Zebra® KR403 Kiosk Receipt Printer Integrator Guide P1016701-001
© 2009 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; E 3® ; and Monotype Imaging fonts.
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv About This Document Who Should Use This Document Who Should Use This Document This Integrators Guide is intended for use by any person who needs to develop a kiosk using the KR403 printer, operate, or to troubleshoot problems with the printer. How This Document Is Organized The Integrators Guide is set up as follows: Topic Description of Content Introduction Identifies basic printer features, functions and information to assist you with your initial decision to select the printer for your kiosk.
About This Document Contacts Contacts Technical Support via the Internet is available 24 hours per day, 365 days per year. Web Site: www.zebra.com E-mail Back Technical Library: emb@zebra.com Subject line: Emaillist Self Service Knowledge Base: www.zebra.com/knowledgebase Online Case Registration: www.zebra.
vi 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. Command Line Examples Command line examples appear in Courier New font.
Contents 2 • About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii 3 • Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Controls, Indicators and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicator Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix 7 • Printer Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 KR403 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrostatic Discharges and Earth Currents . . . . . . . . . . . . . . . . . . 73 8 • Kiosk Hardware Integration Accessories . . . . . . . . . . . . . . . . . 75 Accessories Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Bezel . . . . . . . . . . . . . . . . . . . . . . . . .
x P1016701-001 KR403 Integrators Guide 12/23/2009
1 Introduction Contents KR403™ Thermal Kiosk Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 What’s in the Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Media Guide - Required Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Opening the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Introduction KR403™ Thermal Kiosk Printers KR403™ Thermal Kiosk Printers 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.
Introduction KR403™ Thermal Kiosk Printers • Zebra’s ZBI 2.0 (Zebra BASIC Interpreter) programming language. ZBI allows you to create custom printer operations and software language emulation. This integrators guide provides information you will need to install and operate your printer on a daily basis. To create receipt (label) formats, refer to your programming guides or receipt (label) design applications such as Zebra Designer.
4 Introduction What’s in the Box What’s in the Box 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. • Open and close the printer and remove any media or test prints in the printer.
Introduction What’s in the Box 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. Width (mm) Part Number Width (mm) Part Number 58 09170-058-2 80 09170-080-2 60 09170-060-2 82.5 09170-082-2 A printer evaluation kit is available for the KR403 printer that includes all four media guides.
6 Introduction Printer Orientation Printer Orientation Top of Printer Rear of Printer Media In Side of Printer Media Output 1 (See table below) Front of Printer Base Plate (bottom of printer) Media Output 2 (See table below) P1016701-001 Output Horizontal Mount Output Vertical Mount 1 Media Exit and Present 1 Media Retract and Retain (in kiosk) 2 Media Retract and Retain (in kiosk) 2 Media Exit and Present KR403 Integrators Guide 12/23/2009
Introduction Printer Features Printer Features Printhead Media Sensor (80-82.5mm) Printhead Release Push-Bar (Blackmark, Notch, and Media Out sensing) Cutter Bar Platen (drive) Roller Media Present Sensor Cutter (Hidden under roller assembly) (Inside Slot) Media Guide Status Indicator Power Indicator Media In Retract Sensor Feed Button Media Guide Not Shown Media Sensor (58-60mm) (Blackmark, Notch, and Media Out sensing) Wide Media Guide (80-82.
8 Introduction Printer Features Printer Features (continued) Media Feed Rollers Media Guide (required to operate, sold separately) Feed Button and Indicators (Hidden from view) Ext.
Introduction 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.
10 Introduction General Printing Information KR403 Media Types P1016701-001 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.
Introduction 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.
12 Introduction Basic Printer Dimensions Basic Printer Dimensions The mechanical drawing 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. 8 8.25* Media Exit 51 4.5 7.
Introduction Installing the Media Guide (Required Accessory) Installing the Media Guide (Required Accessory) The media guide configures the printer to one of four (4) common roll paper widths: 58, 60, 80, or 82.5 mm. The printer senses which media guide is installed and adjusts the default print width to match it automatically: narrow (58 or 60 mm) or wide (80 or 82.5 mm). The printer is delivered without a paper guide installed. Caution • Before proceeding, always disconnect the printer from power.
