Zebra® KR403 Kiosk Receipt Printer Hardware Integrator Guide P1016701-001 Rev.
© 2010 ZIH Corp. The copyrights in this manual and the software and/or firmware in the printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware in the printer may result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may be subject to civil liability. This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element Energy Equalizer® Circuit; E3®; and Monotype Imaging fonts.
Contents 1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 KR403 Kiosk Receipt Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Controls, Indicators, and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Button Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensing, Status and Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Button Modes . . .
Contents Printing a Test Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 6 • Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Accessories Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Bezel – P1011185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Bezel Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
1 Introduction KR403 Kiosk Receipt Printer The Zebra KR403 model is the best-in-class thermal kiosk printer with the widest range of features. The KR403 printer provides direct thermal printing at speeds up to 150mm/s (5.9 ips) at a 203 dpi print density. The KR403 supports the ZPL printer programming language and a wide variety of interface and feature options.
2 Introduction KR403 Kiosk Receipt Printer • Industry Leading Bar Code Support – Largest set of common and specialized linear and 2-dimensional bar code symbologies resident in a kiosk printer. • Powerful Font Support – One scalable and 16 bitmap fonts resident with support for downloadable and Unicode fonts. • Interface Support – The KR403 is available with two interface configurations: USB / Serial, and USB / Ethernet. • Storage – 4MB of flash memory with the largest in class 1.
Introduction Package Contents Package Contents • The KR403 printer. • Warranty information. Note • To minimize cost and reduce waste, the KR403 does not include unneeded components or accessories. Additional items are required to make the printer operational. Unpack and Inspect the Printer When you receive the printer, immediately unpack it and inspect for shipping damage. • Save all packing materials. • Check all exterior surfaces for damage.
4 Introduction How This Document Is Organized How This Document Is Organized The manual is set up as follows: Chapter Description Introduction What is covered in this document, contact information. Design Overview Introduction to the KR203 Printer and package contents, design considerations overview. Printer Overview Dimensions, orientation, and other features. Connections Power and communication connections Media Loading, mounting, and feed angles.
Introduction 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.
6 Introduction Document Conventions Document Conventions The following conventions and symbols are used throughout this document to convey certain information: Alternate Color – Cross-references contain links to other sections in this guide. If you are viewing this guide online, click the blue text to jump to its location. Caution • Warns you of the potential for electrostatic discharge. Caution • Warns you of a potential electric shock situation.
2 Design Overview Design Considerations Overview The kiosk designer needs to consider how the printer is being used, operated (media supply and maintenance), serviced, integrated with other kiosk components, and integrated into the enclosure itself. The KR403 printer needs some basic design elements to function properly, safely, and easily for the operator. The general issues are: 9/24/2010 • The KR403 printer should always be installed in some kind of locking enclosure.
8 Design Overview Design Considerations Overview • P1016701-001 Rev. B Operator access to the printer. The operator needs to view, service and maintain the printer. The operator needs access to: • The operator needs to be able to see the printer's control panel for status lights and also press the Feed button while observing the status lights for media loading, setup and servicing the printer (see "Controls, Indicators, and Sensors" on page 24). • Open and clean the printhead or remove jams.
3 Printer Overview Basic Printer Dimensions The illustration below outlines the basic printer mounting dimensions to install the printer in a kiosk. These basic printer dimensions do not illustrate the unique integration requirements needed to use the printer with specific printer accessories, operator servicing access, media mounting, power and cabling access, and printer media handling. 143 122 45 8 8.25 86 107 25 25 51 5 7.5 64.2 114 45.
10 Printer Overview Printer Orientation Printer Orientation REAR Media IN RIGHT LEFT FRONT Media Out Figure 3-2 • Printer Orientation Table 3-1 • Printer Orientation Output P1016701-001 Rev.
Printer Overview Printer Features Printer Features Figure 3-3 • Printer Features Table 3-2 • Printer Features 9/24/2010 Printhead Retractor Platen (drive) Roller Control Panel (right) Cutter Retract Sensor Presenter Media Sensors KR403 Hardware Integrator Guide P1016701-001 Rev.
