language parameter was changed through the control panel or a ZPL command. 1. Press SETUP/EXIT to enter configuration mode. 2. Press the left oval.
Miscellaneous Print Engine Problems Table 15 • Miscellaneous Print Engine Problems (Continued) Problem Possible Cause Recommended Solution The print engine fails to calibrate or detect the top of the label. The print engine was not calibrated for the label being used. Perform the calibration procedure in Calibrate Media and Ribbon Sensor Sensitivity on page 77. The print engine is configured for continuous media. Set the media type to noncontinuous media. See Set Media Type on page 66.
Print Engine Diagnostics Print Engine Diagnostics Self tests and other diagnostics provide specific information about the condition of the print engine. The self tests produce sample printouts and provide specific information that helps determine the operating conditions for the print engine. The most commonly used are the Power-On and the CANCEL self tests. 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.
Print Engine Diagnostics CANCEL Self Test The CANCEL self test prints a configuration label (Figure 27). To perform the CANCEL Self Test, complete these steps: 1. Turn off (O) the print engine. 2. Press and hold CANCEL while turning on (I) the print engine. Hold CANCEL until the first control panel light turns off. A print engine configuration label prints (Figure 27).
Print Engine Diagnostics PAUSE Self Test This self test can be used to provide the test labels required when making adjustments to the print engine’s mechanical assemblies or to determine if any printhead elements are not working. Figure 28 shows a sample printout. To perform a PAUSE self test, complete these steps: 1. Turn off (O) the print engine. 2. Press and hold PAUSE while turning on (I) the print engine. Hold PAUSE until the first control panel light turns off.
Print Engine 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.
Print Engine Diagnostics Figure 29 • FEED Test Label 4. See Figure 30 and Table 16. Inspect the test labels and determine which one has the best print quality for your application. If you have a bar code verifier, use it to measure bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your eyes or the system scanner to choose the optimal darkness setting based on the labels printed in this self test.
Print Engine Diagnostics Figure 30 • Bar Code Darkness Comparison Table 16 • Judging Bar Code Quality 57512L-004 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. • The normal bar code will be “in-spec.
Print Engine Diagnostics Table 16 • 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.
Print Engine Diagnostics FEED and PAUSE Self Test Performing this self test temporarily resets the print engine 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 media calibration procedure must be performed, and you must reset the head resistance value and the applicator port setting to their required values.
Print Engine Diagnostics Table 17 • Control of Parameters (Continued) 6/29/11 Parameter Controlled By ZPL Mode Configuration, ZPL, and WebView Media Power Up Configuration, ZPL, and WebView Head Close Configuration, ZPL, and WebView Backfeed Configuration, ZPL, and WebView Label Top Configuration, ZPL, and WebView Left Position Configuration, ZPL, and WebView Head Resistance Configuration (must match head resistance label value), ZPL, and WebView Verifier Port Configuration, ZPL, and
Print Engine Diagnostics Table 17 • Control of Parameters (Continued) 57512L-004 Parameter Controlled By J8 Interface Fixed J7 Interface Fixed Twinax/Coax ID ZPL 110PAX4/R110PAX4 User Guide 6/29/11
Print Engine Diagnostics Communications Diagnostics Test The communication diagnostics test is a troubleshooting tool for checking the interconnection between the print engine 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 print engine prints all characters received, including control codes such as CR (carriage return).
Print Engine Diagnostics Sensor Profile Use the sensor profile label to troubleshoot the following types of problems: • If the media sensor experiences difficulty in determining gaps (web) between labels. • If the media sensor incorrectly identifies preprinted areas on a label as gaps (web). • If the ribbon sensor cannot detect ribbon. For instructions on printing a sensor profile, see Print Sensor Profile on page 76.
7 Data Ports This section describes the standard communication ports available to connect the print engine to your computer or network. Contents Parallel Data Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Port Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Data Port Parallel Data Port The parallel data interface supports IEEE 1284 bidirectional parallel communications in nibble mode. The parallel interface provides a means of communication that typically is faster than the serial interface methods. In this method, the bits of data that make up a character are sent all at one time over several wires in the cable, one bit per wire.
