S4M™

Industrial/Commercial Printer

User Guide
© 2005 ZIH Corp.

The copyrights in this manual and the label printer described therein are owned by
Zebra Technologies Corporation. 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.

This product may contain ZPL®, ZPL II®, and ZebraLink™ programs; Element
Energy Equalizer® Circuit; E3®; and AGFA fonts. Software © ZIH Corp. All
rights reserved worldwide.

ZebraLink and all product names and numbers are trademarks, and Zebra, the
Zebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit are
registered trademarks of ZIH Corp. All rights reserved worldwide.

All other brand names, product names, or trademarks belong to their respective
holders.

Part Number: 13290L-001 Rev. A

 Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Americas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Europe, Africa, Middle East, and India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 • Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Control Panel LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Printer Language Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
New or Modified Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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2 • Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unpack and Inspect the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspect the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Report Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Select a Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Types of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Data Cable Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ribbon Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
When to Use Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coated Side of Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3 • Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Media Loading Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Print Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Starting a Roll of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inserting Media into the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Load Media in Tear-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Load Media in Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Remove the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Position the Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Select the Transmissive Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjust the Reflective Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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 Contents v

4 • Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Leave Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Password Protection of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Printing Configuration Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Select a Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control Panel LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Password Level 1 and 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Password Level 3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5 • Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clean the Printhead and Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Clean the Peel-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Calibration Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Miscellaneous Printer Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Power-On Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
FEED Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
FEED and PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

7 • Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

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A • ZPL II Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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 About This Document

This section provides you with contact information, document structure and organization, and
additional reference documents.

Contents
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Web Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
The Americas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Europe, Africa, Middle East, and India. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Asia Pacific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10/21/05 S4M User Guide 13290L-001 Rev. A

2 About This Document
Who Should Use This Document

Who Should Use This Document

This User Guide is intended for use by any person who needs to operate or troubleshoot
problems with the printer.

How This Document Is Organized

The User Guide is set up as follows:

Section Description
Introduction on page 7 This section shows the operational controls and
location of major components used when loading
media and ribbon. Other features of the printer are
discussed.
Printer Setup on page 15 This section provides the tasks that you must
complete and the issues that you must consider
before you load and configure your printer.
Operations on page 29 This section provides the procedures for loading
and calibrating the printer.
Configuration on page 51 This section discusses printer configuration
settings and instructs you how to view or change
printer parameters through the control panel.
Routine Maintenance on page 77 This section provides routine cleaning and
maintenance procedures.
Troubleshooting on page 85 This section provides information about errors that
you might need to troubleshoot. Assorted
diagnostic tests are included.
Specifications on page 105 This section provides the features of and
specifications for the printer.
ZPL II Commands on page 111 This section provides the ZPL II commands that
were added or changed for the S4M.

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 About This Document 3
Contacts

Contacts
You can contact Zebra Technologies at the following.

Web Site
http://www.zebra.com

The Americas

Regional Headquarters Technical Support Customer Service Dept.

Zebra Technologies International, T: +1 847 913 2259 For printers, parts, media, and ribbon,
LLC F: +1 847 913 2578 please call your distributor, or
333 Corporate Woods Parkway Hardware: hwtsamerica@zebra.com contact us.
Vernon Hills, Illinois 60061.3109 Software: swtsamerica@zebra.com T: +1 866 230 9494
U.S.A E: VHCustServ@zebra.com
T: +1 847 793 2600
Toll-free +1 800 423 0422
F: +1 847 913 8766

Europe, Africa, Middle East, and India

Regional Headquarters Technical Support Internal Sales Dept.

Zebra Technologies Europe Limited T: +44 (0) 1494 768298 For printers, parts, media, and ribbon,
Zebra House F: +44 (0) 1494 768210 please call your distributor, or
The Valley Centre, Gordon Road Germany: Tsgermany@zebra.com contact us.
High Wycombe France: Tsfrance@zebra.com T: +44 (0) 1494 768316
Buckinghamshire HP13 6EQ, UK Spain/Portugal: Tsspain@zebra.com F: +44 (0) 1494 768244
T: +44 (0)1494 472872 All other areas: Tseurope@zebra.com E: mseurope@zebra.com
F: +44 (0) 1494 450103

Asia Pacific

Regional Headquarters Technical Support Customer Service

Zebra Technologies Asia Pacific, LLC T: +65 6858 0722 For printers, parts, media, and ribbon,
16 New Industrial Road F: +65 6885 0838 please call your distributor, or
#05-03 Hudson TechnoCentre E: tsasiapacific@zebra.com contact us.
Singapore 536204 T: +65 6858 0722
T: +65 6858 0722 F: +65 6885 0837
F: +65 6885 0838

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4 About This Document
Document Conventions

Document Conventions
The following conventions are used throughout this document to convey certain information.

Alternate Color (online only) Cross-references contain hot links to other sections in this
guide. If you are viewing this guide online in .pdf format, you can click the cross-reference
(blue text) to jump directly to its location.

LCD Display Examples Text from a printer’s Liquid Crystal Display (LCD) appears in
Bubbledot ICG font.

Command Line Examples Command line examples appear in Courier New font. For
example, type ZTools to get to the Post-Install scripts in the bin directory.

Files and Directories File names and directories appear in Courier New font. For
example, the Zebra<version number>.tar file and the /root directory.

Icons Used

Caution • Warns you of the potential for electrostatic discharge.

Caution • Warns you of a potential electric shock situation.

Caution • Warns you of a situation where excessive heat could cause a burn.

Caution • Advises you that failure to take or avoid a specific action could result in physical
harm to you.

Caution • (No icon) Advises you that failure to take or avoid a specific action could result in
physical harm to the hardware.

Important • Advises you of information that is essential to complete a task.

Note • Indicates neutral or positive information that emphasizes or supplements important

points of the main text.

Example • Provides an example, often a scenario, to better clarify a section of text.

Tools • Tells you what tools you need to complete a given task.

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 About This Document 5
Document Conventions

Illustration Callouts Callouts are used when an illustration contains information that needs
to be labeled and described. A table that contains the labels and descriptions follows the
graphic. Figure 1 provides an example.

Figure 1 • Sample Figure with Callouts

POWER ALERT

MENU ENTER

1 CANCEL FEED

PAUSE
2

1 FEED button
2 CANCEL button

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6 About This Document
Document Conventions

Notes • ___________________________________________________________________

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13290L-001 Rev. A S4M User Guide 10/21/05

 1
Introduction

This section shows the operational controls and location of major components used when
loading media and ribbon. Other features of the printer are discussed.

Contents
External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Control Panel LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Printer Media Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Printer Language Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Firmware Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
New or Modified Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional Printer Language Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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8 Introduction
External View

External View
Figure 2 shows the outside of the printer.

Figure 2 • Exterior of Printer

Front

Rear

4
5

1 Control panel
2 Media door
3 Electronics cover
4 Power switch (O = Off, I = On)
5 AC power connector

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 Introduction 9
Control Panel

Control Panel
All controls and indicators for the printer are located on the control panel (Figure 3).
• The control panel Liquid Crystal Display (LCD) shows the operating status and printer
parameters.
• The control panel buttons are used to control the printer operations and to set parameters.
• The control panel lights (LEDs) show the printer’s operating status or indicate which
control panel buttons are active.

Figure 3 • Location of Control Panel Buttons and Lights

2 1

POWER ALERT

4
MENU ENTER

5
CANCEL FEED
6
PAUSE
7
8
9

1 Alert light
2 Power light
3 LCD
4 ENTER button
5 MENU button
6 Up arrow button
7 CANCEL or Left Arrow button
8 FEED or Right Arrow button
9 PAUSE or Down Arrow button

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10 Introduction
Control Panel

Control Panel LCD

The control panel LCD functions differently in different printer modes.
• In Operating mode, the LCD displays the printer’s status, sometimes in conjunction with
a control panel light (see Control Panel Lights on page 12). When the printer is receiving
data, the control panel shows the word DATA and cycles through a series of dots and
spaces.
• In Pause mode, the printer stops printing temporarily.
• In Setup mode, you can use the control panel LCD to view or modify printer parameters
(see Control Panel LCD Display on page 60).
• In Error mode, the LCD may display an alert or error message (see LCD Error Messages
on page 87).