12 Printer Overview Printer Features Printer Features (continued) Figure 3-4 • Printer Features (Serial/USB) Figure 3-5 • Printer Features (USB/Ethernet) Table 3-3 • Printer Features P1016701-001 Rev.
Printer Overview Printer Features Printer Features (continued) Figure 3-6 • Printer Features (Serial/USB) Table 3-4 • Printer Features Waste Sensor 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
14 Printer Overview Printer Features Opening the Printer When cleaning or servicing the printer, it is sometimes necessary to access the printhead. 1. Press the green printhead release bar to unlock the printhead. 2. Rotate the printhead assembly upward. Figure 3-7 • Opening the Printhead P1016701-001 Rev.
Printer Overview General Printing Information General Printing Information Printer control • Printer Control Panel - Allows very basic printer configuration setup that include: configuration status (label) receipt, non-default print widths, print darkness (density) • ZPL (Zebra Programming Language), a page (receipt) description language. The printer also supports the Zebra SGD (Set Get Do) printer configuration language that uses a natural language.
16 Printer Overview General Printing Information KR403 Media Types Receipt Media Supply Type Outside Wound Continuous Roll: Plain receipt, receipt with black marks, and pre-printed receipt media with black marks. Fanfold: Stacked receipt media with black marks and pre-printed receipt media with black marks. Outer Roll diameter 250 mm (9.84 inches) maximum Note: The maximum roll diameter is dependent upon roll holder in use and the kiosk design.
Printer Overview Basic Printer Mounting (printer only) Basic Printer Mounting (printer only) The printer can only be mounted to the kiosk using the four printer mounting screw holes shown in the illustration below. The printer is most secure when using all four of the mounting positions connecting the printer’s base to a rigid metal base plate in the kiosk.
18 Printer Overview Basic Printer Mounting (printer only) Y X Z Figure 3-9 • Printer Mounting Table 3-6 • M3 Metric Mounting Screw Length M3 Screw X 1.5mm minimum Printer mounting surface Y 1.5mm Printer base plate thickness Z 2mm maximum Penetration into circuit board area X + Y = minimum length X + Y + Z = maximum length P1016701-001 Rev.
Printer Overview Design Your Own Mounting Design Your Own Mounting The illustration below gives an example of a printer-mounting shelf. m 1.5 m Leaf spring 01473-000 156 mm 132 mm 90.8 mm 12 mm 6.5 mm 10 mm Paper width + 10 mm Min. 100 mm 10 mm Center 10 mm 11 mm 10 mm 20 mm 44 mm Add material for corner radius Figure 3-10 • Printer Mounting Additional space is required for paper loading and service access.
20 Printer Overview Print Modes Print Modes The KR403 is a versatile printer and can print in several modes: Kiosk (the default horizontal with looping presenter or configurable vertical presenter mode), rewind (receipt only with no cut or kiosk mode features supported), and cutter (simple mode to support label media, many kiosk features are supported, except looping, retract and partial cut) modes.
Printer Overview Looping Presenter (Kiosk Mode) Looping Presenter (Kiosk Mode) The loop generating presenter mechanism has many benefits: Loop Print It handles documents of various lengths by storing the printed paper in a loop. Media In Print Cut It holds the printout until fully printed and cut before presenting the completed printout to the customer. This eliminates issues many other printers have when the kiosk client tries to remove media before printing has finished.
22 Printer Overview Vertical Presenter (Kiosk Mode) Vertical Presenter (Kiosk Mode) The vertical presenter operation has many benefits: Media In Print It handles documents of various lengths by storing the printed paper below the printer. It holds the printout until fully printed and cut before presenting the completed printout to the kiosk client. This eliminates print issues caused by kiosk clients trying to remove media before printing has finished.
Printer Overview Receipt (Page) Imaging Modes Receipt (Page) Imaging Modes The printer sets the following modes with programming commands or with the Windows driver. The KR403 printer uses ZPL ‘Page’ mode programming to assemble and print receipts. Page mode printing describes the receipt margins and the image to be placed between the margins and then printed. The image is assembled in the image (memory) buffer and then printed as one continuous print.
