Zebra® 170PAX4™ Print Engine User Guide
© 2006 ZIH Corp. The copyrights in this manual and the software and/or firmware in the label print engine described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the label 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. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and AGFA fonts.
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-
iv 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Web Site . . . .
vi Contents Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Clearance Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii Contents 8 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 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: 57516L-002 Rev. A Section Description Introduction on page 7 This chapter shows the operational controls and location of major components used when loading media and ribbon.
About This Document Contacts Contacts You can contact Zebra Technologies at the following. Web Site http://www.zebra.com Technical Support via the Internet is available 24 hours per day, 365 days per year. Go to http://www.zebra.com/support. The Americas Regional Headquarters Technical Support Customer Service Dept. Zebra Technologies International, LLC 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.
4 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 Illustration Callouts Callouts are used when an illustration contains information that needs to be labeled and described. A table that contains the labels and descriptions follows the graphic. Figure 1 provides an example.
6 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 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 2) and a left-hand configuration (media moves from right to left, Figure 3). Figure 2 • Right-Hand (RH) Print Engine 2 3 1 Figure 3 • Left-Hand (LH) Print Engine 2 3 1 1 2 3 57516L-002 Rev.
Introduction Control Panel Control Panel All controls and indicators for the print engine are located on the control panel (Figure 4). 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.
10 Introduction Control Panel Table 1 • Control Panel Buttons (Continued) Button Description/Function FEED Feeds a blank label. • If the print engine is idle or paused, the label is fed immediately. • If the print engine is printing, the label is fed after the current batch prints. CALIBRATE CALIBRATE functions only in Pause mode. Press CALIBRATE to recalibrate for proper media length, to set media type (continuous/non-continuous), and to set print method (direct thermal/thermal transfer).
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.
12 Introduction Power On/Off Switch Power On/Off Switch The print engine power switch is located to the side of the control panel, as shown in Figure 5. 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 124. Figure 5 • Power Switch Location (Right-Hand) 1 1 57516L-002 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. . . . . . . . . . . . . . . . . . . . . . . . . . .
14 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 15.
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.
16 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 6 • 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 10-32) 0.197 in. (5 mm) 10.433 in. (265 mm) 0.197 in. (5 mm) 0.550 in. (13.97 mm) Label orientation 0.320 in. (8.13 mm) 1/10/06 170PAX4 User Guide 57516L-002 Rev.
Print Engine Setup Print Engine Installation Figure 7 • Right Side View of Right-Hand Print Engine (279.6 mm) First print element 0.613 in. (15.6 mm) Mainframe 18 0.52 in. (13.2 mm) Ribbon and media edge 35° Ref 19.700 in. (500.4 mm) 10.398 in. (264.1 mm) 8.500 in. (215.9 mm) 7.000 in. (177.8 mm) MAX label width 7.1 in. (180 mm) MAX backing width 0.394 in. (10.0 mm) 18.3 in. (465 mm) 18.8 in. (478 mm) 57516L-002 Rev.
Print Engine Setup Print Engine Installation Figure 8 • Rear View of Right-Hand Print Engine 0.197 in. (5 mm) 4.626 in. (117.5 mm) 9.646 in. (245 mm) 9.252 in. (235 mm) 0.197 in. (5 mm) 10.433 in. (265 mm) 11.811 in. (300 mm) 0.451 in. (11.45 mm) 8.748 in. (222.2 mm) Install the Print Engine in an Applicator This section provides the basic instructions for installing the print engine into an applicator.
20 Print Engine Setup Print Engine Installation Figure 9 • Front View of Print Engine in Applicator 1 2 3 4 1 1 1 2 3 4 57516L-002 Rev.
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 22.
22 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 Select a Communication Interface Select a Communication Interface The way that you connect your print engine to a data source depends on the communication options installed in the print engine. You may use any available connection to send commands and label formats from a host computer to the print engine. Caution • Connecting a data communications cable while the power is ON may damage the print engine. Note • You must supply all interface cables for your application.