Parallel Data Port Table 18 • Parallel Cable Pin Configuration (Continued) 36-Pin Connectors 19–30 Ground 31 nInit 32 nFault/NDataAvail 33, 34 6/29/11 Description Not used 35 +5 V through a 1.8 K Resistor 36 NSelectin/1284 active 110PAX4/R110PAX4 User Guide 57512L-004 Rev.
Data Ports Serial Data Port Serial Data Port To communicate using the serial data port of the print engine, you must choose the number of data bits, parity, and handshaking. Parity applies only to data transmitted by the print engine because the parity of received data is ignored. The values selected must be the same as those used by the host equipment connected to the print engine. Default print engine settings are 9600 baud, 8 data bits, no parity, and XON/XOFF.
Data Ports Serial Data Port Pin Configuration Connect the serial data cable to the female DB-9 connector on the back of the print engine. For all RS-232 connections through a DB-25 cable, use a DB-9 to DB-25 interface module (see DB-9 to DB-25 Connections on page 137). Table 19 shows the pin configuration of the serial data connector. Table 19 • Serial Connector Pin Configuration 6/29/11 Pin No.
Data Ports Serial Data Port RS-232 Interface Connections The print engine is configured as Data Terminal Equipment (DTE). Figure 34 shows the internal connections of the print engine’s RS-232 connector. Note • Use a null modem (crossover) cable to connect the print engine to a computer or any other DTE device.
Data Ports Serial Data Port DB-9 to DB-25 Connections To connect the print engine’s RS-232 DB-9 interface to a DB-25 connector, an interface adapter is required. A generic DB-25 adapter can be used, although the +5 VDC signal source would not be passed through the adapter. Figure 35 shows the connections required for the DB-9 to DB-25 interface.
Data Ports Applicator Interface Connector Applicator Interface Connector An external DB-15 connector is present on the rear panel of the print engine for communication with a customer applicator. An optional DB-15 to DB-9 adapter cable (Zebra part number 49609) is available to accommodate existing DB-9 interfaces. Applicator Signals The print engine communicates with a customer applicator through a series of signals on the pins in the DB-15 connector.
Data Ports Applicator Interface Connector Figure 39 • Applicator Signals (Mode 3) label format sent label format processed waiting for start print signal label prints ready for next label not ready DATA READY (pin 14) ready do not start START PRINT (pin 3) start do not end END PRINT (pin 11) end Figure 40 • Applicator Signals (Mode 4) label format sent label format processed waiting for start print signal label prints ready for next label not ready DATA READY (pin 14) ready do not start START
Data Ports Applicator Interface Connector Applicator Interface Connector Pin Configuration The Applicator Interface Assembly is available in two versions: a +5 V I/O and a +24–28 V I/O. Table 20 lists the pin configurations and functions of the applicator interface connector for both +5 V and +24–28 V operation. Table 20 • Applicator Interface Connector Pin Configuration Pin No.
Data Ports Applicator Interface Connector Table 20 • Applicator Interface Connector Pin Configuration (Continued) Pin No. Signal Name Signal Type Description 5 PAUSE Input To toggle the current Pause state, this input must be asserted LOW for 200 milliseconds, or until the SERVICE REQUIRED output (pin 10) changes state. 6 REPRINT Input • If the Reprint feature is enabled, this input must be asserted LOW to cause the print engine to reprint the last label.
Data Ports Applicator Interface Connector Table 20 • Applicator Interface Connector Pin Configuration (Continued) Pin No. Signal Name Signal Type Description 11 END PRINT Output See Applicator Signals on page 138 for more information about the start and end print signals. See Set Applicator Port Mode on page 84 for more information about the modes. Note • A format (^XA ... ^XZ) that does not print will signal that it is being processed.
Data Ports Applicator Interface Connector Jumper Configurations and Pinouts for +5 V I/O Operation Jumpers J4 and J5 are used together to produce isolated or non-isolated modes of operation for applicator input and output control signals. J4 configures the +5 V source for the optoisolator circuits, and J5 configures the ground. For proper operation, when J4 is installed, J5 must be installed, and when J4 is removed, J5 must be removed.
