Professional Documents
Culture Documents
Users
Guide
1
Proprietary Statement
Product Improvements
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that the interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the following
measures:
n Reorient or relocate the receiving antenna.
n Increase the separation between the equipment and the receiver.
n Connect the equipment into an outlet on a circuit different than that to which the receiver is
connected.
n Consult the dealer or an experienced Radio/TV technician for help.
NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded
cables must be used with the unit to insure compliance.
The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies Corporation could void the users authority to operate the equipment.
NOTE:
This digital apparatus does not exceed the Class A limits for radio noise emissions from
digital apparatus as set out in the radio interference regulations of the Canadian
Department of Communications.
Liability Disclaimer
Zebra Technologies Corporation takes steps to assure that its published Engineering
specifications and Manuals are correct; however, errors do occur. Zebra Technologies
Corporation reserves the right to correct any such errors and disclaims liability resulting
therefrom.
In no event shall Zebra Technologies corporation or anyone else involved in the creation,
production, or delivery of the accompanying product (including hardware and software) be
liable for any damages whatsoever (including, without limitation, damages for loss of
business profits, business interruption, loss of business information, or other pecuniary
loss) arising out of the use of or the results of use of or inability to use such product, even
if Zebra Technologies Corporation has been advised of the possibility of such damages.
Because some states do not allow the exclusion or limitation of liability for consequential
or incidental damages, the above limitation may not apply to you.
Copyrights
This copyrighted manual and the label printer described herein are owned by Zebra
Technologies Corporation. All rights are reserved. Unauthorized reproduction of this
manual or the software in the label 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.
All products and brand names are trademarks of their respective companies. All rights
reserved.
1998 Zebra Technologies Corporation
Stripe Series
S400 and S600
manufactured by:
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061-3109 U.S.A.
have been shown to comply with the applicable technical standards of the FCC
Contents
Introduction
Unpacking . . . . . . .
Reporting Damage. . .
Site Requirements . . .
Introduction to Printers
Tear-Off Mode . . .
Peel-Off Mode . . .
Cutter Mode . . . . .
Printer Overview . . .
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1
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18
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20
20
20
Cleaning . . . . . . . . . . . . . . . . . . . .
Cleaning the Exterior . . . . . . . . . . . .
Cleaning the Interior . . . . . . . . . . . . .
Cleaning the Printhead and Platen Roller . .
Cleaning the Cutter Module . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . .
AC Power Fuse Replacement . . . . . . . . .
Mechanical Adjustments . . . . . . . . . . . .
Print Quality Adjustments . . . . . . . . . .
Toggle Pressure Adjustment. . . . . . . . .
Media Rest Position Adjustment . . . . . .
Top of the Label Position Adjustment. . . .
Media Sensor Position Adjustment . . . . .
Ribbon Supply Spindle Adjustment . . . . .
Backing Rewind Power Roller Adjustment .
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21
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37
43
45
46
Troubleshooting
Troubleshooting Table . . . .
Printer Status Sensors . . . .
Manual Calibration. . . . . .
Resetting Printer Parameters .
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46
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51
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53
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59
59
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61
62
Specifications
General Specifications . . . . . . . . . .
Printing Specifications . . . . . . . . . .
Ribbon Specifications . . . . . . . . . .
Media Specifications . . . . . . . . . . .
Media Handling . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . .
Zebra Programming Language (ZPL II)
Bar Codes . . . . . . . . . . . . . . . .
Standard Printer Fonts . . . . . . . . . .
Optional Printer Fonts . . . . . . . . . .
Appendix
Glossary
Index
iv
Introduction
Congratulations! You have just purchased a high-quality thermal label
printer manufactured by the industry leader in quality, service, and value.
For over 25 years, Zebra Technologies Corporation has provided customers
with the highest caliber of products and support.
n This user's guide provides all the information you will need to operate
Unpacking
Save the carton and all packing materials in case reshipping is required.
Inspect the printer for possible shipping damage.
Reporting Damage
If you discover shipping damage:
n Immediately notify and file a damage report with the shipping company.
Zebra Technologies Corporation is not responsible for any damage
incurred during shipment of the printer and will not cover the repair of
this damage under its warranty policy.
n Keep the carton and all packing material for inspection.
n Notify your authorized Zebra distributor.
For storage and reshipping information, refer to the Appendix.
Site Requirements
CAUTION: To insure that the printer has proper ventilation and cooling,
do not place any padding or cushioning material under the unit, because
this restricts air flow.
This printer may be installed on any solid, level surface of sufficient size
and strength to accommodate the physical dimensions and weight of the
unit. The area enclosure in which the printer will operate must meet the
environmental conditions specified. Electrical power must be available and in
close proximity to the printer.
Since this printer was designed and is fabricated as an industrial-type unit, it
will function satisfactorily in areas such as warehouses, factory floors, and
office environments that conform to specified environmental and electrical
conditions.
Introduction to Printers
The first thing you want to do is identify your printer. This makes certain
tasks -- such as media loading -- much easier to do!
If your printer
looks like this
(Figure 1), it is
set up for
Tear-Off mode.
Tear-Off allows
you to tear away
each label, or a
strip of labels,
after it is
printed.
To load media,
refer to
Loading the
Media -Tear-Off Mode
in Getting Ready
to Print.
Figure 1
10
This printer
(Figure 2)
operates in
Peel-Off mode.