24 Printer Overview Controls, Indicators, and Sensors Controls, Indicators, and Sensors The KR403 printer has integrated controls, indicators, and sensors to enhance the usability of the printer for the client’s kiosk experience, the kiosk operator’s service and maintenance duties, and expand the developer’s ability to provide printing and service information to the host kiosk system. The controls, indicators and sensors include: • Media ‘Feed’ button with configuration and diagnostic functionality.
Printer Overview Sensing, Status and Error Reporting Status Indicator Immediately after power is applied to the printer, a brief self test is performed and the status light will report the status of the printer. Status conditions are reset and rechecked when: • The conditions causing them are removed • The printer has power removed and reapplied. • The printhead is opened or closed. Refer to Table 7-1, “Application LED States,” on page 87 for condition descriptions.
Printer Overview Sensing, Status and Error Reporting Table 3-9 • Error Flags (~HQES) Group 1 (X = Value can be any hexadecimal number [0-9, A-F]) Nibble8 Nibble7 Nibble6 Nibble5 Nibble4 Nibble3 Nibble2 Nibble1 Group 2 Nibbles16-9 26 No Error 0 00000000 0 0 0 0 0 0 0 0 Error Present 1 00000000 X X X X X X X X Printhead Thermistor Open 1 00000000 X X X X X 2 X X Invalid Firmware Config.
Printer Overview Sensing, Status and Error Reporting Table 3-10 • Warning Flags (~HQES) Group 1 (X = Value can be any hexadecimal number [0-9, A-F]) Nibbles16-9 Nibble8 Nibble7 Nibble6 Nibble5 Nibble4 Nibble3 Nibble2 Nibble1 Group 2 No Warning 0 00000000 0 0 0 0 0 0 0 0 Warning Present 1 Warning Flags Flag 00000000 X X X X X X X X Paper-near-end Sensorc 1 c 00000000 X X X X X X X 8c Replace Printhead 1 00000000 X X X X X X X 4 Clean Printhead 1 00
28 Printer Overview Feed Button Modes Feed Button Modes Ambient Light There is an optical sensor 20 mm behind the paper exit at the front of the printer. Other sensors can also be affected by internal lights (and bright outside light sources entering through seams, vents, etc.) in the kiosk.
Printer Overview Fonts and Your Printer • Zebra Designer — A receipt and label design program that works with the Windows printer driver to help you quickly develop receipt layouts, and manage fonts and objects (graphics, logos and receipt forms) during proof of concept process.
30 Printer Overview Fonts and Your Printer Identifying Fonts in Your Printer Fonts and memory are shared by the programming languages in the printer. Fonts can be loaded in many memory areas in the KR403 printer. ZPL programming can recognize EPL and ZPL fonts. See the respective programmer guides for more information on fonts and printer memory. • To manage and download fonts for ZPL print operation, use ZebraNet Bridge.
Printer Overview Fonts and Your Printer Getting Asian Fonts Asian font sets are downloaded into the printer by the user or integrator. The fonts are purchased separately from the printer. • Simplified and Traditional Chinese • Japanese — JIS and Shift-JIS mappings • Korean • Thai Stand Alone Printing Your KR403 printer can be configured to work without being attached to a computer. The printer has the ability to automatically run a single receipt form.
32 Printer Overview Fonts and Your Printer P1016701-001 Rev.
4 Connections Cabling and Cable Routing Always tie cable down, use locking connectors where possible, allow for kiosk component servicing, and avoid electrical noise sources. • Tie all cables to the kiosk chassis or printer mounting hardware that are near the printer, the media path or media. The operator can accidentally disconnect the printer or other kiosk components when maintaining the kiosk. Cabling must not interfere with the proper operation of the printer and media.
34 Connections Attaching Power Attaching Power Caution • Never operate the printer and power supply in an area where they can get wet. Serious personal injury could result! The KR403 printer has unique power requirements to operate efficiently, safely and within safety and compliance regulation guidelines. To achieve optimum performance, an approved power supply should be used to operate the KR403 printer. Refer to "Printer Power Supply – 808099-004" on page 76.