14 Introduction Installing the Media Guide (Required Accessory) 2. Select the media guide that matches the width of the media you want to use for your application. Loosen or remove the media guide screw, if present. Note • Media guides are ordered separately. Only Printer Evaluation kits contain all input guides available for the KR403. 3. Open the printhead by pushing green printhead release push-bar back towards the rear of the printer and lift up the printhead. 4.
2 Printer Overview Contents Print Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Looping Presenter (Kiosk Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Presenter (Kiosk Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receipt (Page) Imaging Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Media Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . Media Supply Method . .
16 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 • It handles documents of various lengths by storing the printed paper in a loop. Print 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.
18 Printer Overview Vertical Presenter (Kiosk Mode) Vertical Presenter (Kiosk Mode) The vertical presenter operation has many benefits: • 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.
20 Printer Overview 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.
Printer Overview Basic Media Mounting Considerations Media Input Aperture The KR403 printer has a wide aperture to support a wide range of media mounting locations. The media can enter the printer directly or indirectly with the addition of custom media guides or printer roll or mounting accessory kits.
22 Printer Overview Basic Media Mounting Considerations Mounting Orientations The printer has two basic kiosk operation modes and orientations: Horizontal and Vertical. Horizontal Vertical 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.
Printer Overview 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.
24 Printer Overview Basic Media Mounting Considerations Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __
3 Controls Contents Controls, Indicators and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicator Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensing, Status and Error Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Button Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 Controls Controls, Indicators and Sensors Controls, Indicators and Sensors The KR403 printer has a variety of 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.
Controls Controls, Indicators and Sensors Feed Button The Blue Feed button has several functions: • Press and Release will feed media, cut, and present a complete receipt page in the default kiosk mode. All the other integrator set modes and variations of the kiosk mode will at minimum, feed a page length of media when the Feed button is pressed and released. • Any data in the print buffer will be printed. If the buffer is empty the page will be blank.
28 Controls Sensing, Status and Error Reporting Status conditions are reset and rechecked when: 1. When the conditions causing them are removed 2. When the printer has power removed and reapplied. 3. When the printhead is opened or closed. Sensing, Status and Error Reporting The KR403 has an extensive array of sensing and error reporting capability available to the printer for internal process control, status reporting to the host and custom printer software development by the software integrator.
Controls Sensing, Status and Error Reporting a3a Error Flags (~HQES) Error Flags Flag Group 2 Group 1 (X = Value can be any hexadecimal number [0-9, A-F]) Nibbles16-9 Nibble8 Nibble7 Nibble6 Nibble5 Nibble4 Nibble3 Nibble2 Nibble1 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.
30 Controls Sensing, Status and Error Reporting Warning Flags (~HQES) Warning Flags Flag No Warning 0 Group 2 Group 1 (X = Value can be any hexadecimal number [0-9, A-F]) Nibbles16-9 Nibble8 Nibble7 Nibble6 Nibble5 Nibble4 Nibble3 Nibble2 Nibble1 00000000 0 0 0 0 0 0 0 0 Warning Present 1 00000000 X X X X X X X X Paper-near-end Sensor c 1c 00000000 X X X X X X X 8c Replace Printhead 1 00000000 X X X X X X X 4 Clean Printhead 1 00000000 X X X
Controls Feed Button Modes Feed Button Modes Power Off Mode (Communications Diagnostics Mode) With the printer power off, press and hold the Feed button while you turn on the power. The status light will be Amber. After approximately one (1) second, the printer will begin a series of flash sequences described below. Status Flash Sequence 12/23/2009 Action Rapid Amber Flashing Firmware Download Mode - The printer starts rapidly flashing red to denote entry into the Firmware Download mode.
32 Controls Feed Button Modes Power On Modes With the printer power on and top cover closed, press and hold the Feed button for several seconds. The green status light will flash a number of times in sequence. The explanation at the right (Action) shows what happens when you release the key after the start specific number of flashes and before the next flash sequence starts. For flash sequences 4-7, the status light will flash 3-4 times before pausing and starting the next flash sequence.