In Peel-Off,
backing material
is peeled away
from the label as
it is printed.
After this label is
removed from the
printer, the next
one is printed.
Backing
Rewind Spindle
To load media,
refer to Loading
the Media -Peel-Off Mode
in Getting Ready
to Print.
Figure 2
Cutter
Module
To load the
media, refer to
Loading the
Media -- Cutter
Mode in Getting
Ready to Print.
Figure 3
11
18
17
11
2
16
14
13
12
15
10
9
8
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Figure 4
12
Control Panel
Platen Roller
AC Power Cable Connection
Parallel Interface
Serial Interface
Fuse
Power On/Off Switch
Head Open Lever
Pressure Toggles
AC
POWER
CONNECTOR
3 CONDUCTOR
CABLE
Figure 5
13
NEUTRAL
LIVE
EARTH
RS-232
(Serial)
Interface
Power
On/Off
Switch
Parallel
Interface
AC Power Cable
Connection
Figure 6
14
Fuse
a
d
e
c
Figure 7
15
4. Adjust the media supply guide and the media guide against the outer
edge of the media. These guides must not cause pressure or excessive
drag on the media.
5. Close the head open lever, and see Adjusting the Media Sensor later in
this chapter to adjust the media sensor position.
For loading fanfold media:
6. Refer to Figure 8. Make sure the fanfold media feeds through either the
bottom (e) or rear (f) access slot.
NOTE: When utilizing the bottom access slot, be sure to thread media over
the media supply hanger.
7. Thread the media through the printhead as shown in Figure 8.
8. Adjust the media supply guide and the media guide against the outer
edge of the media. These guides must not cause pressure or excessive
drag on the media.
9. Close the head open lever, and see Adjusting the Media Sensor later in
this chapter to adjust the media sensor position.
Figure 8
16
h
f
j
a
g
b
d
Figure 9
17
10
8. To hold the media against the spindle, place the hold down hook over
the backing and insert both ends into the small slots in the round plate at
the far end of the spindle. Again, rotate the backing rewind spindle
counterclockwise to remove any slack in the backing material.
9. Adjust all of the guides:
n Push the media supply guide inward until it is just touching the outer
side of the media supply roll, then lock the guide in place with its
locking screw. The guide must not cause pressure or excessive drag on
the media supply roll.
n Adjust the outer edge guides on both the lower guide rod and the platen
guide rod until they just touch the outer edge of the media and backing
without causing the material to buckle.
n Adjust the media guide until it just touches the outer edge of the media
quired)
When the amount of backing wound on the backing rewind spindle reaches
full capacity, the backing rewind spindle full sensor activates, the
paper/ribbon light flashes, and printing pauses.
To remove the backing material, follow these steps (you dont need to
power off the printer for this procedure):
1. Unwind about 24" of backing from the backing rewind spindle and cut it
off at the spindle.
2. Pull out the hold down hook and slide the backing material off of the
spindle and discard.
3. Feed the new starting edge of the backing through the mechanism and
attach it to the backing rewind spindle as described in the loading procedure.
NOTE: While holding the media in position against the tear-off/peel-off
plate, open and close the printhead without disturbing the media position.
The printer is now ready to print more labels.
18
Figure 10
19
11
12
Normal Position
a
Low-Tension Position
a
Figure 11
20
smooth backing of the ribbon protects the printhead from wear and
premature failure due to excessive abrasion. (For the direct thermal
print method, ribbon is not used and should not be loaded in the
printer.)
n Zebra recommends the use of ribbon that is outside wound (the ink side
21
13
14
Ribbon Removal
Refer to Figure 12.
When its time to change the ribbon, cut the ribbon where it is stretched
between the upper ribbon guide arm and the takeup spindle. To remove
ribbon from the takeup spindle, press the release button (d) and slide the
ribbon off the spindle.
c
b
a
Figure 12
22
This type of media has some type of physical characteristic (web, notch,
perforation, etc.) that indicates the start/end of each label.
The media sensor must be properly positioned to sense these indicators.
See Adjusting the Media Sensor (above). Then, turn on the printer. If the
printer will not auto calibrate, press the MODE button three times, and then
the FEED button once, to manually calibrate (a label will print that shows
the sensor profile).
Continuous Media
Since continuous media does not contain label start/end indicators, you
must tell the printer via software how long each label is. If you are using
ZPL or ZPL II, include a Label Length (^LL) instruction in each label
format you send to the printer (refer to your ZPL II Programming Guide).
If you are using other software to operate your printer, refer to the
instructions provided with that software.
Figure 13
23
15
16
Auto Calibration
This procedure occurs whenever the printer is turned on or the printhead is
opened and closed. During this procedure, the printer automatically
determines the media type, label length, media and ribbon sensor settings,
and printing method (direct thermal or thermal transfer). This procedure is
set at the factory but may be changed via ZPL II command.
NOTE: If the printer fails to auto calibrate when you are using pre-printed
labels or pre-printed label backing, or if the printer will not auto calibrate,
see Manual Calibration in Troubleshooting.
1. Load the media and ribbon (if used).
2. Turn on the printer power.
3. Two or three blank labels will feed, completing auto calibration.
Operator Controls
Front Panel Buttons
Refer to Figure 14.