24 Print Engine Setup Select a Communication Interface Types of Connections The method of connecting the print engine to a data source depends on the communication options installed in the print engine and the host. This section provides basic information about common interfaces. When communicating via the serial data port (RS-232), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or DTR control should be set to match those of the host computer.
Print Engine Setup Select a Communication Interface IEEE 1284 Bidirectional Parallel A common communication method available on most PCs and other hosts. • Advantages: Fastest of the communication interfaces; cables and connectors are readily available from computer equipment stores and suppliers; two-way communication between the host and the print engine; easy to connect. • Disadvantages: Shorter recommended cable length of 6 feet (1.
26 Print Engine Setup Select a Communication Interface Data Cable Requirements Data cables must be fully shielded and fitted with metal or metallized connector shells. Shielded cables and connectors are required to prevent radiation and reception of electrical noise. To minimize electrical noise pickup in the cable: • Keep data cables as short as possible. • Do not bundle the data cables tightly with the power cords. • Do not tie the data cables to power wire conduits.
Print Engine Setup Types of Media Types of Media The print engine can use various types of media (Table 3). 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.
28 Print Engine Setup Types of Media Table 3 • Types of 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 divisions as noncontinuous roll media. The divisions would fall on or near the folds. Continuous Roll Media Continuous media is wound on a core and is without gaps, holes, notches, or black marks. This allows the image to be printed anywhere on the label.
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.
30 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 13, follow the instructions in this chapter to load and calibrate your print engine. Contents Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Used Ribbon . . . . . . . . . . . . . . . . . . . .
32 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 20 identifies the media-handling components.
Operations Load Media Figure 21 • Loaded Media Left-Hand Right-Hand 1/10/06 170PAX4 User Guide 57516L-002 Rev.
34 Operations Load Media To load media, complete these steps: 1. Load media on the media supply reel of the applicator (refer to the applicator’s user guide). 2. Open the media door. 3. Press down on the pinch roller release latch. The pinch roller assembly springs up. 4. Under the print engine, grasp the brass thumb nut (1) of the outer media guide (2), and slide the outer media guide all the way out. 1 2 57516L-002 Rev.
Operations Load Media 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. See Figure 22. Thread the media through the upper media path as follows: a. Under the upper guide post (1) b. Between the top media sensor track assembly (2) and the label guide shelf assembly (3) c. Below the pinch roller assembly (4) d. Under the printhead assembly (5) 7.
36 Operations Load Media 8. Position the media (1) so that it is aligned with and just touching the inner media guide (2—not visible from this angle). 2 1 9. Under the print engine, grasp the brass thumb nut of the outer media guide (1), and position the outer media guide so that it just touches the outer edge of the media. 1 57516L-002 Rev.
Operations Load Media 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 downward. 1 2 1/10/06 170PAX4 User Guide 57516L-002 Rev.
38 Operations Load Media 13. Thread the liner around the peel bar (1), under the platen roller (2), and through the peel roller assembly (3). Note • If the applicator has an air tube, route the liner between the air tube and the peel bar. Do not thread the liner over the air tube. 1 2 3 14. Rotate the peel roller assembly up until it locks into the closed position. 15. Thread the liner around the take-up spindle of the applicator (refer to the applicator’s user guide). 16. Close the media door.
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 23 identifies the ribbon system components inside the media compartment of a right-hand print engine. Figure 24 on page 40 shows the print engine with ribbon loaded.
40 Operations Load Ribbon Figure 24 • Loaded Ribbon Left-Hand Right-Hand 57516L-002 Rev.
Operations Load Ribbon To load ribbon, complete these steps: 1. Place a full ribbon roll onto the ribbon supply spindle (1) so the ribbon rotates as shown, and then push the roll toward the print engine frame until it is fully seated. Left-Hand Right-Hand 1 1 2. Thread the ribbon under the lower ribbon guide roller (1). 1 3. Make sure that the ribbon passes directly below the ribbon sensor (1), which is located near the back wall of the print engine. 1 1/10/06 170PAX4 User Guide 57516L-002 Rev.