4 Operation Contents Basic Printer Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attaching Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Printer Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining Thermal Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing a Media Roll for Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 Operation Basic Printer Operation Overview Basic Printer Operation Overview To assist the kiosk operator in maintaining and supporting the KR403 printer when deployed and in use, this section has media handling instructions, tips and tricks that include: P1016701-001 • Applying Power and Manual Reset • Identifying direct thermal media • Preparing the media for use • Loading media • Printing a test receipt (configuration status label) • Clearing media jams • Cleaning the printhead • Att
Operation 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! 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.
36 Operation Attaching Power Manual Printer Reset The KR403 printer does not have a power switch or reset button. To manually reset the printer, disconnect the 24 VDC power from the printer. Wait a few seconds for the Power LED to turn off and reconnect the power plug. The printer will take around a 25 seconds to reboot and initialize. The printer can also be reset with the ZPL ~JR command when sent by the kiosk application.
Operation Preparing a Media Roll for Use Preparing a Media Roll for Use 1. Turn the new paper roll as shown below. Paper Roll Orientation Temperature-sensitive coating 1 2. Tear off a full turn of the paper from the new paper 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.
38 Operation 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.
Operation 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 rear 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 back of the printer.
40 Operation 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 to load media for normal operations. 1. Open the printhead by pushing green printhead push-bar back towards the rear of the printer and lift up the printhead. 2. Insert the media through the rear of the printer and under the open printhead. Pull the media just past the cutter and platen (drive) roller.
Operation Clearing Paper Jams Clearing Paper Jams Should a paper jam occur, follow the procedure below: 1. Cut or tear the media off the back of the printer. Pull the media up towards the top of the printer and side to use the rear of the printhead door as a tear bar/straight edge. This is to use the Auto Load media loading method after clearing the jam. 2. Open the printhead by pressing the green release lever toward the rear of the printer and swing the printhead up to access the media path. 3.
42 Operation Cleaning the Printhead Cleaning the Printhead The KR403 kiosk receipt printer needs be cleaned periodically to maintain optimal print quality and maximize printhead life. Even in the cleanest environments, the printhead will get contaminates and build-up on the printhead’s pixel heating elements. These contaminates may include: dust, body oils (acids), paper or media fibers, airborne chemicals, etc. Contaminates shorten the printhead's usable life.
Operation Cleaning the Printhead 12/23/2009 KR403 Integrators Guide P1016701-001 43
44 Operation Printing a Test (Printer Configuration) Receipt Printing a Test (Printer Configuration) 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 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.
Operation Connecting the Printer to the Host Connecting the Printer to the Host The KR403 printer has a Universal Serial Bus (USB) and a RS232 Serial port 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. Important • This printer complies with FCC “Rules and Regulations,” Part 15, for Class B .
46 Operation Connecting the Printer to the Host USB Interface Requirements Universal Serial Bus (version 2.0 compliant) provides a fast interface that is compatible with your existing PC hardware. USB’s “plug and play” design makes installation easy. Multiple printers can share a single USB port/hub. When using a USB cable (not supplied with your printer), verify that the cable or cable packaging bears the “Certified USB™” mark (see below) to guarantee USB 2.0 compliance. .
Operation Connecting the Printer to the Host Serial Communications 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.
48 Operation Connecting the Printer to the Host Resetting the Default Serial Port Parameters Do the following to reset the communications parameters on the printer to the factory defaults (serial communication settings are: 115k baud, 8 bit word length, NO parity, 1 stop bit, and XON/XOFF data flow control). 1. Press and hold the feed button until the green status LED flashes once, waits a moment and flashes twice, and then waits again before flashing three times (release immediately). 2.
Operation Connecting the Printer to the Host Communicating with the Printer The easiest way to begin using your complete kiosk printing solution is to utilize the Zebra Designer Windows Driver in PC based systems. With the driver loaded; you can test the kiosk printing system, configure your printer, send programming commands, use Windows applications to print directly to the printer, and download files (fonts, graphics, logos, update firmware, etc.).