PAUSE Button
n Starts and stops the printing process.
n The first time the button is pressed, any partially printed label is
immediately feeds.
n When the button is pressed while the printer is printing, one blank label
n Once the blank label has been fed, pressing the button again will feed a
second label.
n When in the configuration mode, functions as the UP button.
24
POWER
PRINTHEAD
PAPER/RIBBON
PAUSE
FEED
MODE Button
n Puts the printer into the
configuration mode.
n Used to change print darkness
CANCEL
DARKEN
POSITION
CALIBRATE
MODE
Figure 14
25
17
18
26
27
19
20
length, no parity, 1 stop bit, and XON/XOFF), press and hold the PAUSE,
FEED, and MODE buttons while turning on the printer, then release the
buttons when the CALIBRATE LED goes out. All of the LEDs will go on,
while the DARKEN, POSITION, and CALIBRATE LEDs will flash. Press
and hold the MODE button until all of the lights go out, then release the
MODE button. The factory defaults have now been reset. Next, set the
communications parameters on your computer to match this.
NOTE: To save the default settings, press the MODE button four times.
Otherwise, the previous settings will be restored the next time the printer is
turned on.
AUTOBAUD: To automatically detect the communications parameters,
press and hold the PAUSE, FEED, and MODE buttons while turning on the
printer, then release the buttons when the CALIBRATE LED goes out. All
of the LEDs will go on, while DARKEN, POSITION, and CALIBRATE
LEDs will flash. Send a label format using the host computer settings. If
the printer accepts the host parameters, all of the LEDs will go off (except
for the POWER LED) and the printer will restart with the host
communication settings. If the printer does not accept the host
communications parameters, the printer will not restart and the LEDs will
flash on and off. If this should happen, turn the printer off and then on, and
try again.
NOTES: Label formats sent to the printer at this time only help the printer
determine the host settings. No label will print until settings are recognized.
In order for autobaud to work, your label must start with either a ^XA or
~XA ZPL II command. If all the LEDs are on, send another label format.
Save the new communication settings by pressing MODE four times.
Autobaud only works for 9600 baud and higher.
^SC: Use the Set Communications (^SC) command to change the
communications settings on the printer. 1) With the host computer set at
the same communications settings as the printer, send the ^SC command to
change the printer to the desired settings. 2) Then, change the host
computer settings to match the printer settings.
28
29
Method
Alcohol
Alcohol
Air blow
Alcohol
Air blow
Alcohol
Alcohol
Alcohol
Alcohol
Citrus
based
adhesive
remover
Interval
After every roll of media (or 500
feet of fanfold media) when
printing in the direct thermal
mode.
After every roll of ribbon when
printing in the thermal transfer
mode.
Alcohol and
After every 2 or 3 rolls of media.
air blow
Alcohol
Air blow
Once a month.
Once every six months.
21
22
c
d
g
f
Figure 15
30
b
c
d
Figure 16
31
23
24
2. Open the printhead (a) by moving the head open lever (b) to the open
position.
3. Remove the media and ribbon (if present).
4. With a swab, wipe the print elements (c) from end to end (the print elements are the grayish/black strip just behind the chrome strip.) Allow a
few seconds for the solvent to evaporate.
5. Rotate the platen roller (d) and clean thoroughly with alcohol.
6. Brush/vacuum any accumulated paper lint and dust away from the rollers and media sensors.
7. Reload ribbon and/or media, close and latch the printhead, close the
front cover and the media access cover, and continue printing.
If print quality has not improved after performing this procedure, try
cleaning the printhead with Save-a-Printhead cleaning film. This specially
coated material removes contamination buildup without damaging the
printhead. Call your authorized Zebra distributor for more information.
Cleaning the Cutter Module (for Printers
Equipped with the Optional Cutter)
The cutter module requires periodic cleaning to remove paper dust and
gummed label residue. The procedure on the following pages should be
performed by the operator according to the cleaning schedule table.
However, depending on your application and media type, you may need to
clean the cutter more or less frequently.
NOTE: In the figures shown, media and ribbon have been removed for
clarity. It is not necessary to remove media or ribbon before performing the
maintenance procedures described.
IMPORTANT: Do not exchange cutter modules between different
printers. The cutter module adjustments are optimized during installation to
work with a particular printer and may not perform correctly if the module
is placed on a different printer.
I. Removing the cutter module from the printer.
1. Turn off the printers AC power.
2. See Figure 17. Remove the label catch tray (a) by lifting it up and away from
the front of the cutter module (b).
3. Raise the printers media access cover and lower the printers front cover.
4. See Figure 18. Gently pull straight down on the cutter cable connector (a) to
remove it from the mating socket on the cutter module.
5. Turn the cutter mounting screw (b) with a screwdriver or by hand in a
counterclockwise direction until it is loose.
See Figure 19. Hold the cutter module as shown. Apply gentle upward pressure to
6. the left and right ends while raising the cutter module up and away from the
mounting posts (a). If necessary, rock the module side to side to loosen it.
32
b
a
Figure 17
b
a
Figure 18
33
25
26
Figure 19
c
b
a
Figure 20
34
2.
3.
4.
5.
See Figure 20. Hold the cutter module as illustrated. Put your thumbs on the
two wire spring loops (a) and your index fingers on the top of the rear cutter
blade guard (b). It may help to lay the cutter module on a table or other
surface throughout this process.
To remove the rear cutter blade guard, first press down simultaneously on the
two wire spring loops. While pressing down on the loops, press the rear
cutter blade guard back toward you and over the top of the loops. (Youre
trying to tuck the loops underneath the blade guard in this process.)
