S400 s600usersguide

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Customer Order # 11996L
Manufacturer Part # 11996LB Rev. 1

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This manual contains proprietary information of Zebra Technologies Corporation. It is intended solely for the
information and use of parties operating and maintaining the equipment described herein. Such proprietary
information may not be used, reproduced, or disclosed to any other parties for any other purpose without the expressed
written permission of Zebra Technologies Corporation.
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Continuous improvement of products is a policy of Zebra Technologies Corporation. All specifications and signs are
subject to change without notice.
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NOTE: 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:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment into an outlet on a circuit different than that to which the receiver is connected.
• 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 ensure compliance.
“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies Corporation
could void the user’s authority to operate the equipment.”
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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.
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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.
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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 or inability to use such product, even if Zebra
Technologies Corporation has been advised of the possibility of such damages. Because some states so not allow the
exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.
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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.
© 2001 Zebra Technologies Corporation. All rights reserved.

ii Zebra S400 S600 User’s Guide

Zebra S400 S600 User’s Guide iii

iv Zebra S400 S600 User’s Guide

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Unpacking ................................................................................................................1
Reporting Damage ...................................................................................................2
Storage and Reshipping ...........................................................................................2
Site Requirements ....................................................................................................3
Introduction to Printers ............................................................................................3

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AC Power Cable ......................................................................................................7
Loading the Media ...................................................................................................8
Tear-Off Mode....................................................................................................9
Peel-Off Mode ..................................................................................................11
Cutter Mode ......................................................................................................14
Loading the Ribbon................................................................................................15
Ribbon Supply Spindle: Normal Position........................................................15
Ribbon Supply Spindle: Low-Tension Position ..............................................15
Ribbon Loading Instructions ............................................................................16
Ribbon Removal ....................................................................................................17
Adjusting the Media Sensor...................................................................................18
Non-Continuous Media ....................................................................................19
Continuous Media.............................................................................................19
Auto Calibration.....................................................................................................19
Operator Controls...................................................................................................20
Front Panel Buttons ..........................................................................................20
AC Power On/Off Switch ......................................................................................22
Printing a Test Label ..............................................................................................22

Zebra S400 S600 User’s Guide v

Connecting the Printer and Computer ................................................................... 23
RS-232 Interface Requirements ....................................................................... 23
Parallel Interface Requirements ....................................................................... 23
Serial and Parallel Cabling Requirements........................................................ 24
Communicating with the Printer ........................................................................... 24
Via the Parallel Port ......................................................................................... 24
Via the Serial Port ............................................................................................ 24
Setting Up the Software......................................................................................... 26

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Cleaning................................................................................................................. 27
Cleaning the Exterior ....................................................................................... 29
Cleaning the Interior......................................................................................... 29
Cleaning the Printhead and Platen Roller ........................................................ 29
Cleaning the Cutter Module ............................................................................. 30
Lubrication ............................................................................................................ 37
AC Power Fuse Replacement ................................................................................ 38
Mechanical Adjustments ....................................................................................... 38
Print Quality Adjustments ................................................................................ 38
Toggle Pressure Adjustment ............................................................................ 40
Media Rest Position Adjustment...................................................................... 41
Top of the Label Position Adjustment ............................................................. 41
Media Sensor Position Adjustment .................................................................. 41
Ribbon Supply Spindle Adjustment ................................................................. 41

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Troubleshooting Tables ......................................................................................... 45
Printer Status Sensors ............................................................................................ 51
Manual Calibration ................................................................................................ 53
Resetting Printer Parameters ................................................................................. 54
Resetting Factory Defaults ............................................................................... 54
Resetting Communications Parameters............................................................ 54
Resetting Ribbon Parameters ........................................................................... 55

vi Zebra S400 S600 User’s Guide

Printer Diagnostics.................................................................................................55
Power-On Self Test...........................................................................................55
Additional Printer Self Tests ............................................................................56
CANCEL Key Self Test ...................................................................................57
PAUSE Key Self Test.......................................................................................58
FEED Key Self Test .........................................................................................59
MODE Key Self Test........................................................................................60

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General Specifications ...........................................................................................61
Printing Specifications ...........................................................................................62
Ribbon Specifications ............................................................................................62
Media Specifications..............................................................................................63
Media Handling .....................................................................................................63
Options ...................................................................................................................63
Zebra Programming Language (ZPL II) ................................................................64
Bar Codes...............................................................................................................64
Standard Printer Fonts............................................................................................65
Optional Printer Fonts............................................................................................65

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RS-232 Connector Technical Information.............................................................67
Interconnecting to DTE Devices ......................................................................67
Interconnecting to DCE Devices ......................................................................67
Parallel Interface Technical Information ...............................................................69

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Zebra S400 S600 User’s Guide vii

viii Zebra S400 S600 User’s Guide

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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.
This user’s guide provides all the information you need to operate the
printer on a daily basis.
• ZPL II® is Zebra Technologies Corporation’s Zebra Programming
Language II label design language. ZPL II lets you create a wide variety
of labels from the simple to the very complex, including text, bar codes,
and graphics. To create and print label formats, refer to the ZPL II
Programming Guide (part #46469L). If one was not ordered with your
printer, simply call your distributor or Zebra Technologies Corporation.
• In addition, label preparation software is available. Contact your
distributor or Zebra Technologies Corporation for further information.
Or, visit our web site at www.zebra.com for a free demo copy.
• The S400/S600 Maintenance Manual (part #44895L) contains all the
information you need to maintain your printer. To order, contact your
distributor or Zebra Technologies Corporation.

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Save the carton and all packing materials in case reshipping is required.
• Inspect the printer for possible shipping damage.
• Check all exterior surfaces for damage.
• Raise the media access cover (refer to Figure 4 on page 5) and inspect
the media compartment for damage.

Zebra S400 S600 User’s Guide 1

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If you discover shipping damage:
• Immediately notify the shipping company and file a report with them.
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.
• Keep the carton and all packing material for inspection.
• Notify your authorized Zebra distributor.

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If you are not placing the printer into operation immediately, repackage it
using the original packing materials. The printer may be stored under the
following conditions:
• Temperature: –40° to 140° F (–40 to 60° C)
• Relative humidity: 5% to 85% non-condensing
To ship the printer, carefully pack it in a suitable container to avoid
damage during transit. Whenever possible, use the original container from
the factory. A shipping container can be purchased from Zebra
Technologies Corporation, if the original one has been lost or destroyed.
If you use a different container, package the printer carefully to avoid
damage.
CAUTION: When packaging the printer in a rigid container,
use shock mounts or shock-absorbing packing material. A
rigid container allows shock on the outside to be transmitted
undamped to the printer which may cause damage. Also,
before packing, remove all ribbon and media from the supply
and take-up spindles to prevent damage to the printer.

2 Zebra S400 S600 User’s Guide

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CAUTION: To ensure that the printer has proper ventilation
and cooling, do not place any padding or cushioning material
under the unit as 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 operates 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 functions satisfactorily in areas such as warehouses, factory floors, and
office environments that conform to specified environmental and electrical
conditions.

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The first thing you want to do is identify your printer. This makes certain
tasks — such as media loading — much easier to do!
Figure 1 shows a
printer that 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 the media
for Tear-Off mode,
see page 9.