Control Panel Buttons

The printer has six basic control buttons on the control panel. Some of these buttons also
function as navigational keys when the printer is in Setup mode. The current function of a
particular button is determined by which light is illuminated next to it (Figure 4).

Figure 4 • Example of Active Control Panel Buttons

1 FEED FEED

1 FEED active
2 Right arrow active

Table 1 describes the function of each button. The MENU, PAUSE, and FEED buttons are
active when the printer is in normal operating mode.

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 Introduction 11
Control Panel

Table 1 • Control Panel Buttons

Button Appearance Function/Description

MENU MENU Enters and exits Setup mode.

ENTER ENTER If a parameter or option in Setup mode needs to be selected, pressing

ENTER selects the item. This button is active only when necessary.

CANCEL CANCEL CANCEL functions only in Pause mode. Pressing CANCEL once has these
effects:
• Cancels the label format that is currently printing.
• If no label format is printing, the next one to be printed is canceled.
• If no label formats are waiting to be printed, CANCEL is ignored.
To clear the printer’s entire label format memory, press and hold
CANCEL.
FEED FEED Advances a blank label.
• If the printer is idle or paused, the label is fed immediately.
• If the printer is printing, the label is fed after printing finishes.
PAUSE PAUSE Stops and restarts the printing process or removes error messages and
clears the LCD. When the printer is paused, the PAUSE light blinks.
• If the printer is idle, it enters Pause mode immediately.
• If the printer is printing, the label is completed before the printer
pauses.
Left Arrow When in Setup mode, scrolls the LCD to the previous parameter.

Right Arrow When in Setup mode, scrolls the LCD to the next parameter.

Up Arrow When in Setup mode, increases values or scrolls to the next option.

Down Arrow When in Setup mode, decreases values or scrolls to the previous option.

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12 Introduction
Control Panel

Control Panel Lights

Table 2 describes lights on the control panel that indicate different printer conditions.

Table 2 • Control Panel Lights

Light Appearance Function/Description

POWER POWER Indicates that the printer is on.

ALERT ALERT
In an error or alert situation, the ALERT light operates as follows:
• Remains on (solid) when the printer requires operator attention,
such as when the print mechanism is open.
• Flashes when the ribbon or media is out.
PAUSE (part of the PAUSE Flashes when the printer is in Pause mode unless the printer enters
PAUSE button) Setup mode and the down arrow becomes active.

FEED (part of the FEED On during normal printer operation, indicating that the printer can
FEED button) feed a blank label.

CANCEL (part of CANCEL On when canceling a label format is a valid option.

the CANCEL button)

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 Introduction 13
Printer Media Compartment

Printer Media Compartment

Figure 5 shows a simplified view of the media compartment of your printer. Depending on
installed options, your printer may look slightly different.

Figure 5 • Media Compartment

3
4
5
2
6

11 10 9 8 7

1 Printhead assembly
2 Ribbon supply spindle*
3 Ribbon take-up spindle*
4 Media supply hanger
5 Media supply guide
6 Fanfold media slot
7 Dancer assembly
8 Media guide
9 Printhead release latch
10 Peel release lever**
11 Peel assembly**
* Present only on printers that have the Thermal Transfer option installed.
** Present only on printers that have the Peel option installed.

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14 Introduction
Printer Language Modes

Printer Language Modes

Depending on how your printer was ordered, it came from the factory with firmware that
operates in or allows you to use certain commands for one of the following printer languages:
• Zebra Programming Language (ZPL)
• Eltron Programming Language (EPL)
• Datamax Programming Language (APL-D)
• Intermec Printer Language (APL-I)

Firmware Downloads
You may download S4M firmware to the printer at any time to change from one printer
language to another. For the latest firmware versions and instructions for downloading them,
go to http://www.zebra.com/firmware.

Note • When the printer changes from one printer language to another, error messages may
appear on the LCD, and some control panel lights may activate in error mode. You may
ignore these error messages and lights. When the firmware download is complete, reboot the
printer and load printer defaults to return the printer to Operating mode.

New or Modified Commands

See ZPL II Commands on page 111 for ZPL II commands that changed or that were added
specifically for this printer.

Additional Printer Language Information

The following manuals contain specific information about the different printer language
modes. Copies of these manuals are on the CD that came with your printer and at
http://www.zebra.com/manuals.
• ZPL II Programming Guide, volumes 1 and 2
• EPL2 Programming Guide
• APL-D Reference Guide
• APL-I Reference Guide

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 2
Printer Setup

This section provides the tasks that you must complete and the issues that you must consider
before you load and configure your printer.

Contents
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Report Shipping Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Store the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Select a Site for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Select a Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Provide Proper Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Allow Proper Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Provide a Data Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Provide a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connect the Printer to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Types of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Data Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Ribbon Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
When to Use Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coated Side of Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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16 Printer Setup
Before You Begin

Before You Begin

Review this checklist, and resolve any issues before you set up or use your printer.

‰ Unpack and Inspect the Printer Have you unpacked the printer and inspected it for
damage? If you have not, see Unpack and Inspect the Printer on page 17.

‰ Select a Site Have you selected an appropriate location for the printer? If you have not,
see Select a Site for the Printer on page 18.

‰ Attach a Power Cord Do you have the correct power cord for your printer? If you are
unsure, see Power Cord Specifications on page 20. To attach the power cord and connect
the printer to a power source, see Connect the Printer to a Power Source on page 19.

‰ Connect to a Data Source Have you determined how the printer will connect to a
data source (usually a computer)? For more information, see Select a Communication
Interface on page 21.

‰ Select Media Do you have the correct media for your application? If you are unsure,
see Types of Media on page 25.

‰ Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, if
needed? If you are unsure, see Ribbon Overview on page 27.

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 Printer Setup 17
Unpack and Inspect the Printer

Unpack and Inspect the Printer

When you receive the printer, immediately unpack and inspect it for shipping damage. Save all
packing materials.

Inspect the Printer

Inspect the printer for possible damage incurred during shipment:
• Check all exterior surfaces for damage.
• Raise the media door, and inspect the media compartment for damage to components.

Report Shipping Damage

Important • Zebra Technologies is not responsible for any damage incurred during the
shipment of the equipment and will not repair this damage under warranty

If you discover shipping damage upon inspection:

• Immediately notify the shipping company and file a damage report.
• Keep all packaging material for shipping company inspection.
• Notify your authorized Zebra reseller.

Store the Printer

If you are not placing the printer into immediate operation, repackage it using the original
packing materials. You may store the printer under the following conditions:
• Temperature: –40°F to 140°F (–40°C to 60°C)
• Relative humidity: 5% to 85%, non-condensing

Shipping
If you must ship the printer:
• Remove any media or ribbon from the printer to avoid damaging the printer.
• Carefully pack the printer into the original container or a suitable alternate container to
avoid damage during transit. A shipping container can be purchased from Zebra if the
original packaging has been lost or destroyed.

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18 Printer Setup
Select a Site for the Printer

Select a Site for the Printer

Consider the following when selecting an appropriate location for your printer.

Select a Surface
Select a solid, level surface of sufficient size and strength to accommodate the printer and
other equipment (such as a computer), if necessary. The choices include a table, countertop,
desk, or cart.

Provide Proper Operating Conditions

This printer is designed to function in a wide range of environmental and electrical conditions,
including a warehouse or factory floor. For more information on the required conditions, see
General Specifications on page 106.