Continue pressing the rear cutter blade guard toward you and allow the back
edge of the guard to pop up as the guard comes free from its holders. You
may now remove the rear cutter blade guard by lifting it off of the module.
NOTE: The wire springs may flip up out of position during this process.
Springs will be repositioned during reassembly.
Observe the ends of the rear cutter blade guard and note the small metal pins
protruding toward the inside. During the reassembly procedure, these pins
will be mounted into the corresponding mounting slots in the cutter side
panels.
To provide complete access to the area to be cleaned, raise the upper cutter
blade guard (c) as shown in Figure 20.
35
27
28
b
c
CUTTER
SIDE PANEL
CUTTER
SIDE PANEL
Figure 21
Figure 22
36
37
29
30
Lubrication
No lubricating agents of any kind are required on this printer. Some
commercially available lubricants will damage the finish if used.
38
Mechanical Adjustments
This printer has been designed with minimal operator adjustments required.
Print Quality Adjustments
When changing from one media/ribbon combination to another, only slight
changes in print darkness or toggle pressure may be required. For these
situations, refer to the toggle pressure adjustment in this chapter.
I. Checking the initial print quality.
1. Open the media access cover and front cover on the printer (see
Figure 4).
2. Load the recommended media and ribbon for your application and adjust the
media sensor position.
Send a label format to the printer or activate the PAUSE key self test (see
3. Troubleshooting), print a few labels, and press the PAUSE button to stop
printing.
Observe the print quality of the test labels. If it is satisfactory, exit the PAUSE
4. key self test by pressing and holding the CANCEL button until the DATA LED
goes off. Otherwise, continue to step II.
If you are still experiencing poor print quality, perform the following toggle
pressure adjustment. Otherwise, exit the PAUSE key self test by pressing
and holding the CANCEL button until the DATA LED goes off.
Toggle Pressure Adjustment
The toggle assembly presses the printhead against the ribbon (if used), the
media, and the platen.
39
31
32
Right
Toggle
Figure 23
40
41
33
34
NOTE: This roller is only present on printers with the Peel-Off option.
Zebra presets this roller during manufacture for proper operation with most
applications. Only adjust this roller when necessary.
In the Peel-Off mode, proper media tracking is critical. The rewind power
roller automatically turns along with the movement of media, to insure
continuous rewind of the label backing material. When adjusting this roller,
the operating position may vary due to the type, width, and thickness of the
backing material.
Before performing this adjustment, review the media loading procedure in
Getting Ready to Print. Insure minimal sideways movement during the
printing process by positioning the left edge of the label backing even with
the edge guide mark on the tear-off/peel-off plate. Position the media
guides against the outside (right) edge of the media, but not so tight as to
bind the material.
When the power roller is properly adjusted, the backing material should
have even tension across its entire width and be wrapped snugly around all
guides and rollers. If the tension is not even, the media/backing material
may slide (walk) to the left or to the right as printing occurs. This can cause
print registration problems on the labels.
Right
Edge
Left
Edge
Up
a
c
Down
Figure 24
42
43
35
36
44
Troubleshooting
If the printer operates in an abnormal fashion, consult the troubleshooting
table below. The printer diagnostics following the troubleshooting table
may also help you to determine the problem.
The troubleshooting of some problems may be beyond the abilities of the
operator. In these cases, call a service technician to perform additional
troubleshooting and repair procedures.
Troubleshooting Table
Symptom
Diagnosis
Action
No AC power
applied to the
printer.
Faulty AC power
fuse.
No voltage
available from the
internal power
supply.
Hardware failure.
Boot-block CRC
error.
DRAM error.
Firmware
decompression
error.
Firmware error.
Firmware error.
45
37
38
Symptom
Diagnosis
Media incorrectly
or not loaded.
Cutter error.
Calibration error.
Misadjusted
media sensor.
Are you using
pre-printed
media?
Ribbon
incorrectly or not
loaded.
Backing rewind
spindle is full.
Malfunctioning
ribbon sensor.
Ribbon not
calibrated.
Printhead is not
fully closed.
Printer stops, PAUSE
LED on and PRINTHEAD Printhead open
sensor not
LED flashing.
detecting its
position flag.
Printhead
element is
Printer stops, PAUSE
overheated.
LED and PRINTHEAD
LED both on.
Power supply
over temperature.
Printhead open.
Youre using
Printer will not
pre-printed
successfully perform an
labels.
auto calibration.
Media is out.
Media is out of
Printer will not perform a specification.
manual calibration.
Printing continues,
PRINTHEAD LED on.
PAUSE LED flashing.
Hardware failure.
Printhead is
under
temperature.
Waiting for user
to peel label.
46
Action
Load media correctly, then turn the
printer off and on. See Getting
Ready to Print.
Clear jam, then open and close the
printhead.
Re-calibrate printer.
Check position and sensitivity of
media sensor. See Getting Ready
to Print.
Calibrate the printer. Refer to
Getting Ready to Print.
Load ribbon correctly, then turn the
printer off and on. See Getting Ready
to Print.
Remove label backing from the
spindle.
Call a service technician.
Calibrate the ribbon. Refer to
Resetting Ribbon Parameters
later in this chapter.
Close printhead completely, then
turn the printer off and on.
Call a service technician.