Connections Attaching Power DC Power Plug Requirement The KR403 printer uses a locking two pin connector. The mating connector is Tyco part number 1445022-2. The wiring for this connector and to meet the power requirements should be 20 AWG insulated wiring (UL type 1007). Ground +24 VDC Figure 4-12 • Power Plug Electrostatic Discharges and Earth Currents The printer should have a dedicated earth ground connection.
36 Connections Connecting the Printer to the Host Connecting the Printer to the Host The KR403 printer has a Universal Serial Bus (USB), an RS232 Serial port interface, and an Ethernet interface. Caution • Keep the kiosk OFF when attaching the interface cable. The power cord must be inserted into the power supply and the power receptacle on the back of the printer before connecting or disconnecting the communications cables.
Connections Connecting the Printer to the Host Refer to Figure 4-14. On the USB / Ethernet configuration , the USB connection is to the left of the ethernet connection. On the USB / Serial configuration , the USB connection is to the right of the serial connection. Figure 4-14 • USB Connection When using a USB cable (not supplied with your printer), verify that the cable or cable packaging bears the “Certified USB™” mark to guarantee USB 2.0 compliance.
38 Connections Connecting the Printer to the Host Serial Communications Refer to Figure 4-15. The required cable must have a nine-pin “D” type (DB-9P) male connector on one end, which is plugged into the mating (DB-9S) serial port located on the back of the printer . The other end of this signal interface cable connects to a serial port at the host computer. Depending on the specific interface requirements, this will most likely be a Null Modem (cross-over) cable.
Connections Connecting the Printer to the Host Serial communications between the printer and the host computer can be set by: • Autobaud synchronization • ZPL programming ^SC command • Resetting the printer to its default printer configuration. Autobaud Autobaud synchronization allows the printer to automatically match the communication parameters of the host computer. To Autobaud: 1. Press and hold the feed button until the green status LED flashes once, twice, and then three times. 2.
40 Connections Connecting the Printer to the Host Ethernet Interface Refer to Figure 4-16. The USB/Ethernet KR403 includes an RJ45 Ethernet connection resident on the main logic board . It is compatible with CAT5, CAT5e, and CAT6 cables. Cables are not supplied with the printer, the integrator should supply an 802.3 compliant cable.
Connections Connecting the Printer to the Host These operating systems automatically detect the printer when connected via the USB interface. The operating system automatically starts a “Add new hardware’ wizard when connecting the printer for the first time to the PC. Close the wizard. Install the printer following the wizard. The latest driver is found at www.zebra.com. Select the USB and then media size (closest match). Click on the ‘Print test page’ button to verify a successful installation.
42 Connections Connecting the Printer to the Host P1016701-001 Rev.
5 Media Designing Your Own Media Dispensing System Properly dispensing the media to the printer is critical to the operation of the printer and quality print. The media, roll or fan-fold, needs to flow smooth and free with minimal drag or binding. Ideally it should have a clean and cool location for dispensing and storing media. Loading or dispensing media to the printer should not have interference or access restrictions with the kiosk enclosure or internal components.
44 Media Designing Your Own Media Dispensing System • Minimal drag. Do not use wires, cables or bars as a roll holder - all of these cause the roll to stop and start and rock back and forth. Narrow radius roll supports case these behaviors to a lesser extent. Some media vendors use roll cores made of fiberboard that can have seams.
Media Basic Media Mounting Considerations Basic Media Mounting Considerations The KR403 printer has a few basic requirements for dispensing the media to the printer from a roll or fan-fold media. The KR403 printer exclusively uses direct thermal media and it is chemically treated to react to heat.
46 Media Basic Media Mounting Considerations Media Supply Method The KR403 printer supports two basic media supply method types: outside wound roll mount and stacked fan-fold receipt media. The media printing surface faces up towards the ‘top’ of the printer and away from the body of the printer. Top of Printer (Any Orientation) Printing Surface Printing Surface Figure 5-17 • Media Supply Media Input Aperture The KR403 printer has a wide aperture to support a wide range of media mounting locations.