Table 3 shows the temperature and relative humidity requirements for the printer when it is
operating.

Table 3 • Operating Temperature and Humidity

Mode Temperature Relative Humidity

Thermal Transfer 40° to 104°F (5° to 40°C) 20 to 85% non-condensing
Direct Thermal 32° to 104°F (0° to 40°C) 20 to 85% non-condensing

Allow Proper Space

The printer should have enough space around it for you to be able to open the media door. To
allow for proper ventilation and cooling, leave open space on all sides of the printer.

Caution • Do not place any padding or cushioning material behind or under the printer
because this restricts air flow and could cause the printer to overheat.

Provide a Data Source

If the printer will be located away from the data source, the selected site must provide the
appropriate connections to that data source. For more information on the types of
communication interfaces, see Select a Communication Interface on page 21.

Provide a Power Source

Place the printer within a short distance of a power outlet that is easily accessible.

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 Printer Setup 19
Connect the Printer to a Power Source

Connect the Printer to a Power Source

The AC power cord must have a three-prong female connector on one end that plugs into the
mating AC power connector at the rear of the printer. If a power cable was not included with
your printer, refer to Power Cord Specifications on page 20.

Caution • For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific three-conductor grounded
plug configuration.

To connect the printer to a power source, complete these steps:

1. Turn the printer power switch to the Off (O) position.

2. Refer to Figure 6. Plug the power cord into the AC power connector on the rear of the
printer.

3. Plug the other end of the power cord into a power outlet near the printer.

Figure 6 • Power Connection

1 Power switch
2 AC power connector

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20 Printer Setup
Connect the Printer to a Power Source

Power Cord Specifications

Caution • For personnel and equipment safety, always use an approved three-conductor
power cord specific to the region or country intended for installation. This cord must use an
IEC 320 female connector and the appropriate region-specific, three-conductor grounded
plug configuration.

Depending on how your printer was ordered, a power cord may or may not be included. If one
is not included or if the one included is not suitable for your requirements, refer to the
following guidelines:
• The overall cord length must be less than 9.8 ft. (3.0 m).
• The cord must be rated for at least 10 A, 250 V.
• The chassis ground (earth) must be connected to ensure safety and reduce electromagnetic
interference. The third wire in the power cord grounds the connection (Figure 7).

Figure 7 • Power Cord Specifications

2 3
1

1 AC power plug for your country—This should bear the

certification mark of at least one of the known
international safety organizations (Figure 8).
2 3-conductor HAR cable or other cable approved for
your country.
3 IEC 320 connector—This should bear the certification
mark of at least one of the known international safety
organizations (Figure 8).
4 Length ≤ 9.8 ft (3 m). Rating 10 Amp, 250 VAC.

Figure 8 • International Safety Organization Certifications

+
R

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 Operations 21
Select a Communication Interface

Select a Communication Interface

The way that you connect your printer to a data source depends on the communication options
installed in the printer. You may use any available connection to send commands and label
formats from a host computer to the printer.

Caution • Connecting a data communications cable while the power is ON may damage
the printer.

Note • You must supply all interface cables for your application. Refer to Data Cable
Requirements on page 24 for specific cable requirements.

Connector Locations
Refer to Figure 9. The printer comes standard with an Electronics Industries Association (EIA)
RS-232 serial interface (DB-9 connector), an IEEE 1284 bidirectional parallel interface
(unless replaced with an optional print server port), and a USB 1.1 port. You may use any of
these interface methods to send commands and label formats from a host to the printer.

Figure 9 • Cable Connections

1 Parallel interface connector (not available on units

that have an optional print server port)
2 DB-9 serial interface connector
3 USB 1.1 connector

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22 Operations
Select a Communication Interface

Types of Connections
The method of connecting the printer to a data source depends on the communication options
installed in the printer and the host. This section provides basic information about common
interfaces.

When communicating via the serial data port (RS-232), the baud rate, number of data and stop
bits, the parity, and the XON/XOFF or DTR control should be set to match those of the host
computer. See Password Level 3 Parameters on page 65 to configure these parameters. When
communicating via the parallel port or the USB port, the previously mentioned parameters do
not apply.

RS-232 Serial A serial communication method consisting of data and control signals;
available as a standard feature on most PCs and other hosts.
• Advantages: Cables and connectors are readily available from computer equipment stores
and suppliers; easy to connect; two-way communication between the host and the printer.
• Disadvantages: Slower than the parallel connection; limited to 50 feet (15.24 m) of cable.

Figure 10 • Communicating Using a Serial Data Port

Printer Computer

9
Male

25

9
9
Null modem adaptor
(if using a standard
modem cable)

50 ft. (15 m) maximum

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 Operations 23
Select a Communication Interface

IEEE 1284 Bidirectional Parallel A common communication method available on most

PCs and other hosts.
• Advantages: Fastest of the communication interfaces; cables and connectors are readily
available from computer equipment stores and suppliers; two-way communication
between the host and the printer; easy to connect.
• Disadvantages: Shorter recommended cable length of 6 feet (1.83 m) with a maximum of
length 10 ft (3 m); many computers are equipped with only one parallel port, allowing
only one IEEE 1284 bidirectional device to be connected at a time.

Figure 11 • Communicating Using a Parallel Port

Printer Computer

36-pin
male

25-pin
male

10 ft. (3 m) maximum

USB 1.1 Port Communicating using the USB port (see Figure 12) does not require special
settings.
• Advantages: Many computers are equipped with more than one USB port, allowing
multiple USB devices to be connected at one time; cables and connectors are readily
available from computer equipment stores and suppliers; two-way communication
between the host and the printer; easy to connect.
• Disadvantages: Cable length limited to 16.4 ft (5 m).

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24 Operations
Select a Communication Interface

Figure 12 • Communicating Using a USB Port

=

16.4 ft (5 m) maximum

Optional Print Servers Ethernet-based print severs also are available to connect your
printer to a data source. Both wired and wireless options are available.
• With the ZebraNet Wireless Print Server board installed, a wireless PCMCIA card can be
used to communicate with a network. For more information on this option, see the
ZebraNet Wireless Print Server User Guide.
• ZebraNet 10/100 Print Server (10/100 PS). For more information on 10/100 PS, see the
ZebraNet 10/100 Print Server User and Reference Guide.

Data Cable Requirements

Data cables must be fully shielded and fitted with metal or metallized connector shells.
Shielded cables and connectors are required to prevent radiation and reception of electrical
noise.

To minimize electrical noise pickup in the cable:

• Keep data cables as short as possible.
• Do not bundle the data cables tightly with the power cords.
• Do not tie the data cables to power wire conduits.

Note • Zebra printers comply with FCC Rules and Regulations, Part 15 for Class B
Equipment using fully shielded, 6.5 ft (2 m) data cables. Use of unshielded cables may
increase radiation above the Class B limits.

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 Printer Setup 25
Types of Media

Types of Media
The printer can use various types of media (Table 4). Zebra strongly recommends the use of
Zebra-brand supplies for continuous high-quality printing. A wide range of paper,
polypropylene, polyester, and vinyl stock has been specifically engineered to enhance the
printing capabilities of the printer and to ensure against premature printhead wear.

Table 4 • Types of Media

Media Type How It Looks Description

Non-Continuous Roll media is wound on a core that can be 1 in. to
Roll Media 3 in. (25 to 76 mm) in diameter. Labels have
adhesive backing that sticks them to a liner, and they
are separated by gaps, holes, notches, or black marks.
Tags are separated by perforations.

Figure 13 • Non-Continuous Web Media

Figure 14 • Black Mark Media

Figure 15 • Tag Stock

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26 Printer Setup
Types of Media

Table 4 • Types of Media (Continued)

Media Type How It Looks Description

Non-Continuous Fanfold media is folded in a zigzag pattern. Fanfold
Fanfold Media media can the same label divisions as non-continuous
roll media. The divisions would fall on or near the
folds.