Printer resumes printing when the
printhead element cools.
Printer resumes printing when the
power supply cools.
Close the printhead.
Perform a manual calibration. See
Manual Calibration later in this
chapter.
Load media. Ensure that the media
sensor is properly positioned.
Ensusre that the media sensor is
properly positioned. Or, perform a
manual calibration. See Manual
Calibration later in this chapter.
Call a service technician.
Continue printing.
Remove label.
Symptom
Diagnosis
CANCEL button
was pressed and
a format was
deleted.
Firmware error.
Printer is
receiving data.
Printer sent a
stop
transmitting to
the host
computer.
Dirty printhead.
Action
No action required.
Call a service technician for
instructions on how to download
and install firmware.
Printing resumes when data is
received.
No action required.
Clean the printhead. See Routine
Care and Adjustments.
Printhead
element going
Call a service technician.
bad. Print quality
problems.
Default the printer. Refer to
Print width set
Resetting Factory Defaults later in
incorrectly.
this chapter.
Adjust media sensor position and
Possible media
call a service technician if
sensor problem.
Loss of printing
necessary.
registration on labels.
Printer set for
non-continuous
Set printer for correct media. See
media, but
Getting Ready to Print.
continuous media
loaded.
Improperly
Refer to Getting Ready to Print and
adjusted media
Routine Care and Adjustments for
For Peel-Off mode:
edge guides or
proper positioning and
power roller.
adjustments.
Incorrect media
See Loading the Media or
Excessive vertical drift in loading or media
Adjusting the Media Sensor in
top-of-form registration. sensor
Getting Ready to Print.
adjustments.
Dirty head or
See Printhead Cleaning in
Light vertical lines
Routine Care and Adjustments.
approximately .006 wide ribbon rollers.
running through all
Defective printhead
Call a service technician.
labels.
elements.
Light printing or no
Adjust balance. See Toggle
Printhead needs
printing on the left or
Pressure Adjustment in Routine
balancing.
right side of the label.
Care and Adjustments.
Short printed lines at 45 Too much
Reduce the pressure. See Toggle
to label edge on left or
printhead
Pressure Adjustment in Routine
right side of label.
pressure.
Care and Adjustments.
Dots missing in printed
area of label.
47
39
40
Symptom
Diagnosis
Action
Media or ribbon
improperly
loaded.
Truncated print, no
print, or FEED button
operates incorrectly
while using
non-continuous media.
Wrinkled ribbon.
Wrinkled ribbon.
Print element
damaged.
Ribbon fed
through machine
incorrectly.
Incorrect
darkness setting.
Incorrect
printhead
pressure.
Wrinkled ribbon.
Incorrect
dual-tension
spindle setting.
48
Symptom
Changes in parameter
settings did not take
effect.
Diagnosis
Action
Communications
parameters are
set incorrectly.
49
41
42
Cutter is dirty.
Cutter is dirty.
Label length is
too short.
Cutter option not
enabled.
Connecting cable
not connected to
cutter module.
Printing stops,
PAPER/RIBBON, PAUSE, Out of media.
Load media.
and CANCEL LEDs on.
Media jammed in Remove media, clean cutter
cutter.
module if necessary.
Cutter module is Clean cutter module. See Routine
dirty.
Care and Adjustments.
For printers with the
End of the media
Reposition media so that the end is
cutter option installed.
not positioned
on top of the platen. See Getting
correctly on top of
Ready to Print.
platen.
If error condition persists after attempting each of the
above solutions, call a service technician.
50
What it Monitors
How it Works
Ribbon sensor
Label available
sensor (PeelOff option
required. See
Figure 25.)
In Peel-Off mode, it
checks to see if a label
is available.
Backing rewind
spindle full
sensor (PeelOff option
required. See
Figure 26.)
51
43
44
Label
Available
Sensor
Tear-Off/
Peel-Off
Plate
Edge Guide Mark
Figure 25
Rewind
Spindle Full
Sensor
Figure 26
52
Manual Calibration
Perform a manual calibration whenever you are using pre-printed
media, if the printer is in manual calibration mode, or when the printer
will not auto calibrate.
During this procedure, the media type, label length, media and ribbon
sensor settings, and printing method are determined. Media type is
determined by sensing either continuous or non-continuous media as blank
labels move through the printer. If non-continuous media is sensed, label
length is also calibrated. If ribbon is sensed, the thermal transfer print
method is configured; otherwise, the direct thermal print method is
configured.
The results of this calibration are stored in the printers memory and are
retained even if printer power is removed. These parameters remain in
effect until the next calibration is performed.
NOTES: This procedure should only be done once to put the printer into
manual calibration. After that, press the MODE button three times and the
FEED button once when you change media (a label will print that shows the
sensor profile).
If the printer is in the Peel-Off mode, the operator must catch the labels as
they are peeled away from the backing during this procedure.
1. Place the head open lever in the open position.
2. Remove the ribbon.
3. Remove approximately 6 of labels from the media roll, enough so that
only the backing material is threaded under the media sensor when the
media is loaded.
4. Reload the media.
5. Press and hold down the PAUSE, FEED, and CANCEL buttons.
6. Turn on the power switch.
7. After the CALIBRATE LED goes out, release the PAUSE, FEED, and
CANCEL buttons.
8. When the PRINTHEAD LED flashes, reload the ribbon.
9. Make sure the media sensor is properly positioned.
10.Close the printhead.