Figure 1. Tear-Off Mode


In Figure 2, the printer
is shown 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.
To load media in
Peel-Off mode, see
page 11.
Figure 2. Peel-Off Mode

Figure 3 shows a
printer that is
equipped for Cutter
mode. When in cutter
mode, the printer
automatically cuts the
label after it is printed.
Then, the cutter catch
tray “catches” the
label.
To load the media in
Cutter mode, see
page 14.
Figure 3. Cutter Mode


Figure 4. Printer Components


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The AC power cable has a three-prong female connector on one end (see
Figure 5). This connector must be plugged into the mating connector on
the left side of the printer. See Figure 6.
The connector at the other end of the AC power cable is one of the
following:
• US Standard 110 VAC three-prong plug
• Great Britain Standard 230 VAC three-prong plug
• European Standard 230 VAC three-prong plug
• Australian Standard 230 VAC three-prong plug
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Ensure that the AC power on/off switch is in the “off” position before
connecting the AC power cable to a nearby electrical outlet.

Figure 5. AC Power Connection


Figure 6. AC Mating Connector

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Media widths and thicknesses vary between applications. To maintain
print quality from one application to another, see “Print Quality
Adjustments” beginning on page 38.
NOTE: Zebra recommends using media that is outside wound
(i.e., you can see the labels on the outside of the roll).


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1. Refer to Figure 7. Move the head open lever (a) counterclockwise to
the open position to raise the printhead (b).
2. Slide the media guide (c) and the media supply guide (d) as far out
from the printer frame as possible.
If you are loading roll media in Tear-Off mode, follow steps 3-5. For
loading fanfold media in Tear-Off mode, skip to step 6.
3. Place the media roll on the media supply hanger (e), and thread the
media through the printhead assembly as shown.

Figure 7. Loading — Tear-Off Mode


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” on
page 18 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 (f) or rear (g) 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” on
page 18 to adjust the media sensor position.

Figure 8. Loading — Fanfold Media


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(Peel-Off mode is optional).
Refer to Figure 9 and follow the procedure below.
1. Slide the media supply guide (a), media guide (b), and the outer edge
guides on both the platen guide rod (c) and the lower guide rod (d) as
far out from the printer frame as possible.
2. Open the head open lever (e) to raise the printhead (f).
3. Remove the hold down hook (g).
4. Thread the media through the printhead as shown in Figure 9.
5. From the front of the printer, pull the media through the printhead until
approximately 24 of media extends out from the printer. Remove the
labels from the backing of the 24 of media that extends from the front
of the printer.
6. Align the inside edge of the media with the edge guide mark (h) near
the left side of the tear-off/peel-off plate, then close the head open
lever. (See Figure 25 on page 52 for a detailed illustration.)
7. Thread the label backing behind the lower label available sensor (i),
through the slot under the rewind power roller (j), and below the lower
guide rod (k) to the backing rewind spindle (l). Then, wind the
backing material around the backing rewind spindle three or four
times in a counterclockwise direction. To ensure proper winding,
press the edge of the backing material against the round plate at the far
end of the spindle.
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.


Figure 9. Loading — Peel-Off Mode
9. Adjust all of the guides:
• 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.
• 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.
• Adjust the media guide until it just touches the outer edge of the
media without causing the material to buckle.
10. See “Adjusting the Media Sensor” on page 18 to adjust the media
sensor.
NOTE: In the Peel-Off mode, proper media tracking is critical.
Refer to “Backing Rewind Power Roller Adjustment” on page 42
to make sure that the media tracks properly through the printer.


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(Peel-Off option required).
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 don’t 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.


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(Cutter mode is optional).
To ensure proper media loading, follow the directions for the Tear-Off
mode with the exception that the end of the media must be positioned on
top of the platen roller. See Figure 10.
With the end of the media positioned directly on top of the platen roller (a),
close the head open lever. The printer automatically calibrates, feeds out,
and cuts the label when the printer is powered on or the printhead is
opened and closed.
NOTE: The cutter only cuts if the printer is in cutter mode. Refer
to the ZPL II Programming Guide or the label preparation software
user’s guide for instructions.
NOTE: The cutter cycles once at power up or resets (even when
NOT in cutter mode).

Figure 10. Loading — Cutter Mode


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Before you load the ribbon, make sure the ribbon supply spindle is
adjusted properly.

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In the normal position, the “dual-tension” ribbon supply spindle provides
the desired amount of ribbon back tension for different ribbon widths.
To place the spindle in the normal position, firmly pull the spindle end cap
(a) until it clicks into place, as shown in Figure 11.

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Low-tension position is used in limited applications to provide lower
ribbon back tension. Low-tension position is only recommended when
normal tension hampers the ribbon movement (for example, you will see
scuffing or image breakup on the label).
To put the spindle in the low-tension position, firmly push the spindle end
cap (a) until it clicks into place, as shown in Figure 11.
.

Figure 11. Ribbon Supply Spindle Positions


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NOTE: Zebra recommends the use of ribbon that is wider than the
media. The 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.)
NOTE: Zebra recommends the use of ribbon that is outside wound
(i.e., the ink side is on the outside of the roll).
To load ribbon, see Figure 12 and follow the procedure below.
1. Adjust the ribbon supply spindle position for normal or low tension.
2. Align the blades (b) on the two sections of the spindle as shown in
Figure 11. (You do not need to do this if your ribbon width is 2.4
[60 mm] or less.)
3. Place the ribbon roll on the ribbon supply spindle (a). Make sure the
roll is pushed in to the stop at the end of the spindle.
4. Open the printhead by moving the head open lever (b)
counterclockwise to the open position.
5. Thread the ribbon as shown. Wind the ribbon onto the ribbon takeup
spindle (c) for several turns in a clockwise direction until wrinkles and
creases disappear.
6. Close the printhead by moving the lever clockwise to the closed
position.


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Refer to Figure 12.
When it’s 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.

Figure 12. Ribbon Removal


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This adjustment aligns the position of the light sensor with the notch or
edge of the label, so the printer can determine the correct label size.
See Figure 13. With the printhead open, look through the side of the print
mechanism and locate the media sensor adjustment lever (a). Reposition
the sensor until the top of the adjustment lever is in line with the notch or
web in the media or the edge of the label. Close the printhead by moving
the head open lever to the closed position.
When continuous media (no notch or opening to sense) is used, position
the media sensor anywhere over the media so that an “out-of-media”
condition is sensed.

Figure 13. Media Sensor Adjustment


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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 as
described above. Then, turn on the printer. If the printer does not auto
calibrate, press the MODE button three times, and then the FEED button
once, to manually calibrate (a label prints showing the sensor profile).

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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.

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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 does not
auto calibrate, see “Manual Calibration” on page 53.
1. Load the media and ribbon (if used).
2. Turn on the printer power.
3. Two or three blank labels feed, completing auto calibration.