Media Basic Media Mounting Considerations The direct media input (or angle of contact with media guides - not shown here) will change as the media is being consumed. Minimum Clearance Area for Printer Power and Cabling This area should have a continuous physical barrier separating the media and folds from binding in the cabling, printer body, kiosk chassis seams, etc. Figure 5-19 • Media Aperture 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
48 Media Basic Media Mounting Considerations Mounting Orientations The printer has two basic kiosk operation modes and orientations: Horizontal and Vertical. Horizontal Vertical Figure 5-20 • Mounting Orientations The maximum angle that the printer can operate from the nominal vertical or horizontal orientations is dependent upon environmental conditions and the media in use.
Media Basic Media Mounting Considerations The areas of primary concern are the horizontal operation’s ‘loop area’ and ‘waste bin’, and vertical operations ‘receipt presented storage’, ‘waste bin’ and open ‘loop area’ (with no loop). These two areas can require special attention when designing the inside of the kiosk. The printer needs the space to store the printed receipt before presenting it to the customer. The longer the receipt, the greater the area needed.
50 Media Media Guide - Required Accessory Media Guide - Required Accessory For the printer to operate correctly, at minimum you must order and install at least one of the four (4) media guides listed below. Figure 5-22 • Media Guide Width (mm) Part Number Width (mm) Part Number 58 09170-058-3 80 09170-080-3 60 09170-060-3 82.5 09170-082-3 A printer evaluation kit is available for the KR403 printer that includes all four media guides.
Media Media Guide - Required Accessory 3. Insert the media guide under the printhead. Insert the T-shaped tab of the media guide into the “T”-hole, slide it forward, and fasten the screw. The screw is pre-installed at the factory on the printer. One is included in the bag with the media guide in case the screw is damaged or lost. Many times, the installer will only need to loosen the attached screw. 4. Close the printhead. Push down on the push-bar to securely latch the printhead closed.
52 Media Media Guide - Required Accessory Determining Thermal Media Types The KR403 printer uses direct thermal media. Direct thermal media has a chemically treated print surface that uses heat to expose or darken the area where heat is applied. Thermal transfer media or ordinary un-treated paper requires ribbon or ink for printing while direct thermal media does not. To determine what type of media is being used and print surface of the media, perform a media scratch test: 1.
Media Black Mark Media Requirements Black Mark Media Requirements The printer is optimized to detect black marks printed with IR sensitive ink and ignore preprint in IR blind ink. For 80 and 82.
54 Media Preparing a Media Roll for Use Preparing a Media Roll for Use 1. Orient the roll as shown below. Temperature-sensitive coating 1 SW96074C Figure 5-24 • Paper Roll Orientation 2. Tear off a full turn of paper from the new roll. Caution • This is important since the outer end of the paper is usually fixed to the roll with some type of glue or self-adhesive substance that might otherwise cause paper jam or even print head damage.
Media Preparing a Media Roll for Use 3. The loading process works best with the cut as a square, straight edge. Cut the paper in a suitable angle. If the media is not cut square and the operator does not have the ability to cut or tear a straight edge, then the printer can fail to load the media or even cause a media jam. The media should not make contact with the platen roller before the sensor detects the media. The distance between the platen roller and media sensor is approximately 10 mm (0.
56 Media Automated Media Loading Automated Media Loading The printer is designed to detect media when it is inserted into the empty media input slot at the front of the printer. The printer begins turning the platen (drive) roller when the leading edge of the media passes over the media sensor. 1. Insert the paper through the paper entry opening at the front of the printer.
Media Manual Media Loading Manual Media Loading Manual media loading is intended for maintenance operations, such as printhead cleaning and removing media jams. Please use the Auto Load procedure (page 56) to load media for normal operations. 1. Open the printhead. 2. Insert the media through the front of the printer and under the open printhead. Pull the media just past the cutter and platen (drive) roller. 3. Close the printhead. Push down on the push-bar to securely latch the printhead closed. 4.
58 Media Clearing Paper Jams Clearing Paper Jams Should a paper jam occur, follow the procedure below: 1. Cut or tear the media off the front of the printer. 2. Open the printhead. 3. Remove and discard the damaged media. 4. Close the printhead and reload the media using the Auto Load media loading method (page 56). Figure 5-29 • Clearing Paper Jams P1016701-001 Rev.