11.A media and ribbon sensor profile will print.
NOTE: To return to Auto Calibration, press and hold the PAUSE,
CANCEL, and MODE buttons when you turn on the printer.
53
45
46
54
Printer Diagnostics
Power-On Self Test
A Power-On Self Test (POST) is performed automatically each time the printer
is turned on. This test checks for proper initialization of various electronic
circuits and establishes starting parameters as those stored in the printers
memory. During this test sequence, the front panel lights will turn on and off to
insure proper operation.
At the end of this self test, only the POWER LED will remain lit. If other
LEDs are also lit, refer to the troubleshooting table.
Additional Printer Self Tests
These self tests produce sample labels and provide specific information that
help the operator determine the operating conditions for the printer.
Each self test is enabled by holding in a specific front panel button while
turning the power switch on. Keep the button depressed until the
CALIBRATE LED goes out. When the Power-On Self Test is complete,
the selected printer self test will automatically start. To return to printing
mode, turn off and then turn on the printer.
NOTES:
n When canceling a self test before its actual completion, always turn the
printer power switch off and back on.
n When performing these self tests while in the Peel-Off mode, the
operator must remove the labels as they become available.
n When the cutter option is installed and enabled, the labels printed in
these self tests should be automatically cut as they are printed.
55
47
48
This self test prints the printers configuration parameters (for example,
printing darkness, label length, and media type) that are currently stored in
configuration (Flash) memory. See Figure 27.
To perform the CANCEL key self test:
1. Press the CANCEL button while turning on the printer.
2. Release the button when the CALIBRATE LED turns off.
3. To return to printing mode, turn off and then turn on the printer.
Figure 27
56
This self test can be used to provide the test labels required when making
adjustments to the printers mechanical assemblies. See Figure 28.
To perform the PAUSE key self test:
1. Press the PAUSE button while turning on the printer.
2. Release the button when the front panel LEDs turn on.
3. To return to printing mode, turn off and then turn on the printer.
NOTE: This self test consists of four individual test features:
n The initial self test prints 15 labels at 2.4/second then automatically
n While the printer is paused, pressing the CANCEL button once alters the
self test. Now each time the PAUSE button is pressed, the printer prints
15 labels at maximum speed, up to 9999 labels.
n While the printer is paused, pressing the CANCEL button a second time
alters the self test again. Now each time the PAUSE button is pressed,
the printer prints 50 labels at 2.4/second, up to 9999 labels.
n While the printer is paused, pressing the CANCEL button alters the self
test a third time. Now each time the PAUSE button is pressed, the
printer prints 50 labels at maximum speed, up to 9999 labels.
Figure 28
57
49
50
The results of this self test will be used to determine the best darkness
setting for a specific media/ribbon combination. Refer to Figure 29.
To perform the FEED key self test:
1. Press the FEED button while turning on the printer.
2. Release the button when the front panel LEDs turn on.
3. To return to printing mode, turn off and then turn on the printer.
NOTES:
n The FEED key self test
printout is added to
(plus) or subtracted from
(minus) the current
darkness value. (For
example, relative
darkness is 5, so add
that to the number on the
current configuration
label [see the next step]
for the new darkness
setting.)
58
Figure 30
59
51
52
60
Specifications
NOTE: Printer specifications are subject to change without notice.
NOTE: Your printer may not have all of the options described in these
specifications.
General Specifications
Height
Width
Depth
Weight (option-dependent)
Electrical
Agency approvals
Temperature
Relative
humidity
Operating
Storage
Operating
Storage
Communications
Interface
13"
330 mm
8.25"
210 mm
17"
432 mm
17 lbs
7.71 kg
Auto range 110 VAC +/-20% or
230 VAC +/-15%, 47-63 Hz
3 Amps @ 110 VAC, 1.5 Amps @ 230 VAC
UL1950 3rd Edition; CSA22.2 No950-95;
CISPR22-B; EN50082-1:1997; EN60950
Meets FCC Class B and CAN.DOC Class A Rules
40 to 105 F
5 to 40 C
-40 to 140 F
-40 to 60 C
20 to 85%, non-condensing
5 to 85%, non-condensing
DB-9S-type RS-232 serial data interface;
110-57,600 baud; parity, bits/char. and XON-XOFF
or DTR handshake protocols -- all software
selectable
Bi-directional parallel data interface
61
53
54
Printing Specifications
Printing Specifications
S400 Printer
S600 Printer
203 dots per inch (8 dots per mm)
0.005" (0.127 mm)
4.09" (104 mm)
0.005" (0.127 mm)
36" (914 mm)
39" (991 mm)
Resolution
Dot size (square)
Maximum print width
Minimum
Print length
Maximum
Bar code modulus (X)
dimension
5 mil to 55 mil
2" (51 mm)
3 (76 mm)
4 (102 mm)
Programmable constant
printing speeds
1MB
n/a
DRAM memory
Flash memory (E:)
Ribbon Specifications
Ribbon width (we
Minimum
recommend using ribbon
at least as wide as the
Maximum
media to protect the
printhead from wear).