Data Ports Applicator Interface Connector Pinouts for +24-28 V I/O Operation Table 22 describes the pin configurations for +24–28 V I/O operation. There are no jumpers to configure for this mode. Table 22 • Non-Isolated and Isolated Modes for +24–28V Operation Non-Isolated (Internal Print Engine Power) Isolated (External Power) Pin 1 External Ground +24-28V I/O ground must be connected to an external ground.
Data Ports Applicator Interface Connector Fuse and Jumper Locations Figure 41 shows the location of the fuses on the applicator interface board and the location of jumpers J4 and J5. Figure 41 • Applicator Interface Board 1 2 3 1 2 3 4 6/29/11 4 Fuse F2 for +28 V at pin 7 Fuse F3 for +5 V at pin 2 (+5 V I/O only) Jumper J4 Jumper J5 110PAX4/R110PAX4 User Guide 57512L-004 Rev.
Data Ports Applicator Interface Connector Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ____________
8 Specifications This chapter provides routine cleaning and maintenance procedures. Contents General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . .
Specifications General Specifications General Specifications Physical Height 11.8 in. (300 mm) Width 9.6 in. (245 mm) Depth 16.4 in. (417 mm) Weight 36 lb (16.
Specifications General Specifications Communications Specifications 6/29/11 Parallel • High-speed bi-directional parallel interface, IEEE 1284:Compatibility mode, EPC, Nibble mode. Serial • Serial RS-232C with DTR hardware handshake via DB-9 connector (standard) • Serial RS-422/485 via 2- or 4-wire with XON/XOFF handshake on alternate pins of DB-9 connector (standard) • Configurable baud rates from 110 to 57.
Specifications General Specifications Other Standard Features • Real Time Clock • Fast 32 bit 133 MHz RISC processor • 10MB RAM memory • Flash memory including 2MB non-volatile memory storage for downloadable objects • Type I & II Series C & D PC Card Interface, memory only • Zebra printer driver for windows 3.X and 95/98/NT 2000 operating systems • Advanced counter Additional Options • Radio Frequency Identification (RFID) capability.
Specifications Agency Approvals Agency Approvals The agency approvals and product markings provided in this section apply only to the print engines specified. 110PAX4 Non-RFID or RFID-Ready without RFID Reader Installed The following apply only to print engines that do not have RFID readers installed. Agency Approvals • IEC 60950-1 • UL60950-1 • CAN/CSA-C22.2 No.
Specifications Agency Approvals European Union and EFTA (869.7–870 MHz) Agency Approvals • EN 55022 • EN 61000-6-2 • EN 300 220-3 • EN 301 489-3 • EN 60950 • IEC 60950-1 Product Markings • CE Mark This device is intended for commercial and industrial use in all EU and EFTA member states. 57512L-004 Rev.
Specifications Media Specifications Media Specifications Media width (label and liner) Minimum Non-RFID 0.63 in. (16 mm) RFID “smart” labels Minimum label widths for RFID “smart” labels varies for each transponder type. Maximum Label length Minimum Registration tolerance (not including label/liner position tolerances) 4.5 in. (114 mm) Non-RFID, applicator mode* 0.5 in. (12.7 mm) with backfeed on 0.25 in. (6.4 mm) with backfeed off Non-RFID, tear-off mode 0.5 in. (12.7 mm) with backfeed on 0.
Specifications Ribbon Specifications Media Unwind Force Steady State Must be uniform and must not exceed 2 lb. (907 g) Transient (Start/Stop) Must not exceed 4 lb (1814 g) Applicator take-up pull tension must be uniform from 1 to 4 lb (454 to 1818 g) and must not vary more than ±20% during operation. Media Rewind Force * PAX4 printers are not recommended for use with fanfold media in applicator mode. Ribbon Specifications 57512L-004 Rev. A Thickness 4.
Specifications Printing Specifications Printing Specifications Specification 203 DPI 300 DPI Resolution 203 dots per inch (8 dots per mm) 300 dots per inch (12 dots per mm) Dot size 0.0049 in. x 0.0049 in. (0.125 mm x 0.125 mm) 0.0033 in. x 0.0039 in. (0.084 mm x 0.100 mm) Maximum print speed 12 ips 8 ips First dot location (from inside media edge) 0.093 in. (2.4 mm) 0.093 in. (2.4 mm) Maximum print width 4.1 in. (104 mm) 4.2 in.