50 Operation Connecting the Printer to the Host Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________
5 Printer Configuration Contents Printer Configuration Methods and Tools . . . . . . . . . . . . . . . . . . . . . . . Fonts and Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifying Fonts in Your Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Localizing the Printer with Code Pages . . . . . . . . . . . . . . . . . . . . . . . . Asian fonts and Other Large Font Sets. . . . . . . . . . . . . . . . . . . . . . . . . Getting Asian Fonts . . . .
52 Printer Configuration Printer Configuration Methods and Tools Printer Configuration Methods and Tools The KR403 printer has a variety of printer configuration methods for the software and hardware integrator. Each is designed to assist you with various kiosk design and integration tasks. These integration tasks include printer startup, proof of concept, receipt design, status reporting, multi-printer configuration, and kiosk application design.
Printer Configuration Fonts and Your Printer Fonts and Your Printer The KR403 printer supports your language and font requirements with a variety of internal fonts, on-board font scaling, international font sets and character code page support, Unicode support, and font download. The KR403 printer’s font capabilities are programming language dependent.
54 Printer Configuration Fonts and Your Printer Asian fonts and Other Large Font Sets Asian language pictographic fonts have large character sets with thousands of characters that support single language code page. In order to support the large Asian character sets, the industry adopted a double-byte (67840 maximum) character system instead of the single-byte characters (256 maximum) used by Latin based language characters to address large font sets.
6 Printer Maintenance Contents KR403 Printer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust Removal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Site Service Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 Printer Maintenance KR403 Printer Maintenance KR403 Printer Maintenance There are three types of printer servicing: Operator, Service Technician (on site) and Service Depot level servicing. • Operator — Can do simple maintenance procedures that do not require the printer to be disconnected or removed from the kiosk, and do not (potentially) change the printer configuration setting in the kiosk.
Printer Maintenance Operator Maintenance Use a can of compressed air to remove dust and particle build-up from the printer. 1. Spray the dust off the outside of the printer. 2. If you have access to the media output slot on the bottom of the printer, then spray the Waste Bin sensor and through out the media output slot. Waste Bin (media) Sensor Me dia S ut tp Ou lot 3. Open the printhead and remove the media guide plate (see Installing the Media Guide (Required Accessory) on page 13). 4.
58 Printer Maintenance Operator Maintenance 6. Spray the Present and In Retract media sensors under the present and feed roller assemblies.
Printer Maintenance On-Site Service Cleaning On-Site Service Cleaning The KR403 printer may require a periodic deep cleaning to remove accumulated debris that can build-up on the media path, sensors and rollers. Normally this type of cleaning will rarely need to be done if the operator does the Dust Removal Cleaning regularly. Labels and some non Zebra media can increase the need for cleaning. Labels can slowly transfer adhesive from the edges of the label to the media path (and printhead).
60 Printer Maintenance On-Site Service Cleaning 3. Remove the Retract/Dispense Roller Assembly. Pinch the assembly at each end (next to the printer’s side plates) and lift it out of the printer. Rotate and clean the rollers, and the rest of the assembly. Set the assembly aside. 4. Open the printhead if it is closed.
Printer Maintenance On-Site Service Cleaning 5. Clean all the all of the feed and drive rollers with a fiber-free swab (such as a Texpad swab) lightly moistened with medical grade alcohol (90% pure or better). Rotate the rollers with your fingers to expose all of the roller’s surface. Slide a swab into the media retract slot and clean the spring 6. Clean all the sensors with a fiber-free swab (such as a Cleaning swabs - p/n 105909-057) lightly moistened with medical grade alcohol (90% pure or better).
62 Printer Maintenance Replacing the Printhead Replacing the Printhead The KR403 printer has a new adjustment free printhead. You only need a #1 Phillips screwdriver. No alignment or printing special test patterns. Caution • Prepare your work area by protecting against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Caution • The printhead becomes hot while printing.
Printer Maintenance Replacing the Printhead 2. Open the printhead. The printhead is now loose. Disconnect the printhead cable by gently and firmly pulling the cable connectors straight out of the printhead. Printhead (Cables not shown) 3. Put the new printhead in position and connect the cables to the printhead. The connectors are keyed and will only insert one way. Do not force the connectors. 4. Re-attach the printhead to the printhead assembly with the screws.