Standard 2:1 media to ribbon roll ratio
lengths
3:1 media to ribbon roll ratio
Ribbon core inside diameter
Maximum ribbon roll diameter
62
1.57"
40 mm
4.5"
114 mm
984
1476
1.0"
3.2"
300 m
450 m
25 mm
81 mm
Media Specifications
Total
media
width
Label
length
Total
thickness
(includes
liner)
Minimum
Maximum
Maximum (cutter installed)
Tear-Off
Minimum
Peel-Off
Cutter
Maximum
Minimum
Maximum (printhead
position may need to be
adjusted above 0.01")
Core size
Maximum roll diameter
Inter-label Minimum
gap
Maximum
Ticket/tag notch size (W x L)
0.75"
19 mm
4.5"
114 mm
4.0"
102 mm
0.63"
16 mm
1.00"
25 mm
1.50"
38 mm
See Printing Specifications
0.0023"
0.058 mm
0.012"
0.305 mm
3.0"
8.0"
0.08"
(0.118" preferred)
0.16"
0.08" x 0.48"
76 mm
203 mm
2 mm
(3 mm preferred)
4 mm
2 mm x 12 mm
Media Handling
n Tear-off mode: Produced in strips
n Peel-off mode: Dispensed and peeled away from the liner
n Cutter mode: Printed and individually cut
63
55
56
Options
n 4 MB flash expansion
n 8 MB flash expansion
n *Peel-Off mode with backing-only rewind feature
n *Cutter with label catch tray
n Scalable and bitmap smooth fonts available for text
n Ethernet
* Factory installed
Contact your authorized Zebra distributor for information.
n
n
print pause
Communicates in printable ASCII
characters
Controlled via mainframe, mini,
PC, Portable Data Terminal
Serialized fields
In-Spec OCR-A and OCR-B
n
n
n UPC/EAN (nominal 100%
magnification)
64
Bar Codes
1D
2D
Interleaved 2 of 5 (supports
ratios of 2:1 to 3:1,
Modulus 10 Check Digit)
Codablock
Code 11
LOGMARS
Code 49
MSI
Data Matrix
Plessey
MaxiCode
Code 93
POSTNET
MicroPDF417
EAN 8
Standard 2 of 5
PDF 417
EAN 13
UPC-A
QRcode
EAN extensions
UPC-E
Industrial 2 of 5
UPC extensions
65
57
58
66
Appendix
RS-232 Connector Technical Information
RS-232 Connector Pinouts
Pin. No.
Description
Not used
DTR (data terminal ready) output from the printer -controls when the host may send data
Chassis ground
Not used
5 V fused
67
59
60
DTE
1
2
3
4
5
6
7
8
9
DTE
(RD)
(RD)
(TD)
(TD)
(DTR)
(DTR)
(SG)
(SG)
(DSR)
(DSR)
(RTS)
(RTS)
1
2
3
4
5
6
7
8
9
Figure 31
DCE
1
2
3
4
5
6
7
8
9
DTE
CARRIER DETECT (CD)
RECEIVE DATA (RD)
TRANSMIT DATA (TD)
DATA TERMINAL READY (DTR)
SIGNAL GROUND (SG)
DATA SET READY (DSR)
REQUEST TO SEND (RTS)
CLEAR TO SEND (CTS)
Figure 32
68
1
2
3
4
5
6
7
8
9
Description
nStrobe/Host Clk
2-9
10
nACK/PtrClk
11
Busy/Per Busy
12
13
Select/Xflag
14
15
Not Used
16-17
18
19-30
Ground
+5V @ 1A Fused
Ground
31
nlnit
32
nFault/nData Avail.
33-34
Not Used
35
36
NSelectIn/1284 active
69
61
62
70
Glossary
alphanumeric Indicating letters, numerals, and characters such as punctuation
marks.
backfeed Backfeed is when the printer pulls the media and ribbon (if used)
backward into the printer so that the beginning of the label to be printed is
properly positioned behind the printhead. Backfeed occurs when youre
operating the printer in tear-off, peel-off, or cutter mode.
bar code A code by which alphanumeric characters can be represented by a series
of adjacent stripes of different widths. Many different code schemes exist,
such as the universal product code (UPC) or Code 39.
calibration (of a printer) A process in which the printer determines some basic
information needed to print accurately with a particular media/ribbon
combination. To do this, the printer feeds some media and ribbon (if used)
through the printer and senses whether to use the direct thermal or thermal
transfer print method, whether continuous or non-continuous media will be
used, and (if non-continuous media) the length of individual labels/tags.
character set The set of all letters, numerals, punctuation marks, and other
characters that can be expressed by a particular barcode.
check digit A character added to a barcode symbol that indicates to the scanner
that it has read the symbol correctly.
continuous media Label or tagstock that has no web (space between labels),
notch, or gap to separate each label/tag, but rather the media is one long piece
of material.
core diameter The inside diameter of the cardboard core at the center of a roll of
media/ribbon.
cutter A device that can cut each label/tag immediately after it is printed.
diagnostics Information about what printer functions are not working. This
information is used for troubleshooting problems.
direct thermal printing Printing in which direct thermal media is used. No
ribbon is used. Instead, the media is coated with a substance that reacts to
heat to produce an image.
fanfold media Media that comes folded in a rectangular stack, rather than on a
roll.
71
63
64
72
ribbons also have a back coating that protects the printhead from damage.
The ribbon transfers ink onto the media when heated by the printhead.
ribbon wrinkle A wrinkling of the ribbon caused by improper alignment of the
strip plate and/or printhead pressure. This wrinkle can be seen just above the
strip plate. Ribbon wrinkle can cause voids in the print and/or the spent
ribbon to rewind unevenly. This is a condition that should be corrected by
performing adjustment procedures.
roll media Media that comes supplied rolled up on a core (usually cardboard).