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Refer to Figure 14.
PAUSE Button
• Starts and stops the printing process.
• The first time the button is pressed, any partially printed label is
completed; then, the printing process is stopped.
• If the printer is idle when the button is pressed, no new print requests are
printed until PAUSE is pressed again.
FEED Button (also referred to as the UP button)
• Forces the printer to feed one blank label.
• If the button is pressed when the printer is idle or paused, a blank label
immediately feeds.
• When the button is pressed while the printer is printing, one blank label
feeds after the completion of the current batch of labels.
• Once the blank label has been fed, pressing the button again feeds a
second label.
• When in the configuration mode, functions as the UP button.
CANCEL Button (also referred to as the DOWN button)
• This button only functions when the printer is paused.
• If the button is pressed, the label format that is currently printing is
canceled.
• If pressed when no label format is printing, then the next format to be
printed is canceled.
• Press for at least three seconds to cancel all label formats the printer has
received and return the printer to an idle state.
• When in the configuration mode, functions as the DOWN button.


MODE Button
• Puts the printer into the configuration
mode.
• Used to change print darkness and
media position, and to calibrate the
printer.
Front Panel LEDs
Refer to Figure 14.
The front panel LEDs give you a quick
indication of the printer’s current status.
During normal operation, the POWER
LED is on and all other LEDs are off. For
all other conditions, please refer to
“Troubleshooting” beginning on page 45.
Now, you’re ready to turn on the printer!

Figure 14. Front Panel


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This switch is located on the left side of the printer near the AC power cord
and fuse (see Figure 6 on page 8). The AC power switch should be turned
off before connecting or disconnecting any cables.
Turning the switch on activates the printer and causes it to perform a
Power-On Self Test, which can take up to 30 seconds, as it begins
operation. Turning the printer power on while holding down certain front
panel keys activates additional printer self tests following the Power-On
Self Test. See page 56.
External influences, such as lightning storms or unwanted noise on the
power or data cables, may cause erratic printer behavior. Turning the AC
power off and then back on may re-establish proper printer operation.
Otherwise, see “Troubleshooting” beginning on page 45.

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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
label (see “CANCEL Key Self Test” on page 57.) If you can’t get this
label to print, refer to “Troubleshooting” beginning on page 45.
To make print quality adjustments, see “Print Quality Adjustments”
beginning on page 38.


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This printer comes with both a nine-pin Electronics Industries Association
(EIA) RS-232 serial data interface and an IEEE 1284 bi-directional
parallel data interface. In either case, you must supply the required
interface cable for your application.
CAUTION: This printer complies with FCC “Rules and
Regulations,” Part 15, for Class B Equipment, using fully
shielded six-foot data cables. Use of longer cables or
unshielded cables may increase radiated emissions above the
Class B limits.

56 ,QWHUIDFH 5HTXLUHPHQWV
Refer to Figure 6 on page 8.
The required cable must have a 9-pin “D” type (DB-9P) connector (male)
on one end, which is plugged into the mating (DB-9S) connector (female)
located inside the access opening on the left side of the printer.
The other end of the signal interface cable connects to a serial port at the
host computer. This cable is one of two types — standard or null modem
— depending on the specific interface requirements.
For pinout information, as well as information on how to interconnect to
either a DTE (data terminal equipment) or DCE (data communication
equipment) device, refer to the “Appendix” on page 67.

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Refer to Figure 6 on page 8.
An IEEE 1284 compatible bi-directional parallel data cable is required
when this communication method is selected. The required cable must
have a standard 36-pin parallel connector on one end, which is plugged
into the mating connector located inside the access opening on the left side
of the printer. The parallel interface cable is connected using bail clips
instead of screws.


The other end of the parallel interface cable connects to the printer
connector at the host computer.
For pinout information, see “Parallel Interface Technical Information” on
page 69.

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Data cables must be fully shielded and fitted with metal or metallized
connector shells. Shielded cables and connectors are required to prevent
radiation and reception of electrical noise.
To minimize electrical noise pickup in the cable:
1. Keep data cables as short as possible.
2. Do not bundle the data cables tightly with power cords.
3. Do not tie the data cables to power wire conduits.

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• Set the parallel connection on the host computer. For instructions, refer
to your computer’s user’s guide.

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• Set the host computer to the factory defaults of the printer: 9600 baud, 8
bit word length, no parity, 1 stop bit, and XON/XOFF. For instructions,
refer to your computer’s user’s guide.
NOTE: If you can’t reset the host computer communications
settings, then you must establish a temporary parallel connection to
send down the Set Communications (^SC) command that changes
the printer’s settings to match the host settings.


Defaulting the Printer: To reset only the communications parameters on
the printer to the factory defaults (9600 baud, 8 bit word 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 turn on, while the
DARKEN, POSITION, and CALIBRATE LEDs 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 are 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 turn on, while DARKEN, POSITION, and CALIBRATE
LEDs flash. Send a label format using the host computer settings. If the
printer accepts the host parameters, all of the LEDs turn off (except for the
POWER LED) and the printer restarts with the host communication
settings. If the printer does not accept the host communications
parameters, the printer does not restart and the LEDs flash on and off. If
this should happen, turn the printer off and then on, and try again.
NOTE: Label formats sent to the printer at this time only help the
printer determine the host settings. No label prints until settings are
recognized.
NOTE: 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.
NOTE: Save the new communication settings by pressing MODE
four times.
NOTE: Autobaud only works for 9600 baud and higher.


^SC: Use the Set Communications (^SC) command to change the
communications settings on the printer. 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. Then, change the host computer
settings to match the printer settings.

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In order to create labels, you must decide whether to use ZPL II or
commercial label preparation software. To use ZPL II, refer to the ZPL II
Programming Guide. If you choose to use a label preparation software,
follow the installation instructions included in the package.


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CAUTION: Use only the cleaning agents indicated below.
Zebra Technologies Corporation will not be responsible for
any other products being used on this printer. No lubricants
are needed.
Table 1 provides a brief cleaning schedule. Specific cleaning procedures
are provided on the following pages. Cleaning swabs saturated with 70%
isopropyl alcohol are available from your distributor as a preventive
maintenance kit.
Refer to Figure 15 for cleaning locations.
Table 1. Cleaning Schedule
Area Method Interval
Printhead (a) Alcohol After every roll of media (or 500 feet
Platen roller (b) Alcohol of fanfold media) when printing in
Media sensor (c) Air blow the direct thermal mode.
Media path (d) Alcohol
Ribbon path (e) Air blow After every roll of ribbon when
Upper guide rod (f) (Peel-Off) Alcohol printing in the thermal transfer
Platen guide rod (g) (Peel-Off) Alcohol mode.
Rewind power roller (h) (Peel-Off) Alcohol
Lower guide rod (i) (Peel-Off) Alcohol
Cutting continuous, Citrus based After every roll of media or more
pressure-sensitive adhesive often, depending upon your
media remover application and the media.
Cutter Assembly (j) Cutting tagstock or Alcohol and After every 2 or 3 rolls of media.
(if used) label backing air blow
material only
Tear-Off/Peel-Off plate (k) Alcohol Once a month.
Label available sensor (l) Air blow Once every six months.


Figure 15. Cleaning Locations


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The exterior surfaces of the printer may be cleaned with a lint-free cloth.
Do not use harsh or abrasive cleaning agents or solvents. If necessary, a
mild detergent solution or desktop cleaner may be used sparingly.

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Remove any accumulated dirt and lint from the interior of the printer using
a soft bristle brush and/or vacuum cleaner. Inspect this area after every
roll of media.