Media Printing a Test Receipt Printing a Test Receipt Before you connect the printer to your computer, make sure that the printer is in proper working order. You can do this by printing a test (printer configuration) receipt. 1. Make sure the media is properly loaded and Ready with the printhead closed. Then, turn the printer power on if you have not already done so.
60 Media Printing a Test Receipt P1016701-001 Rev.
6 Accessories Accessories Overview The KR403 printer has a wide range of accessories designed and tested to work with your printer. The accessories can be used by themselves, combined with other printer accessories, or as part of your own unique printer integration design.
62 Accessories Accessories Overview P1016701-001 Rev. B • Media Roll Low Sensor — Optical sensor designed to mount into the Roll Support accessory or other KR403 printer mounting accessory and plug directly into the rear of the printer. • Universal Roll Holder — This versatile mounting accessory supports three roll positions with the ability to mount it on either side of the printer.
Accessories Nozzle Bezel – P1011185 Nozzle Bezel – P1011185 The nozzle bezel is used not only as a decorative accessory, but also serves to prevent customers from unknowingly inserting payment cards into the printer; which could cause damage to the printer and the customer’s payment card. The nozzle bezel is installed on the front of the printer (at the media exit) using two 2.5mm hex screws. The nozzle bezel kit comes with screws and 10 bezels per kit.
64 Accessories Nozzle Bezel – P1011185 Nozzle Bezel Mounting Dimensions P1016701-001 Rev.
Accessories Shutter Bezel – 104591 Shutter Bezel – 104591 Supports vertical mounting orientations only. Shutter Mounting Dimensions 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
66 Accessories Small Core Media Adapter – G105156 Small Core Media Adapter – G105156 The KR403 mounting becomes even more versatile if the Small Roll Media Roll Adapter accessory is used to guide the leading edge of receipt into the input of the media drive rollers. This allows the printer to be mounted in a wider range of mounting orientations shown below. The small core media roll adapter accessory is used to prevent the page curl that occurs at the end of a tightly wound media roll.
Accessories Quick-Fit Hubs – 103939 Quick-Fit Hubs – 103939 The quick-fit hubs are designed to use the printer’s mounting holes when mounted on a sheet metal surface 1.5 mm thick. See the "Design Your Own Mounting" on page 19 for more details. Quick Fit Leaf Spring Retainer – 01473-000 The leaf spring retainer is designed to be used as a locking mechanism when using the quick-fit hubs on a custom mounting surface. 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
68 Accessories Roll Support – P1014124 Roll Support – P1014124 The roll support bracket and mounting are designed (and tested) to mount to a sheet metal wall 1.5 mm thick for media rolls up to 250 mm O.D. (Outer Diameter) with media roll cores of 25.4 mm I.D. (Inner Diameter). The wider approved media roll widths (80 and 82.5 mm) align to the vertical centerline of the roll support bracket. The diagrams below show the how the narrower approved media roll widths are offset lower by 3.2 mm.
Accessories Media Roll Low Sensor Media Roll Low Sensor The media roll low sensor is available in two lengths: • 01890-300 – KIT PAPER-LOW SENSOR 300MM CBL • 01890-500 – KIT PAPER-LOW SENSOR 500MM CBL The sensor alerts the system when a fixed level of media is remaining on the roll. The media roll low sensor operates by reflecting a light against the white side of a media roll to detect it. When the media is low, no light is reflected.
70 Accessories Universal Roll Holder – P1014125 Universal Roll Holder – P1014125 This roll holder can be fitted on the right or left side of the printer. The arm can be set at three different angles. This makes make integration in the kiosk easy. • 58 mm, 60 mm, 80 mm, and 82.5 mm media widths can be used without adjustments. • The universal roll holder supports up to Ø200 mm rolls in the ‘high’ and ‘low’ arm positions, and Ø250 mm rolls in the ‘under’ position with clearance for cabling.
Accessories Universal Roll Holder – P1014125 ‘High’ Position (No Mounting Plate) Minimum Printhead Access Clearance Minimum Printhead Access Clearance Mounting Plate ‘Low’ Position with Mounting Plate 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
72 Accessories Universal Roll Holder – P1014125 ‘Under’ Position with Mounting Plate Minimum Printhead Access Clearance Mounting Plate P1016701-001 Rev.