Continuous Continuous media is wound on a core and is without

Roll Media gaps, holes, notches, or black marks. This allows the
image to be printed anywhere on the label. With
continuous media, use the transmissive sensor so the
printer can detect when the media runs out.

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 Print Engine Setup 27
Ribbon Overview

Ribbon Overview

Note • This section applies only to printers that have the Thermal Transfer option installed.

Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is
transferred to the media during the thermal transfer process. The media determines whether
you need to use ribbon and how wide the ribbon must be.

When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is
narrower than the media, areas of the printhead are unprotected and subject to premature wear.

When to Use Ribbon

Thermal transfer media requires ribbon for printing while direct thermal media does not.
To determine if ribbon must be used with a particular media, perform a media scratch test.

To perform a label scratch test, complete these steps:

1. Scratch the print surface of the media rapidly with your fingernail.

2. Did a black mark appear on the media?

If a black mark... Then the media is...

Does not appear on the media Thermal transfer. A ribbon is required.
Appears on the media Direct thermal. No ribbon is required.

Coated Side of Ribbon

Ribbon can be wound with the coated side on the inside or outside (Figure 16). This printer
can only use ribbon that is coated on the outside. If you are unsure which side of a particular
roll of ribbon is coated, perform an adhesive test or a ribbon scratch test to determine which
side is coated.

Figure 16 • Ribbon Coated on Outside or Inside

Outside Inside

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28 Print Engine Setup
Ribbon Overview

Adhesive Test
If you have labels available, perform the adhesive test to determine which side of a ribbon is
coated. This method works well for ribbon that is already installed.

To perform an adhesive test, complete these steps:

1. Peel a label from its liner.

2. Press a corner of the sticky side of the label to the outer surface of the roll of ribbon.

3. Peel the label off of the ribbon.

4. Observe the results. Did flakes or particles of ink from the ribbon adhere to the label?

If ink from the

Then...
ribbon...
Adhered to the label The ribbon is coated on the outer surface.
Did not adhere to The ribbon is coated on the inner surface and cannot be
the label used in this printer. To verify this, repeat the test on the
other surface of the roll of ribbon.

Ribbon Scratch Test

Perform the ribbon scratch test when labels are unavailable.

To perform a ribbon scratch test, complete these steps:

1. Unroll a short length of ribbon.

2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the
ribbon in contact with the paper.

3. Scratch the inner surface of the unrolled ribbon with your fingernail.

4. Lift the ribbon from the paper.

5. Observe the results. Did the ribbon leave a mark on the paper?

If the ribbon... Then...

Left a mark on the paper The ribbon is coated on the outer surface.
Did not leave a mark on The ribbon is coated on the inner surface and cannot be
the paper used in this printer. To verify this, repeat the test on the
other surface of the roll of ribbon.

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 3
Operations

This section provides the procedures for loading and calibrating the printer.

Note • Complete the tasks and resolve the issues in Printer Setup on page 15 before
operating the printer.

Contents
Media Loading Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Starting a Roll of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inserting Media into the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Load Media in Tear-Off Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Load Media in Peel-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Remove the Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Calibrate the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Position the Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Select the Transmissive Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjust the Reflective Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjust Printhead Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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30 Operations
Media Loading Overview

Media Loading Overview

The printer can print on roll or fanfold media and use different print modes for label removal.

Print Modes
The methods for loading media for each print mode follow in this section. Use a print mode
that matches the media being used and the printer options available (Table 5). For more
information on the types of media, see Types of Media on page 25.

Table 5 • Print Mode Options

Mode When to Use Printer Action

Tear-Off (default setting) Use for most applications. Each label or strip of labels
See Load Media in Tear-Off can be torn off after printing.
Mode on page 33.
Peel-Off Use only if printer has the The liner is peeled away
Peel-Off option. See Load from the label during
Media in Peel-Off Mode printing. When the printed
on page 36. label is removed, the next
label prints.

Starting a Roll of Media

Exposed media may become dirty when handled or stored. To start a roll of media, remove and
discard one full revolution of labels or tags and any liner.

Labels Tag Stock

Remove all labels that are held by Detach all exposed tags.
adhesives or tape.

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Media Loading Overview

Inserting Media into the Printer

This section shows how to insert roll or fanfold media into the printer. Fanfold media is loaded
the same way as roll media, except the media is stored outside of the printer. See Figure 17
on page 33 for an illustration.

Note • Depending on the media hanger that came with your printer, the size of the media
core that can be used may vary. See Media Specifications on page 109 for the core sizes that
your printer supports.

Roll Media

To insert roll media, complete these steps:

1. Flip down the media supply guide.

2. Place the roll of media on the media supply hanger. Push the roll as far back as it will go.

3. Flip up the media supply guide, and then slide it in until it touches, but does not restrict,
the edge of the roll.

4. Continue with the media loading procedure for the desired print mode.

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Media Loading Overview

Fanfold Media

To insert fanfold media, complete these steps:

1. Flip down the media supply guide.

2. Thread the fanfold media through the fanfold media slot on the rear of the printer.

3. Drape the media over the media supply hanger.

4. Flip up the media supply guide, and then slide it in until it touches, but does not restrict,
the edge of the media.

5. Continue with the media loading procedure for the desired print mode.

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 Operations 33
Load Media in Tear-Off Mode

Load Media in Tear-Off Mode

Tear-Off is the default mode. Figure 17 shows roll and fanfold media loaded in Tear-Off mode.

Figure 17 • Tear-Off Mode

3
2 4
1

Roll Media

8 7 6 5

3
2 4
1

Fanfold Media

8 7 6 5

1 Printhead assembly 5 Dancer

2 Transmissive sensor 6 Media guide
3 Media supply guide 7 Printhead release latch
4 Media supply hanger 8 Printed label

To load media in Tear-Off Mode, complete these steps:

1. Set the printer to Tear-Off mode. See Select the Label Removal Method on page 63 for
instructions.

2. Insert the media in the printer. See Inserting Media into the Printer on page 31 for
instructions.

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Load Media in Tear-Off Mode

3. Press the printhead release latch to open the printhead assembly. Lift the printhead until it
latches open.

4. Slide out the media guide.

5. Feed the media under the dancer assembly (1), through the slot in the transmissive
sensor (2), and under the ribbon sensor (3). Push the media to the back of the transmissive
sensor.
3 2 1

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Load Media in Tear-Off Mode

6. Slide in the media guide until it just touches the edge of the media.

7. Close the printhead assembly.

8. If the printer is paused (the PAUSE light is blinking), press PAUSE to enable printing.

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Load Media in Peel-Off Mode

Load Media in Peel-Off Mode

This section applies only if the Peel-Off option is installed (Figure 18).

Figure 18 • Peel-Off Mode

5
4
3
2
1

12 6
11
10 9 8
13

1 Peel lever 8 Dancer

2 Tear-off/peel-off bar 9 Media guide
3 Printhead assembly 10 Printhead release latch
4 Transmissive sensor 11 Peel assembly
5 Media supply guide 12 Label
6 Media supply hanger 13 Label liner
7 Liner take-up spindle

To load media in Peel-Off mode, complete these steps:

1. Set the printer to Peel-Off mode. See Select the Label Removal Method on page 63 for
instructions.

2. Insert the media in the printer. See Inserting Media into the Printer on page 31 for
instructions.

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 Operations 37
Load Media in Peel-Off Mode

3. Press the printhead release latch to open the printhead assembly.

4. Lift the printhead until it latches open.

5. Slide out the media guide.

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Load Media in Peel-Off Mode

6. Feed the media under the dancer assembly, through the slot in the transmissive sensor, and
under the ribbon sensor. Push the media to the back of the transmissive sensor.
3 2 1

1 Dancer assembly
2 Transmissive sensor
3 Ribbon sensor

7. Push down the peel-off mechanism release lever to open the peel assembly.

8. Pull approximately 18 in. (500 mm) of media through the front of the printer.

9. Remove the exposed labels so that only the liner remains.

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 Operations 39
Load Media in Peel-Off Mode

10. Feed the liner over the tear-off/peel-off bar and behind the peel assembly. Make sure that
the end of the liner falls outside of the printer.