42 Operations Load Ribbon 4. Open the printhead assembly by unlatching the printhead latch (1) from the locking pin (2). 1 2 5. Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool. Thread the ribbon under the printhead assembly (1) and then around the upper ribbon guide roller (2). 2 1 57516L-002 Rev.
Operations Load Ribbon 6. Place an empty ribbon core (1) onto the ribbon take-up spindle (2), and then push the core toward the print engine frame until it is fully seated. Left-Hand 1 Right-Hand 2 2 1 7. 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. Wind the ribbon evenly on the spindle. Left-Hand Right-Hand 8.
44 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? 57516L-002 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 4 shows the different methods for calibration.
46 Operations Calibrate the Print Engine Table 4 • 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. Select the SENSOR PROFILE option on the control panel. See Print Sensor Profile on page 67 for instructions. Media and Ribbon Sensor Sensitivity Calibration One of the most common adjustments to print engine settings.
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 25) is mounted in a fixed position, and no adjustment is required. Figure 25 • Ribbon Sensor Location 1 1 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. The reflective media sensor senses these black marks.
48 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 26 • Media Sensor Adjustment (Right-Hand Unit Shown) 1 2 1 2 57516L-002 Rev.
4 Configuration This section describes the control panel parameters that are used to configure the print engine for operation. Contents Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 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 PAUSE Self Test on page 110 and FEED Self Test on page 111.
Configuration Setup Mode Exit Setup Mode To leave Setup mode, complete these steps: 1. Press SETUP/EXIT. The LCD displays SAVE CHANGES. 2. Press the left or right oval to display the save options (Table 5). Table 5 • Save Options When Leaving Setup Mode LCD Description PERMANENT Stores values in the print engine even when power is turned off. TEMPORARY Saves the changes until power is turned off.
52 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.
54 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 28).
Configuration Control Panel LCD Displays Control Panel LCD Displays Use the LCD display on the control panel to adjust print engine settings. Table 6 shows parameters in the order in which they are displayed when you press NEXT after entering Setup mode. Table 8 on page 81 shows the additional parameters that appear when a wired or wireless print server is installed in the print engine.
56 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 2 of 26) Parameter SLEW SPEED 6 IPS Action/Explanation + Adjust Slew Speed Adjusts the speed for feeding a blank label (given in inches per second). Default: 6 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 LCD Displays Table 6 • Print Engine Parameters (Page 3 of 26) Parameter TEAR OFF - Action/Explanation +000 + Adjust the Tear-Off Position This parameter establishes the position of the media over the tear-off/peel-off bar after printing. See Figure 29. Higher numbers move the media out (the tear line moves closer to the leading edge of the next label), and lower numbers move the media in (the tear line moves closer to the edge of the label just printed).
58 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 4 of 26) Parameter Action/Explanation MEDIA TYPE -NON-CONTINUOUS + Set Media Type This parameter tells the print engine the type of media that you are using (see Types of Media on page 27 for more information). Selecting continuous media requires that you include a label length instruction in your label format (^LLxxxx if you are using ZPL or ZPL II).
Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 5 of 26) Parameter MAXIMUM LENGTH -39.0 IN 988 MM 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 30).
60 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 6 of 26) Parameter Action/Explanation Set Early Warning System 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 LCD Displays Table 6 • Print Engine Parameters (Page 7 of 26) Parameter Action/Explanation MEDIA REPLACED? NO YES Reset Media Counter for Early Warning This parameter appears only when Early Warning is enabled for media. 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.
62 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 8 of 26) 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 • Update the number of labels per roll when beginning use of the Early Warning System. Also, the print engine does not make any adjustments when power is turned off and on. Default: MAINT. OFF Selections: MAINT.
Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 9 of 26) Parameter HEAD LIFE 1000000 IN Action/Explanation + Set Printhead Life for Early Warning This parameter appears only when Early Warning is enabled for maintenance. 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.
64 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 10 of 26) 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 LCD Displays Table 6 • Print Engine Parameters (Page 11 of 26) 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:. If your print engine is set to require a password, you are prompted to enter the password.
66 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 12 of 26) 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. If your print engine is set to require a password, you are prompted to enter the password. 2. Enter the password.
Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 13 of 26) Parameter SENSOR PROFILE PRINT Action/Explanation Print Sensor Profile The sensor profile may be used to troubleshoot registration problems that may be caused when the media sensor detects preprinted areas on the media or if it experiences difficulty in determining web location. Figure 31 shows a sensor profile.
68 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 14 of 26) 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 LCD Displays Table 6 • Print Engine Parameters (Page 15 of 26) 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.
70 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 16 of 26) Parameter PARITY NONE Action/Explanation + Set Parity 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. Press the left or right oval to scroll through the options.
Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 17 of 26) 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. When DIAGNOSTICS is selected, all data sent from the host computer to the print engine prints as straight ASCII characters, with the hex value below the ASCII text.
72 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 18 of 26) Parameter FORMAT PREFIX <^>5EH Action/Explanation + Set Format Prefix Character The format prefix is a two-digit hex value used as a parameter place marker in ZPL/ZPL II format instructions. The “H” that is displayed indicates Hexadecimal and is not part of the value. The print engine looks for this hex character to indicate the start of a ZPL/ZPL II format instruction.
Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 19 of 26) Parameter RIBBON TENSION HIGH Action/Explanation Set Ribbon Tension This parameter sets the tension applied to the ribbon supply spindle. The correct setting is determined by a combination of the ribbon width and the ribbon length (Table 7). + Table 7 • Ribbon Tension Settings Ribbon Length Ribbon Width 300 Meters 450 Meters 600 Meters 900 Meters 3 to 5 in. Low Low Low Low 4 to 6 in.
74 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 20 of 26) Parameter HEAD CLOSE - CALIBRATION 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.
Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 21 of 26) 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.
76 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 22 of 26) 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 LCD Displays Table 6 • Print Engine Parameters (Page 23 of 26) 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.
78 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 24 of 26) 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 LCD Displays Table 6 • Print Engine Parameters (Page 25 of 26) 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.
80 Configuration Control Panel LCD Displays Table 6 • Print Engine Parameters (Page 26 of 26) Parameter IDLE DISPLAY - FW VERSION Action/Explanation + Select Idle Display This parameter selects the LCD options for the real-time clock. Note • If the default value is not selected, pressing the left or right oval briefly displays the firmware version of the print engine.
Configuration Control Panel LCD Displays Print Server LCD Displays The menu options shown in Table 8 display only if you have a print server installed. Table 8 • Print Server Parameters (Page 1 of 4) Parameter LOAD LAN FROM? PRINTER Action/Explanation Load LAN Source1 This parameter, which serves the same function as the ^NP ZPL command, specifies whether to use the print engine’s or the print server’s IP settings at bootup.
82 Configuration Control Panel LCD Displays Table 8 • Print Server Parameters (Page 2 of 4) Parameter IP ADDRESS 000.000.000.000 Action/Explanation Specify IP Address2 This parameter allows you to select the IP address if PERMANENT was chosen in IP PROTOCOL. (If a dynamic option was chosen, the user cannot select the address.) To change the value shown: 1. Press the left oval to move the cursor. 2. Press the right oval to increase the value of the digit. SUBNET MASK 000.000.000.
Configuration Control Panel LCD Displays Table 8 • Print Server Parameters (Page 3 of 4) Parameter LEAP MODE OFF Action/Explanation Enable LEAP Mode3,4 LEAP is an encryption method that is available with some wireless cards. Set the LEAP user name and password through the print engine web pages. Default: OFF Selections: ON, OFF To change the value shown: 1. Press the left or right oval to toggle between the options.