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Inconsistent print quality, such as voids in the bar code or graphics, may
indicate a dirty printhead. For optimum performance, perform the
following cleaning procedure after every roll of ribbon.
NOTE: It is not necessary to turn the printer off before cleaning
the printhead. If power is turned off, all label formats and images,
as well as any temporarily saved parameter settings stored in the
printer’s DRAM memory, are lost. When power is turned back on,
it is necessary to reload these items.
To clean the printhead, refer to Figure 16 and follow these steps:
1. Open the media access cover and the front cover (see Figure 4 on
page 5).
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.

Figure 16. Printhead and Platen Roller Cleaning
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(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 outlined in
Table 1. 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.

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1. Turn off the printer’s 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).

Figure 17. Label Catch Tray Removal


3. Raise the printer’s media access cover and lower the printer’s 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.

Figure 18. Cutter Cable Connector Removal
5. Turn the cutter mounting screw (b) with a screwdriver or by hand in a
counterclockwise direction until it is loose.


6. See Figure 19. Hold the cutter module as shown. Apply gentle
upward pressure to 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.

Figure 19. Cutter Module Removal


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1. 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.

Figure 20. Cutter Module Disassembly
2. 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. (You’re trying to tuck the loops underneath the blade guard in
this process.)
3. 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 are repositioned during reassembly.


4. 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 are mounted into the corresponding mounting
slots in the cutter side panels.
5. To provide complete access to the area to be cleaned, raise the upper
cutter blade guard (c) as shown in Figure 20.

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1. Remove any label material that has adhered to the cutter parts and use
a small brush to remove any paper dust from the cutter module.
2. If you use pressure-sensitive media, use a lint-free cloth soaked in an
adhesive remover to remove all gum and label residue from the cutting
blades and guards. If you use tag stock, use alcohol to remove any
dirt.

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1. See Figure 21. Position the two wire springs (a) down against the
lower cutter blade.
2. Place the rear cutter blade guard (b) over the wire springs,
perpendicular to its final position. Place your thumbs on the top (flat)
part of the guard.
NOTE: Ensure that the ends of the rear cutter blade guard are
positioned on the outside of the cutter side panels.
3. Press the rear cutter blade guard down and forward, rotating the guard
as you proceed, to lock the mounting pins (c) into position in the cutter
side panel mounting slots (d). Slide the guard forward until the two
wire spring loops pop up on the back side of the guard.
NOTE: Ensure that the wire springs remain positioned under the
rear cutter blade guard when assembly is completed.
4. Lower the upper cutter blade guard back to its normal position. When
reassembled, the back of the cutter module should look like the one
shown in Figure 22.


Figure 21. Cutter Module Reassembly

Figure 22. Cutter Module Reassembly — Rear View


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1. See Figure 19. Position the cutter module above the cutter mounting
posts (a). Press down on the cutter module until the mounting slots (b)
engage the mounting posts on the printer.
2. See Figure 18. Tighten the mounting screw (b) in a clockwise
direction to hold the cutter module in position.
3. See Figure 18. Position the cutter cable connector (a) so the flat side
of the connector faces away from the printer, then insert it up into the
mating connector on the cutter module.
4. Replace the cutter catch tray onto the two mounting posts located on
the front of the cutter module.

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1. If necessary, reload ribbon and label stock into the printer, then close
the printer’s front cover and media access cover.
NOTE: When loading media, make sure the end of the label is
positioned on top of the platen roller, then close the printhead open
lever.
2. When the printer is turned on, the cutter module cycles through one
cutting operation and is then ready to print labels.
3. OPTIONAL: Hold in the PAUSE button while turning on the
printer’s AC power. When the Power-On Self Test begins (all LEDs
on), release the PAUSE button. When the Power-On Self Test ends,
the printer automatically prints test labels that the cutter module
automatically cuts.

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CAUTION: No lubricating agents of any kind are required
on this printer. Some commercially available lubricants will
damage the finish if used.


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A user-replaceable AC power fuse (see Figure 6) is located just to the left
of the power on/off switch. For use with both voltage ranges, the
replacement fuse is a 5 x 20 fast blow style rated at 5 Amp/250 VAC.
1. Before replacing the fuse, turn the AC power switch off and unplug
the AC power cable.
2. To replace the fuse, insert the tip of a flathead screwdriver into the slot
in the end of the fuse holder end cap.
3. Press in slightly on the end cap and turn the screwdriver slightly
counterclockwise. This disengages the end cap from the fuse holder
and permits the removal of the fuse.
4. To install a new fuse, remove the old fuse and insert the new fuse into
the fuse holder.
5. Push the end cap in slightly, then insert the tip of a flat blade
screwdriver into the slot in the end cap and turn clockwise to engage it.
6. Plug in the AC power cable and turn the AC power switch on.

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This printer has been designed so that minimal operator adjustments are
required.

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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 “Toggle Pressure Adjustment” on page 40.


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1. Open the media access cover and front cover on the printer (see
Figure 4 on page 5).
2. Load the recommended media and ribbon for your application and
adjust the media sensor position.
3. Send a label format to the printer or activate the PAUSE Key Self Test
(see page 58), print a few labels, and press the PAUSE button to stop
printing.
4. Observe the print quality of the test labels. If it is satisfactory, exit the
PAUSE Key Self Test by pressing and holding the CANCEL button
until the DATA LED goes off. Otherwise, continue to “Adjusting the
Print Darkness (Burn Temperature)” below.

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1. Press the MODE button once (DARKEN and PAUSE LEDs turn on)
to permit darkness adjustment.
2. Press the PAUSE button to begin printing test labels.
3. While observing the print darkness, repeatedly press the UP (FEED)
button to make the printing darker, or the DOWN (CANCEL) button
to make the printing lighter, until the desired darkness is achieved.
4. Briefly press the MODE button three times. The MODE LEDs flash
on and off to indicate that the settings have been saved in memory.
5. Press the PAUSE button to stop printing.
NOTE: To confirm the change, turn off the printer. Then, turn on
the printer while holding the CANCEL button.
If you are still experiencing poor print quality, perform the toggle pressure
adjustment procedure on the next page. Otherwise, exit the PAUSE Key
Self Test by pressing and holding the CANCEL button until the DATA
LED goes off.


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The toggle assembly presses the printhead against the ribbon (if used), the
media, and the platen.
The pressure applied by the toggle assembly may need to be increased or
reduced when different thicknesses or widths of media are used in the
printer.
NOTE: Before increasing toggle pressure to achieve darker print
darkness, perform the print quality adjustments.
Refer to Figure 23. Turn the two knurled toggle pressure adjust knobs (a)
on top of the toggle assembly to adjust the pressure. Turning clockwise
increases the pressure, and turning counterclockwise decreases the
pressure.
Always use the lowest toggle pressure necessary to provide the desired
print darkness on the label.
NOTE: When using media narrower than 4.5 wide (full media
width), reduce the pressure on the right hand toggle until print
quality is affected, then increase pressure just to the point where
good print quality is achieved. This reduces the wear on those
areas of the printhead and the platen where ribbon and media are
not present. (For very narrow media, zero pressure from the right
toggle may be required.)