64 Printer Maintenance Replacing the Platen Roller Replacing the Platen Roller The platen (drive) roller requires no tools to replace. 1. Open the printhead to gain access to the platen roller. 2. Pinch the top sides of the ‘U’ shaped (shown as red in the illustration below) black plastic platen bearings on each side of the printer. Lift the bearings, platen roller, and printline tab bracket (aligns printhead and platen roller position).
Printer Maintenance Replacing the Platen Roller 3. Slide the two new platen bearings onto each end of the new platen roller’s shaft. Align the printline tab bracket to the platen roller and slide them both into the side plate of the printer. Align the printline tab bracket into the long narrow rectangular slot next to the platen bearing’s ‘U’ shaped slots and push the bearings into both sides until they snap and lock into place.
66 Printer Maintenance Replacing the Cutter Blades Replacing the Cutter Blades Cutter service for the KR403 printer consists of blade replacement only at this time. It does not have a recommended on-site cleaning procedure. You only need a #8 Torx screwdriver to do this procedure. The cutter has a fixed blade (attached to the printhead) and a ‘V’ notch blade. Caution • Prepare your work area by protecting against static discharge.
Printer Maintenance Replacing the Cutter Blades 2. Open the printhead. Loosen the four screws securing the cover plate assembly to the printer. lift the plate out of the printer. #8 Torx Screws (both sides) 3. Rotate the cutter gears with your finger until the cutter blade has reached its highest position and lift the cutter blade out of the printer. See the following instruction step.
68 Printer Maintenance Replacing the Cutter Blades 4. Slide a new cutter blade into the cutter arm’s slot. The cutter blade’s long tab inserts into a slot in the main PCBA below the cutter. Push the blade into the Printline Tab bracket and rotate the cutter gears until the pin is in the lowest position. The cutter should be locked in place. Cutter Arm’s Slot Cutter Gear (note pin position) 5. Replace the cover plate assembly. Hold the plate down while tightening the four #8 Torq screws. 6.
Printer Maintenance Replacing the Cutter Blades 7. Fixed Blade Replacement: Loosely attach the two #8 Torq screws to the to the fixed blade. Turn the screws until they are even with the back side of the blade’s backside 8. With the printhead open half way, pinch the printhead. Hold the springs compressed while loosening the two screws securing the fixed blade to the printhead assembly. Slide the blade out slowly to avoid pulling the push bar‘s spring off. Pinch Screw Screw Spring 9.
70 Printer Maintenance Replacing the Cutter Blades Fixed Blade Mounting Slot 10. Slide the fixed blade with the loose screws onto the printhead assembly on the side away from the screwdriver. Fixed Blade Center Tab 11. Swing the other side into its mounting slot. The center tab on the fixed blade goes under the spring (and screw driver blade). Remove the blade and verify that the spring is straight and sitting 100% on top of the center tab. 12.
7 Printer Power Requirements Contents KR403 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrostatic Discharges and Earth Currents . . . . . . . . . . . . . . . . . . . . 73 DC Power Plug Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72 Printer Power Requirements KR403 Power Requirements KR403 Power Requirements The KR403 printer has some unique power requirements to operate efficiently, safely and within safety and compliance regulation guidelines. To get the best performance, one should use an approved power supply to operate the KR403 printer. See the price list for an approved power supply. If a non-Zebra supplied power supply is used with the KR403, it must comply with the following requirements.
Printer Power Requirements KR403 Power Requirements Electrostatic Discharges and Earth Currents Your power supply should have a earth ground connection as part of the input power and power circuit design. Preventing ESD and earth currents from affecting the printer operation requires proper connection of the printer chassis to protective earth through a mounting platform or through a separate earth conductor. DC Power Plug Requirement The KR403 printer uses a locking two pin connector.
74 Printer Power Requirements KR403 Power Requirements Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___
8 Kiosk Hardware Integration Accessories Contents Accessories Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Bezel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutter Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick-Fit Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Fit Leaf Spring Retainer . . . . . . . . . . . . . . .