Specifications Zebra Programming Language (ZPL II) Zebra Programming Language (ZPL II) • Communicates in printable ASCII characters • Controlled via mainframe, mini, or PC • Downloadable graphics, scalable and bitmap fonts, label templates and formats • Object copying between memory areas (RAM and PC memory card) • Adjustable print cache • Data compression • Automatic memory allocation for “format while printing” • • • • • • • • Status messages to host upon request Format inversion (white on black)
Index A C adhesive test for ribbon coating, 38 adjustments LCD, 87 left position, 83 media sensors, 55 print darkness, 64 printhead pressure, 97 tear-off position, 65 toggle positioning, 95 agency approvals, 151 applicator +24-28V isolated and non-isolated modes, 144 +5V isolated and non-isolated modes, 143 applicator interface connector, 138 interface pin configuration, 140 signals during applicator modes, 138 applicator port setting, 84 auto-calibration, 53 calibration CALIBRATE button description, 18
Index connect printer to power source, 33 contacts, 11 continuous media described, 36 setting media type, 66 control panel buttons, 17 enter and use Setup mode, 58 exit Setup mode, 59 indicator lights, 18 LCD error messages, 103 parameters, 63 control prefix setting, 80 customer service, 11 cutter selecting Cutter mode, 66 dpi format conversion, 87 E electrical specifications, 148 enter Setup mode, 58 environmental conditions, 148 ERROR light, 19 error messages, 103 Ethernet characteristics of inter
Index I M idle display setting, 88 images list, 73 incorporation declaration, 3 initialize Flash memory, 75 initialize memory card, 74 inspect for shipping damage, 23 installation procedure, 29 requirements, 25 international safety organization marks, 34 isolated mode for applicator control signals +24-28V operation, 144 +5V operation, 143 mark LED setting, 87 Mark Med S.
Index P PAPER OUT message, 104 parallel port cabling requirements, 132 characteristics of parallel connection, 31 pin configuration, 132 setting parallel communications, 78 settings, 132 parity setting, 79 passwords default, 60 disable, 60 entering, 60 PAUSE button description, 17 FEED and PAUSE self test, 126 PAUSE self test, 121 PAUSE light, 18 PCMCIA card initialization, 74 peel-off bar cleaning, 90 Peel-Off mode selecting, 66 perforated media, 36 pin configuration applicator interface, 140 paralle
Index product markings, 151 protocol setting, 79 RTC (real-time clock) setting date, 88 idle display, 88 time, 88 R radiation exposure limits, 2, 4 recycling the print engine, 24 recycling the printer, 24 reflective media sensor, 55 remove used ribbon, 52 report shipping damage, 23 reprint mode, 86 requirements for installation, 25 restore factory default settings, 59 network settings, 59 resynch mode setting, 85 Rewind mode selecting, 66 RFID “smart” labels, 35 troubleshooting, 114 ribbon adhesive test,
Index specifications agency approvals and markings, 151 bar codes, 156 communications options, 149 electrical, 148 environmental conditions, 148 fuses, 148 media, 153 physical, 148 power cord, 34 printing, 155 ribbon, 154 Zebra Programming Language (ZPL II), 156 standard data ports, 131 standard features, 150 start print signal setting, 85 storing the print engine, 23 T tag stock described, 35 Tear-Off mode selecting, 66 tear-off bar cleaning, 90 tear-off position adjustment, 65 technical support, 11
Zebra Technologies Corporation Zebra Technologies Corporation 475 Half Day Road, Suite 500 Lincolnshire, IL 60069 USA T: +1 847 634 6700 Toll-free +1 866 230 9494 F: +1 847 913 8766 Zebra Technologies Europe Limited Dukes Meadow Millboard Road Bourne End Buckinghamshire, SL8 5XF, UK T: +44 (0)1628 556000 F: +44 (0)1628 556001 Zebra Technologies Asia Pacific, LLC 120 Robinson Road #06-01 Parakou Building Singapore 068913 T: +65 6858 0722 F: +65 6885 0838 http://www.zebra.com © 2011 ZIH Corp.