1 Tear-off/peel-off bar
2 Peel assembly

11. Slide in the media guide until it just touches the edge of the media.

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Load Media in Peel-Off Mode

12. Close the printhead assembly.

13. Close the peel assembly using the peel-off mechanism release lever.

14. If the printer is paused (the PAUSE light is blinking), press PAUSE to enable printing.
Peeling starts automatically.

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 Operations 41
Load Ribbon

Load Ribbon

Note • This section applies only to printers that have the Thermal Transfer option installed.

The ribbon supply spindle in your printer is a dual-tension variety. Most applications require
the spindle to be in the normal position. The low tension position is recommended only when a
narrow ribbon is used or if normal tension hampers the ribbon movement.

Note • Always use ribbon that is wider than the media to protect the printhead from wear.
For direct thermal printing, do not load ribbon in the printer.

Figure 19 • Ribbon Path

2 3 4

1 Printhead assembly
2 Ribbon supply spindle
3 Ribbon take-up spindle
4 Tension blades

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Load Ribbon

To load ribbon, complete these steps:

1. Set the ribbon supply spindle for normal or low tension.

• To place the ribbon supply spindle in the normal position, firmly pull out the spindle
end cap until it extends and clicks in place, as shown in Figure 20.
• To place the ribbon supply spindle in the low-tension position, firmly push in the end
cap until it retracts and clicks in place, as shown in Figure 20.

Figure 20 • Ribbon Spindle—Normal and Low Tension

1 2

1 Normal Position (Spindle End Cap Extended)

2 Low-Tension Position (Spindle End Cap Retracted)

2. Press the printhead release latch to open the printhead assembly. Lift the printhead until it
latches open.

3. Orient the ribbon with the loose end unrolling clockwise.

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 Operations 43
Load Ribbon

4. Place the ribbon roll onto the ribbon supply spindle (1) and push it all the way back.

5. Pull the end of the ribbon under the printhead assembly (2) and out the front of the printer.

6. Close the printhead assembly.

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Load Ribbon

7. Wind the ribbon clockwise onto the ribbon take-up spindle (3).

Remove the Ribbon

To remove used ribbon, complete these steps:

1. If the ribbon has not run out, cut or break it before the ribbon take-up spindle.

Caution • Do not cut the ribbon directly on the ribbon take-up spindle. Doing so may
damage the spindle.

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Load Ribbon

2. Squeeze the ribbon against the ribbon take-up spindle tension blades (1). At the same
time, turn the ribbon take-up spindle release knob counterclockwise (2).
The tension blades collapse into the ribbon take-up spindle, loosening the ribbon.

1
2

3. Slide the ribbon off of the ribbon take-up spindle.

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46 Operations
Calibrate the Printer

Calibrate the Printer

Auto Calibration
By default, the printer automatically calibrates on power up or when the printhead is closed.
During auto calibration, the printer determines the label length and sensor settings.

The results of the auto 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.

Manual Calibration
Perform a media and ribbon sensor calibration to reset the sensitivity of the sensors so the
media and ribbon are detected more accurately. If you change the type of ribbon or media,
your printer may operate better if you perform this calibration.

For instructions, refer to Calibrate Media and Ribbon Sensors on page 72.

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 Operations 47
Position the Media Sensors

Position the Media Sensors

This printer uses two types of media sensors: transmissive and reflective.

Select the Transmissive Sensor

The standard transmissive sensor (Figure 21) is in a fixed position and enabled from the
control panel. For more information about the operation of this sensor, see Select the Media
Sensor on page 62.

Figure 21 • Transmissive Sensor

1

1 Standard transmissive sensor

Adjust the Reflective Sensor

The reflective sensor is compatible with most types of media. With non-continuous media, the
reflective sensor detects the start-of-label indicator (the notch, hole, black mark, or gap
between die-cut labels). With both continuous media and non-continuous media, the sensor
detects an out-of-paper condition. If you have difficulties with calibration while using this
sensor, use the transmissive sensor (see Select the Transmissive Sensor on page 47).

Position the reflective sensor in the following way:

• directly under the notch, hole, or black mark with these types of labels
• anywhere along the width of the media if there is a gap between labels
• anywhere under the media for continuous media

The glow of the red light through the media may help you accurately position the sensor.

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Position the Media Sensors

Figure 22 • Adjusting the Reflective Sensor

1 Printhead assembly
2 Reflective sensor
3 Adjustment lever
4 Printhead release latch

To adjust the reflective sensor, complete these steps:

1. See Figure 22. Press the printhead release latch.

2. Lift the printhead until it latches open.

3. Locate the reflective sensor positioning lever.

4. Move the reflective sensor positioning lever across the width of the media until the
reflective sensor aligns with the gap or notch.

5. Close the printhead assembly.

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 Operations 49
Adjust Printhead Pressure

Adjust Printhead Pressure

See Figure 23. You may need to adjust printhead pressure if printing is too light on one side or
if you use thick media.

Figure 23 • Printhead Pressure Adjustment Dials

1 2

1 Right dial
2 Left dial

The smallest block (fully counterclockwise) is considered position 1 and the largest block
(fully clockwise) is considered position 4.

To set printhead pressure, complete these steps:

1. Use Table 6 to select the initial dial settings for your media.

Table 6 • Printhead Pressure

Media Width Left Dial Right Dial

1 in. (25.4 mm) 3 1
2 in. (51 mm) 4 1
3 in. (76 mm) 3 2
3.5 in. and up (89 mm and up) 3 3

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50 Operations
Adjust Printhead Pressure

2. If necessary, adjust the pressure adjustment dials as follows:

If the media... Then...

Requires higher pressure to Increase both dials one position.
print well
Shifts left while printing Increase the right dial setting one position, or
decrease the left dial setting one position.
Shifts right while printing Increase the left dial setting one position, or decrease
the right dial setting one position.

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 4
Configuration

This section discusses printer configuration settings and instructs you how to view or change
printer parameters through the control panel.

Contents
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Leave Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Password Protection of Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Printing Configuration Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control Panel LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Password Level 1 and 2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Password Level 3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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52 Configuration
Setup Mode

Setup Mode
After you have installed the media and ribbon and the Power-On Self Test (POST) is complete,
the control panel displays PRINTER READY. You may now set printer parameters for your
application using the control panel LCD and the buttons directly below it. If it becomes
necessary to restore the initial printer defaults, see FEED and PAUSE Self Test on page 103.
Important • Certain printing conditions may require that you adjust some printing
parameters, such as print speed or darkness. These conditions include (but are not limited to):
• printing at high speeds
• peeling the media
• the use of extremely thin, small, synthetic, or coated labels

Because these and other factors affect print quality, run tests to determine the best
combination of printer settings and media for your application. A poor match may limit print
quality or print rate, or the printer may not function properly in the desired print mode.

Enter Setup Mode

To enter Setup mode, complete these steps:

1. Press MENU.

2. Use the left or right arrow to scroll through the parameters.

Leave Setup Mode

You can leave Setup mode at any time. As you leave Setup mode, you may choose to save or
discard changes that you made, or you may return to where you were in Setup mode.

To exit Setup mode, complete these steps:

1. Press MENU.
The printer displays SAVE CHANGES and activates the ENTER button.

2. Do you wish to save changes that were made since you entered Setup mode?

If you wish to... Then...