Figure 23. Toggle Pressure Adjustment


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This procedure sets the end-of-label position relative to the Tear-Off plate
or cutter. Adjust this if your label is not being torn or cut at the correct
point.
1. Briefly press the MODE button twice. The PAUSE and POSITION
LEDs turn on.
2. Press UP (FEED) or DOWN (CANCEL) to adjust the current setting.
3. Briefly press the MODE button twice. The MODE LEDs flash on and
off to indicate that the settings have been saved in memory.
4. Press PAUSE to exit the pause mode. The PAUSE LED turns off.

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This procedure positions the printing on the label relative to the top edge
of the label. Adjust this if your printing is too close or too far away from
the top or bottom edge of the label.
1. Briefly press the MODE button twice, then press and hold it for about
five seconds until the lights change. The PAUSE, DARKEN, and
CALIBRATE LEDs turn on.
2. Press UP (FEED) or DOWN (CANCEL) to adjust the current setting.
3. Briefly press the MODE button twice. The MODE LEDs flash on and
off to indicate that the settings have been saved in memory.
4. Press PAUSE to exit the pause mode. The PAUSE LED turns off.

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Please see “Adjusting the Media Sensor” on page 18 to adjust the media
sensor position.

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Please see page 15 for the ribbon supply spindle adjustment procedure.


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(Peel-Off option required).
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 ensure
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 loading procedure for
“Peel-Off Mode” on page 11. Ensure 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.


Figure 24 illustrates an improperly adjusted backing rewind power roller
(a). On the left side, the backing material (b) is not contacting the power
roller. The backing has more tension on the right edge (c) than on the left
edge (d).
Use a coin or screwdriver to turn the power roller adjustment (e). The
adjustment mechanism changes the position of the right end of the roller,
while the left end is stationary. The right end moves up and down for
tension balance.
Turning this adjustment in a counterclockwise direction causes the right
end of the power roller to move down and increases the tension on the
right side of the backing material. (Turning the adjustment in a clockwise
direction moves the right end of the power roller up and decreases the
tension on the right side.)
Balancing the tension increases the reliability of the printer to provide
properly printed labels by preventing the label backing from walking.
Use the FEED Key Self Test (see page 59) or your own label format to
print several labels to ensure tracking is maintained and tension on both
edges of the backing material remains consistent. Remember to remove
each label as it is automatically peeled away from the backing.

Figure 24. Improper Backing Rewind Power Roller Adjustment


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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.

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Symptom Diagnosis Action
No AC power Ensure the AC power cable is connected to
applied to the a working voltage source.
printer.
Faulty AC power Replace the fuse.
No LEDs turn on. fuse.
No voltage available Call a service technician.
from the internal
power supply.
Printer locks up with all LEDs on when Hardware failure. Call a service technician.
running the Power-On Self Test.
CALIBRATE LED off but all other LEDs Boot-block CRC Call a service technician.
on. error.
CALIBRATE and POSITION LEDs off DRAM error. Call a service technician.
but all other LEDs on.
CALIBRATE, POSITION, and Firmware
DARKEN LEDs off but all other LEDs decompression
on. error. Call a service technician for instructions on
CALIBRATE, POSITION, DARKEN, Firmware error. how to download and install firmware.
and DATA LEDs off but all other LEDs
on.
CALIBRATE, POSITION, DARKEN, Firmware error.
DATA, and PAUSE LEDs off but all
other LEDs on.


Media incorrectly or Load media correctly, then turn the printer
not loaded. off and on. See page 8.
Cutter error. Clear jam, then open and close the
printhead.
Printer stops, PAUSE LED and
Calibration error. Re-calibrate printer.
PAPER/RIBBON LED both on.
Misadjusted media Check position and sensitivity of media
sensor. sensor. See page 18.
Are you using pre- Calibrate the printer. See page 19.
printed media?
Ribbon incorrectly or Load ribbon correctly, then turn the printer
not loaded. off and on. See page 15.
Backing rewind Remove label backing from the spindle.
Printer stops, PAUSE LED on and spindle is full. See page 13.
PAPER/RIBBON LED flashing.
Malfunctioning Call a service technician.
ribbon sensor.
Ribbon not Calibrate the ribbon. See “Resetting
calibrated. Ribbon Parameters” on page 55.
Printhead is not fully Close printhead completely, then turn the
closed. printer off and on.
Printer stops, PAUSE LED on and Printhead open Call a service technician.
PRINTHEAD LED flashing. sensor not detecting
its position flag.
Printhead element is Printer resumes printing when the printhead
Printer stops, PAUSE LED and overheated. element cools.
PRINTHEAD LED both on. Power supply over Printer resumes printing when the power
temperature. supply cools.
Printhead open. Close the printhead.
You’re using pre- Perform a manual calibration. See “Manual
Printer does not successfully perform printed labels. Calibration” on page 53.
an auto calibration.
Media is out. Load media. Ensure that the media sensor
is properly positioned.
Media is out of Ensure that the media sensor is properly
specification. positioned. Or, perform a manual
Printer does not perform a manual calibration. See “Manual Calibration” on
calibration. page 53.
Hardware failure. Call a service technician.
Printing continues, PRINTHEAD LED Printhead is under Continue printing.
on. temperature.
PAUSE LED flashing. Waiting for user to Remove label.
peel label.


DATA LED is single flashing. CANCEL button was No action required.
pressed and a
format was deleted.
PAUSE LED and DATA LED alternately Firmware error. Call a service technician for instructions on
flashing, but all other LEDs on. how to download and install firmware.
DATA LED is flashing. Printer is receiving Printing resumes when data is received.
data.
DATA LED is slow flashing. Printer sent a “stop No action required.
transmitting” to the
host computer.
Dirty printhead. Clean the printhead. See page 29.
Printhead element Call a service technician.
going bad. Print
Dots missing in printed area of label. quality problems.
Print width set Default the printer. See “Resetting Factory
incorrectly. Defaults” on page 54.
Loss of printing Possible media Adjust media sensor position (see page 18)
registration on labels. sensor problem. and call a service technician if necessary.
Printer set for non- Set printer for correct media. See “Non-
continuous media, Continuous Media” and “Continuous Media”
but continuous on page 19.
media loaded.
Improperly adjusted See “Adjusting the Media Sensor” on
media edge guides page 18 and “Backing Rewind Power Roller
For Peel-Off mode: or power roller. Adjustment” on page 42 for proper
positioning and adjustments.
Excessive vertical drift in top-of-form Incorrect media See “Loading the Media” on page 8 or
registration. loading or media “Adjusting the Media Sensor” on page 18.
sensor adjustments.
Dirty head or ribbon See “Cleaning the Printhead and Platen
Light vertical lines approximately 0.006 rollers. Roller” on page 29.
wide running through all labels. Defective printhead Call a service technician.
elements.
Light printing or no printing on the left Printhead needs Adjust balance. See “Toggle Pressure
or right side of the label. balancing. Adjustment” on page 40.
Short printed lines at 45° to label edge Too much printhead Reduce the pressure. See “Toggle
on left or right side of label. pressure. Pressure Adjustment” on page 40.