76 Kiosk Hardware Integration Accessories Accessories Overview 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.
Kiosk Hardware Integration Accessories Nozzle Bezel Nozzle Bezel Horizontal Mounting Orientation Media Exit Vertical Mounting Orientation Media Exit 12/23/2009 KR403 Integrators Guide P1016701-001 77
78 Kiosk Hardware Integration Accessories Nozzle Bezel Nozzle Bezel Kiosk Mounting Dimensions Horizontal Mounting Orientation Vertical Mounting Orientation P1016701-001 KR403 Integrators Guide 12/23/2009
Kiosk Hardware Integration Accessories Shutter Bezel Shutter Bezel Supports vertical mounting orientations only.
80 Kiosk Hardware Integration Accessories Quick-Fit Hubs Quick-Fit Hubs 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 103 for more details.
Kiosk Hardware Integration Accessories Roll Support Roll Support 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.
82 Kiosk Hardware Integration Accessories Media Roll Low Sensor Media Roll Low Sensor The sensor alerts the system when a fixed level of media is remaining on the roll to provide an early warning for operator servicing. The early alert allows you to replace the paper roll in a timely manner in remotely located or critical use kiosks. All paper roll holders supplied by Zebra can be equipped with paper-low sensors. Just install it, and connect the cable to the paper low connector at the back of the printer.
Kiosk Hardware Integration Accessories Universal Roll Holder Universal Roll Holder 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.
84 Kiosk Hardware Integration Accessories Universal Roll Holder ‘High’ Position (No Mounting Plate) Minimum Printhead Access Clearance Minimum Printhead Access Clearance Mounting Plate ‘Low’ Position with Mounting Plate P1016701-001 KR403 Integrators Guide 12/23/2009
Kiosk Hardware Integration Accessories Universal Roll Holder ‘Under’ Position with Mounting Plate Minimum Printhead Access Clearance Mounting Plate 12/23/2009 KR403 Integrators Guide P1016701-001 85
86 Kiosk Hardware Integration Accessories Universal Roll Holder ‘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 P1016701-001 KR403 Integrators Guide 12/23/2009
Kiosk Hardware Integration Accessories Printer Mounting Plate Printer Mounting Plate The Printer Mounting Plate preforms several functions: 12/23/2009 • Provides a solid printer mounting base.
88 Kiosk Hardware Integration Accessories Wall Mount Roll Holder Wall Mount Roll Holder 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.
Kiosk Hardware Integration Accessories Printer Power Supply Printer Power Supply 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 35 for a simple power connection illustration.
90 Kiosk Hardware Integration Accessories Printer Power Supply Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ______________________________________________________________________
9 Troubleshooting This section provides information about printer error reporting that you might need for printer troubleshooting. Assorted diagnostic tests are included. Contents Status Light Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Light Error Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92 Troubleshooting Status Light Descriptions Status Light Descriptions What the Status Light is Telling You LED Status and Color Printer Status For a Resolution, Refer to Number: Off Off 1 Solid Green On 2 Solid Amber Stopped 3 Flashing Green Normal Operation 4 Flashing Red Stopped 5 Double Flashing Green Paused 6 Flashing Amber Paused 7 Alternately Flashing Green and Red Needs Service 8 Flashing Red, Red and Green Needs Service 9 Flashing Red, Amber Green (* - Do NOT reset o
Troubleshooting Status Light Error Resolutions 3. The printer has failed its power on self test (POST). • If this error occurs right after you turn on the printer, contact an authorized reseller for assistance. When the printer is operating normally, the printer status light will be amber for about 30 seconds before turning green (solid or blinking). There is a memory error. • If this error occurs after you have been printing, turn the printer power off and on, and then resume printing.
94 Troubleshooting Print Quality Problems 10. The printer is defragmenting memory. Caution • Do NOT turn off the printer power during defragmentation. Doing so can damage the printer. • Defragmentation is a normal operation of the printer – necessary to manage the memory space for optimal use. The printer will defragment its memory both after a factory default and when the printer detects that a defragment is required. When the printer is in this condition, allow it to finish defragmenting.