84 Configuration Control Panel LCD Displays Table 8 • Print Server Parameters (Page 4 of 4) Parameter RESET NETWORK YES Action/Explanation Reset Network2,3 This option resets the wireless card and the print server when the wireless option is running. Selecting this option has no effect when the wireless option is not running, when there is no card inserted, or when the wireless password is anything other than the default (zero). 1. Press the right oval to select YES. The LCD prompts ARE YOU SURE?.
5 Routine Maintenance This chapter provides routine cleaning and maintenance procedures. Contents Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 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 9. 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 32 for the media and ribbon sensors.
88 Routine Maintenance Clean the Sensors Figure 33 • Door-Open Sensor Location (Right-Hand Unit Shown) 1 1 57516L-002 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 9 on page 86. 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. To clean the printhead and platen roller, complete these steps: Caution • The printhead may be hot and could cause severe burns. Allow the printhead to cool.
90 Routine Maintenance Clean the Printhead and Platen Roller 4. See Figure 35. 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. Figure 35 • Printhead and Platen Roller Cleaning (Right-Hand Unit Shown) 1 2 3 1 2 3 Printhead elements (gray strip) Cotton swab Platen Roller 5.
Routine Maintenance Toggle Positioning Toggle Positioning Proper toggle positioning is important for proper print quality. The toggles should be positioned approximately 1/4 of the way in from each media edge. To adjust the toggles, complete these steps: 1. See Figure 36. Loosen the position locking nut by rotating it to the left. 2. Slide the toggle to the desired position on the toggle shaft. 3. Finger tighten the position locking nut by rotating it to the right.
92 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 91.
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 12 on page 22). 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.
94 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96 Troubleshooting 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 97. Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensor Sensitivity on page 68.
Troubleshooting LCD Error Messages LCD Error Messages The LCD displays messages when there is an error. See Table 10 for LCD errors, the possible causes, and the recommended solutions. Table 10 • LCD Error Messages LCD Display/ Print Engine Condition ERROR CONDITION RIBBON OUT The print engine stops; RIBBON light ON, ERROR light flashes. Possible Cause Recommended Solution In thermal transfer mode, ribbon is not loaded or incorrectly loaded. Load ribbon correctly. See Load Ribbon on page 39.
98 Troubleshooting LCD Error Messages Table 10 • 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 ribbon unless you are using it to protect the printhead. This error message will not affect printing. RIBBON light ON, ERROR light flashes.
Troubleshooting LCD Error Messages Table 10 • LCD Error Messages (Continued) LCD Display/ Print Engine Condition WARNING HEAD COLD The print engine stops and 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.
100 Troubleshooting Memory Errors Memory Errors The memory errors in Table 11 indicate that the print engine does not have enough memory to perform the function shown on the second line of the LCD. Table 11 • 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.
Troubleshooting Print Quality Problems Print Quality Problems Table 12 identifies problems with print quality, the possible causes, and the recommended solutions. Table 12 • 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 55.
102 Troubleshooting Print Quality Problems Table 12 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Wrinkled ribbon Ribbon fed through the machine incorrectly. See Load Ribbon on page 39. Incorrect burn temperature. Set the darkness to the lowest possible setting for good print quality. See Adjust Print Darkness on page 55. Incorrect or uneven pressure. Set the pressure to the minimum needed for good print quality. See Printhead Pressure Adjustment on page 92.
Troubleshooting Print Quality Problems Table 12 • Print Quality Problems (Continued) Problem Possible Cause Recommended Solution Printing too light or too dark over the entire label 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 labels and ribbon for your application. 1. Switch to a different type of media or ribbon to try to find a compatible combination. 2.
104 Troubleshooting Print Quality Problems Table 12 • Print Quality Problems (Continued) Problem Possible Cause Vertical image or label drift The print engine is using Configure the print engine for non-continuous noncontinuous labels but is and run calibration routine, if necessary. configured in continuous mode. The bar code printed on a label does not scan. 57516L-002 Rev. A Recommended Solution Improperly calibrated media sensor. See Calibrate Media and Ribbon Sensor Sensitivity on page 68.