Media or ribbon See “Loading the Media” on page 8 and
Truncated print, no print, or FEED improperly loaded. “Loading the Ribbon” on page 15.
button operates incorrectly while using Incorrect media See “Adjusting the Media Sensor” on
non-continuous media. sensor position or page 18.
sensitivity. See “Auto Calibration” on page 19.
Fine gray lines on blank labels at Wrinkled ribbon. See “Wrinkled Ribbon” in this table.
angles.
Long tracks of missing print on several Wrinkled ribbon. See “Wrinkled Ribbon” in this table.
labels. Print element Call a service technician.
damaged.
Ribbon fed through See “Loading the Ribbon” on page 15.
machine incorrectly.
Incorrect darkness Set to the lowest value needed for good
setting. print quality.
Incorrect printhead See “Toggle Pressure Adjustment” on
pressure. page 40.
Incorrect dual- Pull spindle end cap out when using wide
Wrinkled Ribbon tension spindle media to obtain normal (higher) tension.
setting. See “Loading the Ribbon” on page 15.
Media not feeding Make sure the media is snug by adjusting
properly; it is walking the media guides.
from side to side.
Continuing Call a service technician.
symptoms.
Glue material from Refer to “Routine Care and Adjustments”
back of labels beginning on page 27 and perform
causing media maintenance and cleaning of the printer.
movement
In Peel-Off mode, skewed or stuck problems.
labels. Media and backing Reload media and adjust the power roller, if
not properly aligned needed. See “Loading the Media” on
in printer. page 8 and “Backing Rewind Power Roller
Adjustment” on page 42.
Media was pulled Open and close the printhead, so it
when motor was not calibrates to find the label length.
moving.
Incorrect media See “Adjusting the Media Sensor” on
Image is not positioned correctly and/ sensor position. page 18.
or misprint of 1 to 3 labels.
Media or ribbon See “Loading the Media” on page 8 and
improperly loaded. “Loading the Ribbon” on page 15.
Auto calibrate failed. Perform a manual calibration. See “Manual
Calibration” on page 53.


Parameters are set Reload the factory defaults (see “PAUSE
or saved incorrectly. Key Self Test” on page 58 and “FEED Key
Self Test” on page 59), calibrate the printer,
then cycle the power on/off switch.
Changes in parameter settings did not If problem Call a service technician.
take effect. continues, there
may be a problem
on the main logic
board.
When using wide ribbon (over 2.4), the Too much back- See “Loading the Ribbon” on page 15 to
image gets lighter or smears near the tension on the adjust the ribbon supply spindle to provide
end of the roll of ribbon. Ribbon ribbon. low tension.
appears to slow down or stop.
Communications Print configuration label and verify that the
parameters are set host computer and printer settings match.
incorrectly. If they do, perform the MODE Key Self Test
and check for format or overrun errors. If
they do not, see “Communicating with the
Printer” on page 24.
Prefix and delimiter Set the characters in the printer to match
ZPL was sent to printer, but not characters set in the ZPL format.
recognized. The DATA LED remains printer configuration
off. do not match the Check configuration printout for correct
ones sent in the ZPL characters.
label formats.
If problem continues, check the ZPL format
for changed ^CC, ^CT, and ^CD
instructions.


Cutter is dirty. See “Cleaning the Cutter Module” on
In cutter mode, skewed, stuck, page 30.
improperly cut or partially cut labels. Cutter blades are Call a service technician.
dull.
The cutter is jamming up with labels, or Cutter is dirty. See “Cleaning the Cutter Module” on
labels are being cut more than once. page 30.
Label length is too Increase label length.
short.
Cutter option not See “Reinstalling the Cutter Module” on
enabled. page 37.
Labels are not being cut at all. Connecting cable With printer power off, plug cable into cutter
not connected to module.
cutter module.
Printing stops, PAPER/RIBBON, Out of media. Load media.
PAUSE, and CANCEL LEDs on.
Media jammed in Remove media, clean cutter module if
cutter. necessary.
Cutter module is Clean cutter module. See page 35.
dirty.
For printers with the cutter option
End of the media not Reposition media so that the end is on top
installed.
positioned correctly of the platen. See page 18.
on top of platen.
If error condition persists after attempting each of the above
solutions, call a service technician.


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The printer contains several status sensors. These sensors alert the
operator to various conditions by either stopping the printing or turning on
an LED.

Sensor What it Monitors How it Works
Printhead sensor Checks the open/closed If the printhead is open, the
status of the printhead lever. PRINTHEAD LED flashes.
Media sensor Checks for proper media
loading. If you run out of paper, the
(See page 18 to adjust If non-continuous media is PAPER/RIBBON LED turns on.
this sensor.) used, sets label length for
individual labels.
Ribbon sensor Monitors the presence of If you run out of ribbon, the
ribbon. PAPER/ RIBBON LED flashes.
Label available sensor In Peel-Off mode, it checks to Once a label prints, it passes
(Peel-Off option see if a label is available. between the two parts of this
required. See sensor and causes the printer to
Figure 25.) pause. When the label is
removed, printing resumes.
Backing rewind spindle Senses when the backing When the spindle is full, the
full sensor (Peel-Off rewind spindle is full of used PAPER/RIBBON LED flashes.
option required. See backing material.
Figure 26.)


Figure 25. Label Available Sensor

Figure 26. Backing Rewind Spindle Full Sensor


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Perform a manual calibration if you are using pre-printed media, if
the printer is in manual calibration mode, or if the printer does 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 printer’s memory and are
retained even if printer power is removed. These parameters remain in
effect until the next calibration is performed.
NOTE: 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 if you change media (a label prints
that shows the sensor profile).
NOTE: 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 prints.
NOTE: To return to Auto Calibration, press and hold the PAUSE,
CANCEL, and MODE buttons when you turn on the printer.

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If it is ever necessary to reset all of the factory default values, press and
hold the FEED and PAUSE buttons while turning on the power.
Permanently save these values in memory by pressing the MODE button
four times; the DARKEN, POSITION, and CALIBRATE LEDs flash,
indicating the changes have been saved. To return to printing mode, turn
off and then turn on the printer.

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Pressing and holding the FEED, PAUSE, and MODE buttons while
turning on the power resets only the communications parameters to 9600
baud, 8 bit word length, no parity, and 1 stop bit. Permanently save these
values in memory by pressing the MODE button four times; the
DARKEN, POSITION, and CALIBRATE LEDs flash, indicating the
changes have been saved.


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If it is ever necessary to reset the ribbon parameters to the factory default
values, follow this procedure:
1. Turn off the printer.
2. Open the printhead and remove the ribbon.
3. Turn on the printer while pressing and holding the FEED, CANCEL,
and MODE buttons.
4. After the PRINTHEAD LED flashes, reload the ribbon.
5. Close the printhead.
NOTE: A label automatically prints, showing the ribbon sensor
profile.
6. To save, press the MODE button four times.

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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
printer’s memory. During this test sequence, the front panel lights turn on
and off to ensure proper operation.
At the end of this self test, only the POWER LED remains lit. If other
LEDs are also lit, refer to “Troubleshooting Tables” beginning on page 45.


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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 automatically starts. To return to printing
mode, turn off and then turn on the printer.
NOTE: When performing self tests, disconnect all
communications interface cables from the printer.
NOTE: When canceling a self test before its actual completion,
always turn the printer power switch off and then back on.
NOTE: When performing these self tests while in the Peel-Off
mode, the operator must remove the labels as they become
available.
NOTE: When the cutter option is installed and enabled, the labels
printed in these self tests should be automatically cut as they are
printed.