Accessories Universal Roll Holder – P1014125 ‘High’ Position (No Mounting Plate) ‘Low’ Position with Mounting Plate Mounting Plate ‘Under’ Position with Mounting Plate For illustration purposes: — ‘High’ position - media is not shown — ‘High’ position - both roll supports are shown 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
74 Accessories Printer Mounting Plate – 104208 Printer Mounting Plate – 104208 The Printer Mounting Plate preforms several functions: P1016701-001 Rev. B • Provides a solid printer mounting base.
Accessories Wall Mount Roll Holder – P1014123 Wall Mount Roll Holder – P1014123 The Wall Mount Roll Holder attaches at the front face of the printer to the kiosk wall. It is designed to handle 150 mm diameter media rolls. 58 mm, 60 mm, 80 mm, and 82.5 mm media widths can be used without adjustments. Include the Quick-Fit printer release and mounting system. The service tech can pull the leaf spring (latch) to unlock the printer and quickly slide it out for easy replacement or service.
76 Accessories Printer Power Supply – 808099-004 Printer Power Supply – 808099-004 The KR403 power Supply accessory can easily be incorporated into a kiosk design. The power supply is easily attached to the kiosk with tie wraps. The power supply has been tested to work with the KR403 printer and complies with all of the same safety and compliance regulations. See "Attaching Power" on page 34 for a simple power connection illustration.
Accessories Printer Power Supply – 808099-004 Attaching the Power Supply 1. Make sure the printer’s power supply is turned off. Or if you are using the optional power supply accessory shown in the illustration below, make sure the power supply’s AC power cord is unplugged. Note the printer does not have an integrated power switch. 2. Insert the 24 VDC power supply’s power connector into the printer’s power receptacle.
78 Accessories Universal Serial Bus (USB) Cable – P1027715 Universal Serial Bus (USB) Cable – P1027715 The KR403 power USB Cable accessory can easily be incorporated into a kiosk design. The cable easily be attached to the kiosk with tie wraps. The USB cable has been tested to work with the KR403 printer and complies with all safety and compliance regulations. P1016701-001 Rev.
Accessories Large Media Roll Adapter – P1026858 Large Media Roll Adapter – P1026858 The large media roll adapter is used to prevent excessive pulling force on the printer feed motor when large roll (250mm (10 inch)) media is used. In some cases, when a large media roll is used, the feed motor may stall when slack has built up between the roll and the printer. Note • Make sure you have installed the correct media guide for the width of media selected before installing the adapter.
80 Accessories Large Media Roll Adapter – P1026858 Attaching to the Printer 1. Place the adapter on the printer at an angle as shown. 2. Rotate the adapter upwards as shown and install the screws (1). P1016701-001 Rev.
Accessories Large Media Roll Adapter – P1026858 Loading Media 1. Open the adapter tensioner assembly by pushing the locking tab . 2. Insert the media through the adapter and into the printer. For narrow media, the printer will load automatically. For wide media, manual media loading may be required (see "Manual Media Loading" on page 57). 3. Close and lock the adapter tensioner assembly. 9/24/2010 KR403 Hardware Integrator Guide P1016701-001 Rev.
82 Accessories Mounting Plate for Large Media Roll Adapter – P1027728 Mounting Plate for Large Media Roll Adapter – P1027728 When the large media roll adapter is used with the printer, the standard mounting plate cannot be used. Attaching to the Printer Attach the plate to the printer and the adapter using the screws as shown. P1016701-001 Rev.
Accessories Using other Accessories with the Large Media Roll Adapter Using other Accessories with the Large Media Roll Adapter Universal Roll Holder The universal roll holder (page 70) can be attached to either side of the large media roll adapter. Additionally, the media roll low sensor (page 69) can still be used in this configuration (see "Routing Cables with the Large Media Roll Adapter" on page 84). 1. Attach the mounting block screws . to the large media roll adapter as shown using the two 2.