Troubleshooting Communications Problems Communications Problems Table 13 identifies problems with communications, the possible causes, and the recommended solutions. Table 13 • 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).
106 Troubleshooting Miscellaneous Print Engine Problems Miscellaneous Print Engine Problems Table 14 identifies miscellaneous problems with the print engine, the possible causes, and the recommended solutions. Table 14 • 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.
Troubleshooting Miscellaneous Print Engine Problems Table 14 • 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 68. The print engine is configured for continuous media. Set the media type to noncontinuous media.
108 Troubleshooting 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.
Troubleshooting Print Engine Diagnostics CANCEL Self Test The CANCEL self test prints a configuration label (Figure 39). To perform the CANCEL Self Test, complete these steps: 1. Turn Off (O) the print engine. 2. Press and hold CANCEL while turning the print engine On (I). Hold CANCEL until the first control panel light turns off. A print engine configuration label prints (Figure 39). Figure 39 • Configuration Label 1/10/06 170PAX4 User Guide 57516L-002 Rev.
110 Troubleshooting 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 40 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 the power On (I). Hold PAUSE until the first control panel light turns off.
Troubleshooting 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.
112 Troubleshooting Print Engine Diagnostics Figure 41 • FEED Test Label 4. See Figure 42 and Table 15. 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. 57516L-002 Rev.
Troubleshooting Print Engine Diagnostics Figure 42 • Bar Code Darkness Comparison Table 15 • Judging Bar Code Quality 1/10/06 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.
114 Troubleshooting Print Engine Diagnostics Table 15 • 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 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.
116 Troubleshooting Print Engine Diagnostics Table 16 • Control of Parameters (Continued) 57516L-002 Rev.
Troubleshooting Print Engine Diagnostics Table 16 • Control of Parameters (Continued) Parameter Controlled By J8 Interface Fixed J7 Interface Fixed Twinax/Coax ID ZPL Communications Diagnostics Test Do not perform the following test until all configuration and calibration parameters have been set. For configuration information, see Control Panel LCD Displays on page 55. This test is controlled from the control panel LCD display. See Set Communications Mode on page 71.
118 Troubleshooting Print Engine Diagnostics Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _____________
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120 Data Ports 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.
Data Ports Parallel Data Port Table 17 • Parallel Cable Pin Configuration (Continued) 36-Pin Connectors 31 nInit 32 nFault/NDataAvail 33, 34 1/10/06 Description Not used 35 +5 V through a 1.8 KΩ Resistor 36 NSelectin/1284 active 170PAX4 User Guide 57516L-002 Rev.
122 Data Ports Serial Data Port Serial Data Port See RS-232 Serial on page 24 for basic cabling information. 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.
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 125). Table 18 shows the pin configuration of the serial data connector. Table 18 • Serial Connector Pin Configuration 1/10/06 Pin No.
124 Data Ports Serial Data Port RS-232 Interface Connections The print engine is configured as Data Terminal Equipment (DTE). Figure 44 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 45 shows the connections required for the DB-9 to DB-25 interface.
126 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 49 • 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 50 • 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
128 Data Ports Applicator Interface Connector Table 19 • Applicator Interface Connector Pin Configuration (Continued) Pin No. 2 Signal Name Signal Type Description +5V I/O (Fused at 1 A) Power See Figure 51 on page 133 for fuse location. Using jumper J4, this pin can be configured as isolated or non-isolated from the Applicator Interface Circuit +5 V Supply. See Jumper Configurations and Pinouts for +5 V I/O Operation on page 131 for more information.