Save changes a. Press ENTER.
The printer saves changes and exits Setup mode.

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 Configuration 53
Setup Mode

If you wish to... Then...

Discard changes a. Press the up or down arrow to select NO.
b. Press ENTER.
The printer discards changes and exits Setup mode.
Return to Setup mode a. Press MENU or any arrow button.
• MENU returns you to the same parameter.
• The left arrow takes you to the previous parameter.
• The right arrow takes you to the next parameter.
• The up or down arrow scroll to other options in the
same parameter.

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54 Configuration
Password Protection of Parameters

Password Protection of Parameters

The printer has four levels of passwords. When you enter Setup mode on the control panel,
only those parameters that are not password-protected are displayed. To see more parameters,
you must enter an appropriate password at the ADVANCED SETUP prompt. After you enter a
password correctly, you do not have to enter it again until you leave and reenter Setup mode.

When you are prompted for a password, enter the password for the level displayed or for a
higher level. Entering a higher level password will unprotect the parameters for that level and
for all levels below it (for example, unprotecting level 4 parameters also unprotects levels 1, 2,
and 3).

The password levels and default passwords are shown in Table 7. To change the password for
any level, use the ^KP ZPL II command. For more information, see ^KP, Define Password
on page 112.

Table 7 • Password Levels and Defaults

Password
Features Controlled Default Password
Level
4 All features, including sensor adjustments For advanced use only. See the
and other sensitive parameters Maintenance Manual or contact
technical support.

3 Installation and reconfiguration. The printer 1234

web-page interface also uses this password.
2 Label configuration operations (media type, 0000 (unprotected)
label removal method, label length)
1 Darkness, Tear-Off position, label top 0000 (unprotected)

To enter a password when prompted, complete these steps:

1. When the printer displays ADVANCED SETUP X, press ENTER.

The printer displays PASSWORD and the number 0000.

2. Enter the four-digit password for the password level displayed or for a higher level.
• The left and right arrows change the selected digit position.
• The up and down arrows change the value of the selected digit.

3. After entering the password, press ENTER.

If you entered a valid password, additional parameters are displayed.

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 Configuration 55
Password Protection of Parameters

Note • When you enter a password at an ADVANCED SETUP prompt, the first parameter
that you see is determined in part by whether you pressed the right arrow or the left arrow to
get to the ADVANCED SETUP prompt:
• If you used the right arrow, the first parameter that you see is based on the password level
that the printer prompted for (see Table 8).
• If you used the left arrow, the first parameter that you see is based on which password you
enter at the prompt, regardless of which password level the printer prompted for
(see Table 9).

Table 8 • Right Arrow Used to Reach ADVANCED SETUP Prompt

Advanced Password
Setup Level Level First Parameter Seen
Prompted Entered
1 1, 2, 3, or 4 DARKNESS (top of level 1)
2 2, 3, or 4 MEDIA TYPE (top of level 2)
3 3 or 4 PRINT OUT (top of level 3)
4 4 LABEL LEVEL (top of level 4)

Table 9 • Left Arrow Used to Reach ADVANCED SETUP Prompt

Advanced Password
Setup Level Level First Parameter Seen
Prompted Entered
1 1 LABEL TOP (ZPL, EPL, APL-D)
(bottom of level 1)
Y FORMS ADJUST (APL-I)
(bottom of level 1)
1, 2 2 LENGTH
(bottom of level 2)
1, 2, 3 3 LANGUAGE
(bottom of level 3)
1, 2, 3, or 4 4 LANGUAGE
(bottom of level 4; LANGUAGE parameter appears in
both level 3 and 4)

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56 Configuration
Printing Configuration Labels

Printing Configuration Labels

After you load the media and ribbon (if necessary), print a printer configuration label and a
network configuration label as records of your printer’s current settings. Keep the labels to use
when troubleshooting printing problems. The options to print these labels are located in
password level 3.

A configuration label lists the printer settings that are stored in configuration memory. A
network configuration label lists the print server settings. For the correct settings, print a
network configuration label after the printer connects to the network.

Note • If the printer is paused when you enter Setup mode, these labels will print after you exit
Setup mode and resume printing.

To print a printer configuration label or a network configuration label, complete

these steps:

1. On the control panel, press MENU.

The printer enters Setup mode and displays DARKNESS.

2. Press the left arrow.

If a password is set for any levels, the printer displays ADVANCED SETUP with the level
number, and the ENTER button is enabled. If no passwords are set, the printer displays
LANGUAGE.
3. What does the printer display?

If the printer displays... Then...

ADVANCED SETUP 1 a. Press ENTER.
ADVANCED SETUP 2 The printer displays PASSWORD 0000.
ADVANCED SETUP 3 b. Use the left and right arrows to enter the password for
level 3 or 4.
c. Press ENTER.
The printer displays LANGUAGE.
d. Use the left or right arrow to scroll through the
parameters until you reach PRINT OUT.
ADVANCED SETUP 4 a. You do not need to enter a password to access this
parameter. Use the left or right arrow to scroll through
the parameters until you reach PRINT OUT.
LANGUAGE a. Use the left or right arrow to scroll through the
parameters until you reach PRINT OUT.

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 Configuration 57
Printing Configuration Labels

4. Select the type of label to print.

To print a... Then...

Printer configuration label a. Scroll to SETTINGS.
b. Press ENTER.
A printer configuration label prints (Figure 24).

Figure 24 • Printer Configuration Label

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58 Configuration
Printing Configuration Labels

To print a... Then...

Network configuration label a. Scroll to LIST NETWORK.
b. Press ENTER.
A network configuration label prints (Figure 25). An
asterisk designates whether the wired or wireless print
server is active. If no wireless print server is installed,
the wireless portion of the label does not print.

Figure 25 • Network Configuration Label

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 Configuration 59
Select a Display Language

Select a Display Language

The LANGUAGE parameter is included in password level 3 and level 4 so you can easily reach
the parameter to select a familiar language if you cannot read the one being displayed.

To change the language displayed, complete these steps:

1. On the control panel, press MENU.

The printer enters Setup mode.

2. Press the left arrow.

If a password is set for level 3 or 4, the printer displays ADVANCED SETUP with the
level number, and the ENTER button is enabled. If no passwords are set for level 3 or 4,
the printer displays LANGUAGE.

3. What does the printer display?

If the printer displays... Then...

ADVANCED SETUP 1* a. Press ENTER.
ADVANCED SETUP 2* The printer displays PASSWORD 0000*.
ADVANCED SETUP 3* b. Use the left and right arrows to enter the password
ADVANCED SETUP 4* for level 3 or 4.
c. Press ENTER.
The printer displays LANGUAGE*.
LANGUAGE* Continue with the next step.
* Displays in the last language selected.

4. Use the up and down arrows until you reach the language of your choice.

5. Press MENU.
The printer prompts you to accept changes.

6. Press ENTER to accept the language that you selected.

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60 Configuration
Control Panel LCD Display

Control Panel LCD Display

Use the LCD display on the control panel to adjust printer settings.

Password Level 1 and 2 Parameters

Table 10 shows parameters in the order in which they appear when you press the right arrow
after entering Setup mode. Throughout this process, press the right arrow to continue to the
next parameter or the left arrow to return to the previous parameter in the cycle.

Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 1 of 5)

Parameter Explanation
DARKNESS Adjust Print Darkness
(ZPL, APL-D, and APL-I The best darkness setting depends on a variety of factors, including ribbon
modes) type, labels, and the condition of the printhead. You may adjust the
DENSITY darkness for consistent high-quality printing.
(EPL mode only) Important • Set the darkness to the lowest setting that provides
good print quality. If the darkness is set too high, the ink may
smear, the ribbon may burn through, or the printhead may wear
prematurely.
Note • The printer applies and saves the darkness setting
immediately. Exiting Setup mode without saving changes does not
restore the previous value.
If printing is too light or if there are voids in the printed areas, increase the
darkness. If the printing is too dark or if there is spreading or bleeding of
printed areas, decrease the darkness. Darkness settings also may be
changed by the driver or software settings.
The FEED Self Test on page 100 can be used to determine the best
darkness setting. Because the darkness setting takes effect immediately,
you can see the results on labels that are currently printing.
Range (ZPL, APL-D, APL-I): 0.0 to +30.0
Default Value (ZPL, APL-D, APL-I): +10.0
Range (EPL): 7
Default Value (EPL): 0 to 15
To modify this parameter:
• Press the up arrow to increase value.
• Press the down arrow to decrease value.

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 Configuration 61
Control Panel LCD Display

Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 2 of 5)

Parameter Explanation
TEAR OFF Adjust Tear-Off Position
This parameter establishes the position of the labels over the
tear-off/peel-off bar after printing. Each press of a button adjusts the tear-
off position by one dot row.
Note • The printer applies and saves the tear-off setting
immediately. Exiting Setup mode without saving changes does not
restore the previous value.
Range (ZPL, EPL, APL-I): -120 to +120
Default Value (ZPL, EPL, APL-I): 0
Range (APL-D): +00i to +999i (inches), 0m to 2537m (metric)
Default Value (APL-D): +128i
Note • The APL-D default value does not position the label over
the tear-off/peel-off bar. This is done to work with existing DPL
label formats that account for this positioning.
To modify this parameter:
• Press the up arrow to increase value.
• Press the down arrow to decrease value.
LABEL TOP Adjust Label Top Position
(ZPL, EPL, and APL-D The label top position adjusts the print position vertically on the label.
modes) Positive numbers adjust the label top position farther down the label (away
X FORMS ADJUST from the printhead), and negative numbers adjust the position up the label
(APL-I mode only) (toward the printhead).
The displayed value represents dots.
Range (ZPL, EPL, and APL-I): -120 to +120
Default Value (ZPL, EPL, and APL-I): 0
Range (APL-D): -0.64i to 0.64i (when printer is set to operate in inches)
Default Value (APL-D): 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
Y FORMS ADJUST Adjust Label Left Position
(APL-I mode only) The label left position adjusts the print position horizontally on the label.
Positive numbers move the left edge of the image toward the center of the
label by the number of dots selected while negative numbers shift the left
edge of the image toward the left edge of the label.
Range: -120 to +120
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.

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Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 3 of 5)

Parameter Explanation
MEDIA TYPE Set Media Type
This parameter tells the printer whether you are using continuous media,
non-continuous media or tag stock, or non-continuous black mark media
(see Types of Media on page 25).
Selections:
• GAP/NOTCH—Used for non-continuous web media,
non-continuous fanfold media, and tag stock. Use the SENSOR
SELECT setting that gives the best results.
When using the transmissive sensor with media that has holes or
notches, position the media so that the transmissive media sensor
hole or notch. If the holes or notches cannot be positioned this way
for a particular type of media, use the reflective sensor.
• CONTINUOUS—Used for media that does not have divisions
between labels. SENSOR SELECT should be set to DEFAULT or
TRANSMISSIVE.
• MARK—Used for non-continuous black mark media. SENSOR
SELECT should be set to DEFAULT or REFLECTIVE.
Default Value: GAP/NOTCH
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
SENSOR SELECT Select the Media Sensor
You may allow the printer to select a media sensor based on the media
type, or you may select a specific media sensor to be used if the sensor that
was selected by the printer does not detect media correctly.
Selections:
• DEFAULT—The printer selects a sensor based on the setting
specified for MEDIA TYPE:

Media Type Sensor Used

GAP/NOTCH Transmissive
CONTINUOUS Transmissive
MARK Reflective

• TRANSMISSIVE—Use with all continuous media or with most

types of non-continuous media.
• REFLECTIVE—Use with black mark media or with non-continuous
media that does not work well with the transmissive sensor.
Default Value: DEFAULT
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 4 of 5)

Parameter Explanation
REMOVAL Select the Label Removal Method
The label removal must correspond to the print mode (see Print Modes
on page 30). Be sure to select a label removal mode that your hardware
configuration supports because some of the selections displayed are for
optional printer features.
Selections: TEAR, PEEL, CUTTER, REWIND, DELAYED CUT
Default Value: TEAR
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
PRINT SPEED Adjust Print Speed
Adjusts the speed for printing a label (given in whole numbers of inches
per second). Slower print speeds typically yield better print quality. Print
speed changes take effect upon exiting Setup mode.
Range: 2 to 6 IPS
Default Value (ZPL, APL-I): 2 IPS
Default Value (EPL, APL-D): 6 IPS
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
PRINT WIDTH Set Print Width
Print width determines the printable area across the width of the label.
Important • Setting the width too narrow can result in portions of
the label not being printed on the media. Setting the width too
wide wastes formatting memory and can cause printing off the
label and on the platen roller. This setting can affect the horizontal
position of the label format if the image was inverted using the
^POI ZPL II command.
Range: 2 to 832 for 8 dots/mm, 2 to 1248 for 12 dots/mm
Default Value: 832 for 8 dots/mm, 1248 for 12 dots/mm
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
COMPAT. MODE Set APL-D Compatibility Mode
(APL-D mode only) Sets compatibility with DPL printers.
Selections: ON, OFF
Default Value: OFF
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Table 10 • Printer Parameters, Password Levels 1 and 2 (Page 5 of 5)

Parameter Explanation
CONTROL CODES Set APL-D Control Codes
(APL-D mode only) Selections: STANDARD, MAINFRAME
Default Value: STANDARD
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
MODULE A Set Module A Storage Device for APL-D
(APL-D mode only) Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2
Default Value: NONE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
MODULE B Set Module B Storage Device for APL-D
(APL-D mode only) Selections: NONE, RAM 1, RAM 2, FLASH 1, FLASH 2
Default Value: NONE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
RESOLUTION Set Printer Resolution for APL-I
(APL-I mode only) Sets the dot size for backward compatibility with some older APL-I
printers.
Selections: 5 MIL, 10 MIL, 15 MIL
Default Value: 5 MIL
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
LENGTH Set Maximum Label Length
Maximum label length is used in conjunction with the calibration
procedure. The value of this setting is the maximum label length that is
used during the media portion of the calibration process. Only a few labels
are required to set media sensors. Always set the value that is at least 1 in.
(25.4 mm) longer than the longest label to be used on the printer.
Selections: AUTO, < 1 INCH (25.4 mm) to < 39 INCH (991 mm)
Default Value: AUTO
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.

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Password Level 3 Parameters

Table 11 shows parameters in the order in which they appear when you press the right arrow
after entering the Level 3 password. Throughout this process, press the right arrow to continue
to the next parameter or the left arrow to return to the previous parameter in the cycle.