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This self test prints the printer’s configuration parameters (for example,
printing darkness, label length, and media type) that are currently stored in
configuration (Flash) memory. See Figure 27.
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. Configuration Label


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This self test can be used to provide the test labels required when making
adjustments to the printer’s mechanical assemblies. See Figure 28.
1. Press the PAUSE button while turning on the printer.
2. Release the button when the front panel LEDs turn on.
NOTE: This self test consists of four individual test features:
• The initial self test prints 15 labels at 2.4/second then
automatically pauses the printer. Each time the PAUSE button is
pressed, an additional 15 labels will print, up to 9999 labels.
• 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.
• 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.
• 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. PAUSE Test Label


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The results of this self test are used to determine the best darkness setting
for a specific media/ribbon combination. Refer to Figure 29.
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.
To adjust print darkness, see
“Print Quality Adjustments” on
page 38.

Figure 29. FEED Test Label

NOTE: The FEED Key Self Test labels print at various plus or
minus darkness settings relative to the current darkness setting.
Inspect these printouts and determine which printout has the best
darkness setting.
NOTE: The value on that 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 note] for the new darkness
setting.)
NOTE: Increments to the actual darkness value can be
programmed into the label formats sent to the printer. To see the
actual value of the current darkness setting, perform a CANCEL
Key Self Test; the value prints on the configuration printout.


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This self test places the printer in a communications diagnostics mode. In
this mode, the printer prints the ASCII characters and their corresponding
hexadecimal values for any data received from the host computer. See
Figure 30.
1. Press the MODE button while turning on the printer.
2. Release the button when the front panel LEDs turn on.
NOTE: Turn off the power to exit this self test.

Figure 30. MODE Test Label


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NOTE: Printer specifications are subject to change without notice.
In addition, your printer may not have all of the options described
in these specifications.

*HQHUDO 6SHFLILFDWLRQV
Height 13 330 mm
Width 8.25 210 mm
Depth 17 432 mm
Weight (option-dependent) 17 lbs. 7.71 kg
Auto range 110 VAC +/–20% or
Electrical 230 VAC +/–15%, 47-63 Hz
3 Amps @ 110 VAC, 1.5 Amps @ 230 VAC
Agency approvals UL 1950 3rd Edition; CSA22.2 No950-95;
CISPR22-B; EN50082-1; EN60950.
Meets FCC Class B and
Canadian DOC Class A Rules
Temperature Operating 40 to 105º F 5 to 40º C
Storage –40 to 140º F –40 to 60º C
Relative humidity Operating 20% to 85%, non-condensing
Storage 5% to 85%, non-condensing
DB-9S-type RS-232 serial data interface; 110-57, 600
Communications Interface baud; parity, bits/char. and XON/XOFF or DTR
handshake protocols — all software selectable
Bi-directional parallel data interface


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Printing Specifications S400 Printer S600 Printer
Resolution 203 dots per inch (8 dots per mm)
Dot size (square) 0.005 (0.127 mm)
Maximum print width 4.09 (104 mm)
Print Length Minimum 0.005 (0.127 mm)
Maximum 36 (914 mm) 39 (991 mm)
Bar code modulus (“X”) dimension 5 mil to 55 mil
2 (51 mm)
2 (51 mm) 3 (76 mm)
Programmable constant printing speeds 3 (76 mm)
4 (102 mm)
4 (102 mm)
5 (127 mm)
6 (152 mm)
DRAM Memory 1MB 2MB
Flash Memory (E:) n/a 1MB

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Ribbon width (Zebra recommends Minimum 1.57 40 mm
using ribbon at least as wide as the Maximum 4.5 114 mm
media to protect the printhead from
wear).
Standard lengths 2:1 media to ribbon roll ratio 984' 300 m
3:1 media to ribbon roll ratio 1476' 450 m
Ribbon core inside diameter 1.0 25 mm
Maximum ribbon roll diameter 3.2 81 mm


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Total media width Minimum 0.75 19 mm
Maximum 4.5 114 mm
Maximum (cutter installed) 4.0 102 mm
Tear-Off 0.63 16 mm
Minimum Peel-Off 1.00 25 mm
Label length
Cutter 1.50 38 mm
Maximum See “Printing Specifications”
Total thickness Minimum 0.0023 0.058 mm
(includes liner) Maximum (printhead position may need to 0.012 0.305 mm
be adjusted above 0.01)
Core size 3.0 76 mm
Maximum roll diameter 8.0 203 mm
Minimum 0.08 2 mm
Inter-label gap (0.118 preferred) (3 mm preferred)
Maximum 0.16 4 mm
Ticket/tag notch size (W x L) 0.08 x 0.48 2 mm x 12 mm

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• Tear-Off mode: Produced in strips.
• Peel-Off mode: Dispensed and peeled away from the liner.
• Cutter mode: Printed and individually cut.

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• 8 MB flash expansion • *Cutter with label catch tray
• *Peel-Off mode with backing-only rewind • Ethernet
feature
• Scalable and bitmap smooth fonts available for
text
* Factory installed.
Contact your authorized Zebra distributor for information.


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• Downloadable graphics (with data • Programmable quantity with print pause
compression)
• Bit image data transfer and printing, mixed • Communicates in printable ASCII
text/graphics characters
• Format inversion • Controlled via mainframe, mini, PC,
Portable Data Terminal
• Mirror image printing • Serialized fields
• Four-position field rotation • In-Spec OCR-A and OCR-B
(0º, 90º, 180º, 270º)
• Slew command • UPC/EAN (nominal 100% magnification)

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1D 2D
• Codabar (supports ratios • Interleaved 2 of 5 • Codablock
of 2:1 to 3:1) (supports ratios of 2:1 to
3:1, Modulus 10 Check
Digit)
• Code 11 • LOGMARS • Code 49
• Code 128 (supports • MSI • Data Matrix
serialization in all subsets
and UCC Case Codes)
• Code 39 (supports ratios • Plessey • MaxiCode
of 2:1 to 3:1)
• 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


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• Zebra fonts A, B, C, D, E, F, G, H, GS, 0, P, Q, R, S, T, U, V
• CG Triumvirate Bold Condensed™ scalable smooth font
• IBM Code Page 850 International characters

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There are many optional character fonts that can be purchased for your
printer in addition to those that are standard in the unit. From time to time,
additions may be made to the list of available fonts. Contact Zebra
Technologies Corporation or an authorized Zebra distributor for further
information.
Fonts can be installed in Flash, and additional Flash (up to 8 MB), is
available. Once installed, this font can be used in addition to the standard
fonts available in the printer. Refer to your ZPL II Programming Guide or,
if using another software package to drive your printer, to the instructions
accompanying that package.


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56 RQQHFWRU 7HFKQLFDO ,QIRUPDWLRQ
RS-232 Connector Pinouts
Pin. No. Description
1 Not used
2 RXD (receive data) input to the printer
3 TXD (transmit data) output from the printer
4 DTR (data terminal ready) output from the printer — controls when the host
may send data
5 Chassis ground
6 DSR (data set ready) input to the printer
7 RTS (request to send) output from the printer — always in the ACTIVE
condition when the printer is turned on
8 Not used
9 5 V Fused
NOTE: When XON/XOFF handshaking is selected, data flow is
controlled by the ASCII control codes DC1 (XON) and DC3
(XOFF). The DTR control lead has no effect.