Troubleshooting Print Quality Problems • The rubbery smooth surface has become polished and slippery, There are long tracks of missing print (blank vertical lines) on several labels. • The printhead is dirty. Clean the printhead. • The printhead elements are damaged. The printing does not start at the top of the receipt or misprinting of one to three receipts. • The printer needs to be calibrated. Refer to the two-flash sequence of Feed Button Modes on page 31 in this section.
96 Troubleshooting Manual Calibration Manual Calibration Manual calibration is recommended whenever you are using pre-printed media or if the printer will not correctly auto calibrate. 1. Make sure media is loaded. 2. Turn on the printer power. 3. Press and hold the Feed button until the green status light flashes once, then twice and then continuing until the flash groups reach the group of seven flashes. Release the Feed button. 4.
Troubleshooting Troubleshooting Tests Troubleshooting Tests Printing a Configuration Label To print out a listing of the printer’s current configuration, refer to the one-flash sequence in Feed Button Modes on page 31 in this section Recalibration Recalibrate the printer if it starts to display unusual symptoms, such as skipping receipts. Refer to the two-flash sequence in Feed Button Modes on page 31 in this section.
98 Troubleshooting Resetting the Factory Default Values Resetting the Factory Default Values Sometimes, resetting the printer to the factory defaults may solve some problems. Refer to the four-flash sequence in Feed Button Modes on page 31 in this section. Communications Diagnostics If there is a problem transferring data between the computer and printer, try putting the printer in the communications diagnostics mode.
Troubleshooting Communications Diagnostics The following example of a communications DUMP mode printed out. The printout displays hexadecimal data 00h-FFh (0-255 decimal) with a unique character for each hexadecimal value displayed above the hexadecimal data. The blank lines between the lines of data are where serial port and Bluetooth data handling errors get logged.
100 Troubleshooting Communications Diagnostics Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___________
10 Kiosk Design Considerations Contents Design Considerations Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Your Own Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabling and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrostatic Discharges and Earth Currents . . . . . . . . . . . . . . . . . . . Ambient Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . .
102 Kiosk Design Considerations Design Considerations Overview Design Considerations Overview The kiosk designer needs to consider how the printer is being used, operated (media supply and maintenance), service, integration with other kiosk components, and integration into the enclosure itself. The KR-403 printer needs some basic design elements to function properly, safely, and easily for the operator.
Kiosk Design Considerations Design Your Own Mounting Design Your Own Mounting The illustration below gives an example of a printer-mounting shelf. Example of a Simple Shelf For Fastening a Standard Printer Using Quick-fit Hubs and a Leaf Spring Retainer mm 1 .5 Leaf spring 01473-000 156 mm 132 mm 90.8 mm 12 mm 6.5 mm 10 mm Paper width + 10 mm Min.
104 Kiosk Design Considerations Design Your Own Mounting 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.
Kiosk Design Considerations Designing Your Own Media Dispensing System 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.
106 Kiosk Design Considerations Designing Your Own Media Dispensing System Designing for Fan-Fold Media Fan-fold media creates unique challenges. It has square edges that can get caught and the stack can fall into other components and cabling. Make a tray to hold the fan-fold media unless it is being pulled straight up. Always test and observe with the actual media. Fan-fold media can un-fold erratically and act differently at the beginning and end of the stack.
A Appendix This section provides printer interface connection information. Contents Universal Serial Bus (Mini-USB) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Serial Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 Appendix Universal Serial Bus (Mini-USB) Interface Universal Serial Bus (Mini-USB) Interface The figure below displays the cable wiring required to use the printer’s USB interface. The printer requires cable or cable packaging that bears the “Certified USB™” mark to guarantee USB 2.0 compliance.
Appendix Serial Port Interface Serial Port Interface Pin 1 2 3 4 5 6 7 8 9 Description Not used RXD (receive data) input to the printer TXD (transmit data) output from the printer DTR (data terminal ready) output from the printer -- controls when the host may send data Chassis ground DSR (data set ready) input to the printer RTS (request to send) output from the printer -- always in the ACTIVE condition when the printer is turned on CTS (clear to send) - Not used by the printer Not Used When XON/XOFF han
110 Appendix Serial Port Interface Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________________