Data Ports Applicator Interface Connector Table 19 • Applicator Interface Connector Pin Configuration (Continued) Pin No. Signal Name Signal Type Description 8 POWER GROUND (+28 V DC Return) Ground The Interface Power Ground. Note • If pin 7 is used to supply power to pin 2, use this pin to ground pin 1. 9 RIBBON LOW Output Asserted if the Ribbon Low feature is enabled and the amount of ribbon remaining on the supply spool is below a specific threshold level (see Set Ribbon Low Mode on page 78).
130 Data Ports Applicator Interface Connector Table 19 • Applicator Interface Connector Pin Configuration (Continued) Pin No. Signal Name Signal Type Description 11 END PRINT Output See Applicator Signals on page 126 for more information about the start and end print signals. See Set Applicator Port Mode on page 76 for more information about the modes. • MODE 0—The applicator port is OFF. • MODE 1—Asserted LOW only while the print engine is moving the label forward; otherwise deasserted HIGH.
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.
132 Data Ports Applicator Interface Connector Pinouts for +24-28 V I/O Operation Table 21 describes the pin configurations for +24-28 V I/O operation. There are no jumpers to configure for this mode. Table 21 • 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 51 shows the location of the fuses on the applicator interface board and the location of jumpers J4 and J5. Figure 51 • Applicator Interface Board 1 2 3 1 2 3 4 1/10/06 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 170PAX4 User Guide 57516L-002 Rev.
134 Data Ports Applicator Interface Connector Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ____________
8 Specifications This chapter provides routine cleaning and maintenance procedures. Contents General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . .
136 Specifications General Specifications General Specifications Physical Height 11.8 in. (300 mm) Width 9.6 in. (245 mm) Depth 18.3 in. (465 mm) Weight 35.5 lb. (16.
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 • Linear PCMCIA cards available 8MB and 32MB. • ATA-style PCMCIA or Compact Flash memory cards 32, 64, 128, 256MB.
138 Specifications Agency Approvals Agency Approvals Agency Approvals • IEC 60950-1 • EN55022, Class A • EN61000-6-2 Product Markings • cULus • CE Mark • FCC-A • ICES-003 • VCCI • C-Tick • CCC • Gost-R • TUV-AR/S Mark 57516L-002 Rev.
Specifications Media Specifications Media Specifications Media width (label and liner) Label length Minimum 3.0 in. (76 mm) Maximum 7.1 in. (180 mm) Minimum Registration tolerance (not including label/liner position tolerances) Non-RFID, rewind mode 0.25 in. (6.4 mm) (“loose loop”) Applicator mode 3.0 in. (76.2 mm) with backfeed on 1.0 in. (25.4 mm) with backfeed off Rewind mode 1.0 in. (25.4 mm) Tear-off mode 3.0 in. (76.2 mm) with backfeed on 1.0 in. (25.
140 Specifications Ribbon Specifications Ribbon Specifications 57516L-002 Rev. A Thickness 4.5 microns Width (wound coated side out) 3.0 in. to 7.1in. (76 mm to 180 mm) Maximum length 2955 ft (900 m) Roll size Inner core diameter Maximum roll size 1.0 in. (25.4 mm) 4.0 in. (101.
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 6.6 in. (168 mm) 6.6 in.
142 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)
Glossary alphanumeric Indicating letters, numerals, and characters such as punctuation marks. backfeed When the print engine pulls the media and ribbon (if used) backward into the print engine so that the beginning of the label to be printed is properly positioned behind the printhead. Backfeed occurs when operating the print engine 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.
144 Glossary core diameter The inside diameter of the cardboard core at the center of a roll of media or ribbon. diagnostics Information about which print engine functions are not working that is used for troubleshooting print engine problems. 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.
Glossary liquid crystal display (LCD) The LCD is a back-lit display that provides the user with either operating status during normal operation or option menus when configuring the print engine to a specific application. light emitting diode (LED) Indicators of specific print engine status conditions. Each LED is either off, on, or blinking depending on the feature being monitored.