Contrast this with fanfold media, which comes folded in a rectangular stack.
Supplies Supplies is a general term for ribbon and media.
Tag A type of media having no adhesive backing but featuring a hole or notch by
which the tag can be hung on something. Usually tags are made of cardboard
or other durable material.
take label sensor See label available sensor.
thermal direct printing See direct thermal printing.
thermal transfer printing A printing method in which the printhead heats an
ink- or resin-coated ribbon against the media, causing the ink/resin to transfer
onto the media. By selectively heating the ribbon, you can form an image on
the media. See also ribbon.
void A space where printing should have occurred but, due to some error
condition, it did not occur. A void can cause a bar code symbol to be read
incorrectly or to not be read at all.
73
65
66
74
67
Index
A
AC power cable . . . . . . . . . . . 5
AC power fuse, replacing. . . . . . 30
Adjustments
Backing rewind power roller
Label top position . . . . . .
Media rest position . . . . .
Media sensor . . . . . . . .
Media sensor position. . . .
Print darkness . . . . . . . .
Print quality . . . . . . . . .
Print quality check . . . . .
Ribbon supply spindle . . .
Toggle pressure . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
34
33
33
15
33
31
31
31
33
31
Cleaning
Cutter module . . . . .
Exterior . . . . . . . .
Interior . . . . . . . .
Maintenance schedule
Platen roller . . . . . .
Printhead . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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24
23
23
21
23
23
Communications parameters,
resetting . . . . . . . . . . . . . 46
Communications parameters,
setting . . . . . . . . . . . . . . 19
Cutter mode . . . . . . . . . . . . . 3
Cutter module, cleaning
Cleaning. . . . . . .
Disassembling. . . .
Reassembling . . . .
Reinstalling . . . . .
Removing . . . . . .
Testing . . . . . . .
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27
27
27
29
24
29
Damage, reporting . . . . . . . . . . 1
Darkness, adjusting . . . . . . . . . 31
Defaulting the printer . . . . . . . . 19
DCE devices . . . . . . . . . . . . 59
DTE devices . . . . . . . . . . . . 59
C
Cabling requirements, serial
and parallel . . . . . . . . . . . 19
Calibration, automatic . . . . . . . 16
Calibration, manual . . . . . . . . . 45
75
E
Electrical noise . . . . . . . . . . . 19
68
Lubrication . . . . . . . . . . . . . 30
F
Factory defaults, resetting . . . . . 46
Fanfold media loading . . . . . . . . 8
Fonts
Optional . . . . . . . . . . . . . 57
Standard. . . . . . . . . . . . . 57
Front panel buttons
CANCEL button
DOWN button .
FEED button . .
MODE button . .
PAUSE button .
UP button . . . .
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16
16
16
17
16
16
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17
17
17
17
17
17
17
17
M
Maintenance manual, ordering. . . . 1
Manual calibration . . . . . . . . . 45
Media
Continuous . . . . . . . . . . . 15
Non-continuous . . . . . . . . . 15
Media loading . . . . . . . . . . . . 7
Cutter mode . . . . . . . . . . . 11
Fanfold . . . . . . . . . . . . . . 8
Peel-Off mode . . . . . . . . . . 9
Roll . . . . . . . . . . . . . . . . 7
Tear-Off mode . . . . . . . . . . 7
Media rest position, adjusting . . . 33
Media sensor position, adjusting . . 33
Media sensors. . . . . . . . . . . . 15
N
Null modem cable . . . . . . . . . 59
O
Operator controls . . . . . . . . . . 16
I
Identifying your printer . . . . . . . 2
Interface cables
Crossover (null modem) . . . . 59
Straight-through. . . . . . . . . 59
Options . . . . . . . . . . . . . . . 56
P
Parallel interface . . . . . . . . 19, 61
Peel-Off mode . . . . . . . . . . . . 3
76
Printer diagnostics
CANCEL key self test
FEED key self test . .
MODE key self test . .
PAUSE key self test .
Power-on self test . . .
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48
50
51
49
47
69
S
^SC command . . . . . . . . . . . 20
Sensors . . . . . . . . . . . . . . . 15
Serial communications port. . . . . 59
Serial interface . . . . . . . . . 18, 59
Printer identification . . . . . . . . . 2
Site requirements. . . . . . . . . . . 2
Software, selecting . . . . . . . . . 20
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43
43
43
43
43
Printer/computer connections
Parallel . . . . . . . . . . . . . 19
Serial . . . . . . . . . . . . . . 18
Specifications
General . . . .
Media . . . . .
Media handling
Printing . . . .
Ribbon . . . .
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53
55
55
54
54
Storage . . . . . . . . . . . . . . . 62
Tear-Off mode . . . . . . . . . . . . 2
U
Unpacking . . . . . . . . . . . . . . 1
V
Ventilation . . . . . . . . . . . . . . 2
Ribbon removal . . . . . . . . . . . 14
Ribbon supply spindle
Low-tension position . . . . . . 12
Normal position . . . . . . . . . 12
Ribbon supply spindle, adjusting . . 33
Roll media loading . . . . . . . . . . 7
77
Z
ZPL II Programming Guide,
ordering . . . . . . . . . . . . . . 1
70
78