84 Accessories Routing Cables with the Large Media Roll Adapter Routing Cables with the Large Media Roll Adapter Media Roll Low Sensor When the universal roll holder is attached to the large medial roll adapter, the 500mm media roll low sensor should be used (see "Media Roll Low Sensor" on page 69). Left Side Routing 1. Plug the media roll low sensor into the printer. 2. Secure the wiring to the tie-down point on the large media roll adapter using a plastic cable tie . 3.
Accessories Routing Cables with the Large Media Roll Adapter Right Side Routing 1. Plug the media roll low sensor into the printer. 2. Secure the wiring to the tie-down points on the large media roll adapter using plastic cable ties as shown. 3. Route the wiring under and to the outside of the universal roll holder and secure it using plastic cable ties. 4. Attach the sensor to the roll support using the screw.
86 Accessories Routing Cables with the Large Media Roll Adapter P1016701-001 Rev.
7 Troubleshooting Status Light Descriptions Application LED States Immediately after power is applied to the printer, a brief self test is performed and the status light will report the following conditions: Table 7-1 • Application LED States Solid Green One Red Flash Two Red Flashes 9/24/2010 0 - OK This code is reported when no other codes are active. It indicates the printer is functioning normally. 1 - Paper Jam in Presenter This code indicates that media is stuck in the presenter.
88 Troubleshooting Status Light Descriptions Table 7-1 • Application LED States Three Red Flashes Four Red Flashes Five Red Flashes Yellow Flashing Rapid Amber Flashing P1016701-001 Rev. B 3 - Out of Paper This code indicates that the selected EOP sensor has detected no media present. This value is signaled wither when the mark engine has detected a mark larger than "TOF marker length” plus 5mm, or when the A/D reading of the EOP sensor drops below the “End of paper threshold”.
Troubleshooting Status Light Descriptions Application User Interface With the printer power on, press and hold the feed button. Continue holding the feed button until the status indicator flash sequence occurs. The next flash sequence occurs after completion of the previous flash sequence. The flash sequences perform the following functions: Table 7-2 • Application User Interface Status Flash Sequence Action One Flash, then Solid Green Appears for one second. This will print an internal self-test page.
90 Troubleshooting Print Quality Problems Print Quality Problems No print on the label. • The media may not be direct thermal media, or the thermal media coating is not facing upward. "Determining Thermal Media Types" on page 52. • Is the media loaded correctly? Is the thermal media coating facing upward? "Determining Thermal Media Types" on page 52. • The printhead may be dirty or damaged. • The printhead is dirty. Clean the printhead. Refer to the Service Manual (P1026223) for instructions.
Troubleshooting Media Sensing Problems • The platen may need cleaning or replacement. Refer to the Service Manual (P1026223) for instructions. There are long tracks of missing print (blank vertical lines) on several labels. • The printhead may be dirty or damaged. • The printhead is dirty. Clean the printhead. Refer to the Service Manual (P1026223) for instructions. • The printhead is damaged. Replace the printhead. Refer to the Service Manual (P1026223) for instructions. • The printhead has worn out.
92 Troubleshooting Media Sensing Problems The printer will not load the media. • The media has changed, or a different media guide has been installed. • Make sure the appropriate media guide is installed for the media being used. Refer to "Media Guide - Required Accessory" on page 50. • Perform the two-flash procedure to recalibrate the printer. Refer to "Application User Interface" on page 89. Reload the media (refer to the Hardware Integrator Guide for media loading procedures).
Troubleshooting Other Problems • The presenter sensor is dirty. Refer to the Service Manual (P1026223) for instructions. • The presenter sensor may be damaged and need to be replaced. Refer to the Service Manual (P1026223) for instructions. • The presenter has not cleared the previous receipt. • Check the status light on either side of the printer. If the status light is showing one red flash then the printer is reporting media in the presenter. Remove any media that may be in the presenter.
94 Troubleshooting Resetting the Factory Default Values A receipt format was sent to, but not recognized by, the printer. • If the status LED is on or flashing, refer to Table 7-1 “Application LED States” on page 87. • Make sure the USB cable is correctly installed. Refer to "Connecting the Printer to the Host" on page 36. • A communications problem has occurred. Perform a USB detect (refer to the threeflash sequence of Table 7-2 “Application User Interface” on page 89).