146 Glossary ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper printhead pressure. This wrinkle can cause voids in the print and/or the used ribbon to rewind unevenly. This condition should be corrected by performing adjustment procedures. roll media Media that comes supplied rolled onto a core (usually cardboard). Contrast this with fanfold media. “smart” label Media that comes with an RFID transponder embedded between the label and the liner.
Index A C adhesive test for ribbon coating, 30 adjustments LCD, 79 left position, 75 media sensors, 47 print darkness, 55 printhead pressure, 92 tear-off position, 57 toggle positioning, 91 agency approvals, 138 applicator +24-28V isolated and non-isolated modes, 132 +5V isolated and non-isolated modes, 131 applicator interface connector, 126 interface pin configuration, 127 signals during applicator modes, 126 applicator interface, 25 applicator port setting, 76 authentication type, 82 auto-calibration,
148 Index connect to power source, 21 contacts, 3 continuous media described, 28 setting media type, 58 control panel buttons, 9 enter Setup mode, 50 exit Setup mode, 51 indicator lights, 10 LCD error messages, 97 LCD parameters, 55 control prefix setting, 71 customer service, 3 cutter selecting Cutter mode, 57 D darkness setting, 55 data bits setting, 69 data cable requirements, 26 DATA light, 10 data ports, 119 data source communication interfaces, 119 connections, 23 date setting, 80 DB-9 to DB-25 con
Index I liability, ii lights on control panel, 10 list settings all settings, 64 bar codes, 63 fonts, 63 formats, 64 images, 64 network, 64 setup, 64 load factory defaults, 51 loading media, 32 ribbon, 39 long calibration, 45 low ribbon warning, 78 idle display setting, 80 images list, 64 incorporation declaration, iii initialize Flash memory, 66 initialize memory card, 65 inspect for shipping damage, 15 installation procedure, 19 requirements, 16 interface DB-15 applicator interface, 25 interfaces IEEE
150 Index N network configuration label printing, 54 printing using List Network command, 64 network ID setting, 70 NEXT button description, 9 non-continuous media described, 27 setting media type, 58 non-isolated mode for applicator control signals +28V operation, 132 +5V operation, 131 O optional print servers, 25 ordering ribbon and media, 3 O U T O F M E M O R Y message, 99 P P A P E R O U T message, 98 parallel port cabling requirements, 120 overview, 25 pin configuration, 120 setting parallel comm
Index printer settings applicator port, 76 backfeed, 74 baud, 69 calibration methods, 45 control prefix, 71 data bits, 69 date, 80 delimiter character, 72 format convert, 79 format prefix, 72 head resistor, 75 host handshake, 70 idle display, 80 IP settings, 81 label top, 74 language, 80 LCD, 79 left position, 75 maximum label length, 59 media type, 58 network configuration label as baseline, 54 network ID, 70 parallel communications, 69 parity, 70 print darkness, 55 print method, 58 print server settings,
152 Index S sales, 3 schedule for cleaning, 86 scratch test media type, 29 ribbon coated side, 30 self tests, 108 CANCEL, 109 communications diagnostics, 117 FEED, 111 FEED and PAUSE, 115 PAUSE, 110 Power-On Self Test (POST), 108 Sensor Profile calibration description, 46 sensors adjustment, 47 calibration methods, 45 locations, 87 sensor profile, 67 serial port pin configuration, 123 setting serial communications, 69 settings, 122 setup checklist, 14 unpack the print engine, 15 Setup mode enter Setup mod
Index W Z web media, 27 Web S. setting, 79 Wireless Print Server settings authentication type, 82 default gateway, 82 encryption, 83 ESSID, 82 IP address, 82 IP protocol, 81 MAC address, 82 reset network, 84 subnet mask, 82 Zebra Programming Language (ZPL II) ZPL mode setting, 72 specifications, 142 1/10/06 170PAX4 User Guide 57516L-002 Rev.
154 Index Notes • ____________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________________________________________
Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061.3109 U.S.A. Telephone: +1 847.793.2600 Facsimile: +1 847.913.