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The printer is configured as data terminal equipment (DTE). To connect
the printer to other DTE devices (such as the serial port of a personal
computer), use an RS-232 null modem (crossover) cable. Figure 31 shows
the required cable connections.

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When the printer is connected via its RS-232 interface to data
communication equipment (DCE) such as a modem, a STANDARD
RS-232 (straight-through) interface cable must be used. Figure 32 shows
the connections required for this cable.


Figure 31. DTE Cable Connections

Figure 32. DCE Cable Connections


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Parallel Connector Pinouts
Pin No. Description
1 nStrobe/Host Clk
2-9 Data Bits 1-8
10 nACK/PtrClk
11 Busy/Per Busy
12 PError/ACK Data Req.
13 Select/Xflag
14 nauto Fd/Host Busy
15 Not Used
16-17 Ground
18 +5V @ 1A Fused
19-30 Ground
31 nlnit
32 nFault/nData Avail.
33-34 Not Used
35 +5V through 2.2K× Resistor
36 NSelectIn/1284 active


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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 is
properly positioned behind the printhead. Backfeed occurs when you’re
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 is 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.
Font — A complete set of alphanumeric characters in one style of type.
Example: Times, Helvetica.
Ips “inches-per-second” — The speed at which the label or tag is printed.
Zebra offers printers that can print from 2 ips to 12 ips.
Label — An adhesive-backed piece of paper, plastic, or other material on
which information is printed.
Label available sensor — For printers equipped with the Peel-Off option,
this sensor detects a printed label waiting to be taken or “picked” by the
operator. While it detects this label, the printer does not print additional
labels. Once the label has been taken, printing resumes. Also called
“take-label sensor.”
Label backing (label liner) — The material on which labels are affixed
during manufacture and that is discarded or recycled by the end-users.
Label backing (or liner) has a non-stick surface that allows the label to be
easily removed by the end-user and placed in the desired location.
Media — Material onto which data is printed by the printer. Types of
media include: tagstock, continuous, fanfold, roll, etc.
Media sensor — This sensor is located behind the printhead to detect the
presence of media and, for non-continuous media, the position of the web,
hole, or notch that separates each label.


Media supply spindle — The rotating arm that supports media rolls and
provides consistent media feed to the printhead.
Non-volatile memory — Electronic memory that retains data even when
power is removed.
Print speed — The speed at which printing occurs. For thermal transfer
printers, this speed is expressed in terms of ips (inches per second).
Printhead wear — The degradation of the surface of the printhead and/or
the print elements over time. Heat and abrasion can cause printhead wear.
Therefore, to maximize the life of your printhead, use the lowest print
darkness setting (sometimes called “burn temperature” or “head
temperature”) and the lowest printhead/toggle pressure necessary. Also,
use ribbon that is as wide as or wider than the media to protect the
printhead from the rougher media.
Registration — Alignment of printing with respect to the top of a
label/tag.
Ribbon — A band of inked material that is pressed by the printhead
against the media to transfer an image onto the media, which in turn is
pressed against the platen. A ribbon consists of a base film coated with
wax or resin “ink.” Zebra 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. A void can cause a bar code symbol to be read
incorrectly or to not be read at all.


›clà

A D
Adjustments Damage, 2
Backing Rewind Power Roller, 42 DCE Devices, 67
Media Rest Position, 41 DTE Devices, 67
Media Sensor, 18
Print Quality, 38 F
Toggle Pressure, 40 Factory Defaults (resetting), 54
Top of Label, 41 Fanfold Media Loading, 10
Auto Calibration, 19 FEED Button, 20
FEED Key Self Test, 59
B Fonts
Backing Rewind Power Roller Adjustment, 42 Optional, 65
Bar Codes, 64 Standard, 65
Front Panel Buttons
C CANCEL, 20
Calibration FEED, 20
Auto, 19 MODE, 21
Manual, 53 PAUSE, 20
CANCEL Button, 20 Front Panel LEDs, 21
CANCEL Key Self Test, 57 Fuse Replacement, 38
Cleaning
Cutter, 30 G
Exterior, 29 General Specifications, 61
Interior, 29 Glossary, 71
Printhead and Platen Roller, 29
Communications Parameters (resetting), 54 I
Continuous Media Adjustment, 19 Interface Connections
Cutter Module Parallel, 69
Cleaning, 35 RS-232, 67
Disassembly, 34
Reassembly, 35 L
Reinstallation, 37 Label Backing Material Removal, 13
Removal, 31 Lubrication, 37
Testing, 37


M Print Quality Adjustments, 38
Printer Communication
Manual Calibration, 53
Parallel Port, 24
Mechanical Adjustments
Serial Port, 24
Backing Rewind Power Roller, 42
Set Communications Command, 26
Media Rest Position, 41
Printer Components, 6
Media Sensor Position, 41
Printer Identification
Print Quality, 38
Cutter Mode, 4
Ribbon Supply Spindle, 41
Peel-Off Mode, 4
Toggle Pressure, 40
Tear-Off Mode, 3
Top of Label Position, 41
Printer Status Sensors, 51
Media Handling Specifications, 63
Printer/Computer Connections
Media Loading
Parallel Interface, 23
Cutter Mode, 14
RS-232 Interface, 23
Fanfold, 10
Serial/Parallel Cabling, 24
Peel-Off Mode, 11
Printhead and Platen Roller Cleaning, 29
Tear-Off Mode, 9
Printing a Test Label, 22
Media Rest Position Adjustment, 41
Printing Specifications, 62
Media Sensor Adjustment
Continuous Media, 19 R
Non-Continuous Media, 19
Reporting Damage, 2
Media Specifications, 63
Resetting Printer Parameters
MODE Button, 21
Communications, 54
Mode Key Self Test, 60
Factory Defaults, 54
N Ribbon, 55
Reshipping, 2
Non-Continuous Media Adjustment, 19
Ribbon
O Loading, 15–16
Parameters (resetting), 55
Operator Controls, 20–21 Removal, 17
Options, 63 Specifications, 62
P Ribbon Supply Spindle
Low-Tension Position, 15
Parallel and Serial Cabling Requirements, 24 Normal Position, 15
Parallel Interface RS-232 Connections
Connections, 69 DCE Devices, 67
Requirements, 23 DTE Devices, 67
Parallel Port Communication, 24 RS-232 Interface Requirements, 23
PAUSE Button, 20
PAUSE Key Self Test, 58
Power Cable, 7
Power On/Off Switch, 22
Power-On Self Test, 55


S
Self Tests
Additional Printer Self Tests, 56
CANCEL Key, 57
FEED Key, 59
MODE Key, 60
PAUSE Key, 58
Power-On, 55
Serial and Parallel Cabling Requirements, 24
Serial Port Communication, 24
Set Communications Command, 26
Site Requirements, 3
Software Setup, 26
Specifications
Bar Codes, 64
General, 61
Media Handling, 63
Media, 63
Options, 63
Printing, 62
Ribbon, 62
Zebra Programming Language (ZPL), 64
Storage, 2

T
Toggle Pressure Adjustment, 40
Top of Label Position Adjustment, 41
Troubleshooting Tables, 45–50

U
Unpacking, 1

Z
Zebra Programming Language (ZPL), 64


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