Table 11 • Printer Parameters, Level 3 (Page 1 of 9)

Parameter Explanation
PRINT OUT Print Selected Labels
This parameter allows you to print certain types of labels with information
about the printer.
Selections:
• SETTINGS—Prints a printer configuration label. See Printing
Configuration Labels on page 56.
• FONTS (ZPL, EPL, APL-D)—Prints a label that lists the available
fonts in the printer, including standard printer fonts plus any optional
fonts. Fonts may be stored in RAM, Flash memory, optional memory
cards, or font cards.
• FORMATS (ZPL, EPL, APL-D)—Prints a label that lists the
available formats stored in the printer’s RAM, Flash memory, or
optional memory card.
• BARCODES (ZPL only)—Prints a label that lists the available bar
codes in the printer.
• ALL (ZPL, EPL)—Prints labels that list the available fonts, bar
codes, images, formats, and the current printer and network
configurations.
• IMAGES (ZPL, EPL, APL-D)—Prints a label that lists the images
currently stored in the printer’s RAM, Flash memory, or optional
memory cards.
• NETWORK (ZPL only)—Prints a network configuration label. See
Printing Configuration Labels on page 56.
• APLI SW SETUP (APL-I only)
• APLI HW SETUP (APL-I only)
• APLI PRT QUAL (APL-I only)
• APLI PITCH (APL-I only)
To print labels:
1. Press the up or down arrow to display label choices.
2. Press ENTER to print the desired label.
PARALLEL COMM. Set Parallel Communications
Select the communications port that matches the one being used by the host
computer.
Selections: UNIDIRECTIONAL, BIDIRECTIONAL
Default Value: UNIDIRECTIONAL
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Table 11 • Printer Parameters, Level 3 (Page 2 of 9)

Parameter Explanation
PRINT PAGE Print Stored APL-I Page
(APL-I mode only) Up to 20 pages can be stored and printed.
Selections: 0 through 19
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
PRINT FORMAT Print Stored APL-I Format
(APL-I mode only) Up to 100 formats can be stored and printed.
Selections: 0 through 99
Default Value: 0
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
BAUD Set Baud
The baud setting of the printer must match the baud setting of the host
computer for accurate communications to take place. Select the value that
matches the one being used by the host computer.
Selections: 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800,
38400, 57600, 115200
Default Value: 9600
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
DATA BITS Set Data Bits
The data bits of the printer must match the data bits of the host computer
for accurate communications to take place. Set the data bits to match the
setting being used by the host computer.
Note • Code Page 850 requires the data bits to be set to 8 bits.

Selections: 7 BITS, 8 BITS

Default Value: 8 BITS
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Table 11 • Printer Parameters, Level 3 (Page 3 of 9)

Parameter Explanation
STATUS RESPONSE Send APL-I Status Response
(APL-I mode only) Determines if a response is sent after inquiry commands. The format is set
with the RESPONSE FORMAT parameter.
Selections: ON, OFF
Default Value: ON
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
RESPONSE FORMAT Select APL-I Response Format
(APL-I mode only) If STATUS RESPONSE is set to ON, this parameter determines the
format of the response.
Selections: ASCII, BINARY
Default Value: ASCII
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
PARITY Set Parity
The parity of the printer must match the parity of the host computer for
accurate communications to take place. Select the parity that matches the
one being used by the host computer.
Selections: NONE, ODD, EVEN
Default Value: NONE
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
HOST HANDSHAKE Set Host Handshake
The handshake protocol of the printer must match the handshake protocol
of the host computer for proper communications to take place. Select the
handshake protocol that matches the one being used by the host computer.
Selections (ZPL, APL-D): XON/XOFF, DSR/DTR, RTS/CTS
Selections (EPL): DTR & XON/XOF, DTR, XON/XOFF
Selections (APL-I): XON/XOFF, DSR/DTR, RTS/CTS, APL-I
Default Value: XON/XOFF
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Table 11 • Printer Parameters, Level 3 (Page 4 of 9)

Parameter Explanation
CONTROL CHAR Set Control Character
(ZPL mode only) The printer looks for this two-digit hexadecimal character to indicate the
start of a ZPL/ZPL II control instruction.
Note • Do not use the same hexadecimal value for the control,
command, and delimiter character. The printer must see different
characters to work properly.
Range: 00 to FF
Default Value: 7E (tilde—displayed as an arrow)
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
COMMAND CHAR Set Command Character
(ZPL mode only) The command prefix is a two-digit hexadecimal value used as a parameter
place marker in ZPL/ZPL II format instructions. The printer looks for this
two-digit hexadecimal character to indicate the start of a ZPL/ZPL II
format instruction. See the ZPL II Programming Guide Volume I for more
information.
Note • Do not use the same hexadecimal value for the control,
command, and delimiter character. The printer must see different
characters to work properly.
Range: 00 to FF
Default Value: 5E (caret)
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
DELIM. CHAR Set Delimiter Character
(ZPL mode only) The delimiter character is a two-digit hexadecimal value used as a
parameter place marker in ZPL/ZPL II format instructions. See the ZPL II
Programming Guide Volume I for more information.
Note • Do not use the same hexadecimal value for the control,
command, and delimiter character. The printer must see different
characters to work properly.
Range: 00 to FF
Default Value: 2C (comma)
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.

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Table 11 • Printer Parameters, Level 3 (Page 5 of 9)

Parameter Explanation
HEXDUMP Hex Dump
(ZPL, EPL, APL-D modes) The hexadecimal dump mode is a troubleshooting tool for checking the
interconnection between the printer and the host computer. When YES is
selected, all data sent from the host computer to the printer prints as
straight ASCII characters, with the hexadecimal value below the ASCII
text. The printer prints all characters received, including control codes,
such as CR (carriage return). A sample printout is shown in
Communications Diagnostics Test on page 103.
Selections: NO, YES
Default Value: NO
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
CHANGE RTC DATE Set RTC (Real-time clock) Date
If RTC is installed, this parameter allows you to set the RTC date.
Note • The printer saves the RTC date immediately.

To modify this parameter:

1. Press ENTER.
The printer displays the current RTC date.
2. Modify the values as follows:
• Press the right arrow to move to the next digit position.
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
3. Press ENTER to accept the value shown.
CHANGE RTC TIME Set RTC (Real-time clock) Time
If RTC is installed, this parameter allows you to set the RTC time.
Note • The printer saves the RTC time immediately.

To modify this parameter:

1. Press ENTER.
The printer displays the current RTC time.
2. Modify the values as follows:
• Press the right arrow to move to the next digit position.
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
3. Press ENTER to accept the value shown.

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Table 11 • Printer Parameters, Level 3 (Page 6 of 9)

Parameter Explanation
LOAD DEFAULTS Load Factory Defaults
Sets all parameters back to factory defaults.
Important • Use care when using this command. All printer
parameters are reset to factory values with this command. If
possible, print a configuration label to have as a record of the
printer’s settings before loading defaults.
How to select this parameter:
1. Press ENTER.
The printer asks ARE YOU SURE?
2. To load factory defaults, press ENTER to select YES. To cancel, press
any other key.
INIT FLASH MEM Initialize Flash Memory
This parameter allows you to erase the printer’s Flash memory.
Important • The internal Flash memory is entirely erased with this
command.
To select this parameter:
1. Press ENTER to select YES.
The printer asks ARE YOU SURE?
2. To initialize Flash memory, press ENTER. To cancel, press any other
key.
RIBBON Set Ribbon Use
Note • This parameter appears only for printers that have the
Thermal Transfer option installed.

The printer can automatically detect if you are using ribbon. However, you
may use this parameter to tell the printer the method of printing that you
wish to use each time: direct thermal (no ribbon) or thermal transfer (using
ribbon).
Selections:
• AUTO (the printer detects if ribbon is present)
• NO (direct thermal mode, no ribbon)
• YES (thermal transfer mode, with ribbon)
Default Value: AUTO
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Table 11 • Printer Parameters, Level 3 (Page 7 of 9)

Parameter Explanation
ZPL OVERRIDE Override Certain ZPL Commands
(ZPL mode only) Prevents the printer from accepting the following ZPL commands:
• ^MM (media mode)
• ^MT (media type direct thermal or thermal transfer)
• ^MN (media non-continuous or continuous)
Selections:
• NO—allows the printer to accept the listed ZPL commands.
• YES—tells the printer to ignore the listed ZPL commands.
Default Value: NO
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
EPL OVERRIDE Override Certain EPL Commands
(EPL mode only) Prevents the printer from accepting certain EPL commands.
Selections:
• DISABLED—allows the printer to accept the listed EPL commands.
• ENABLED—tells the printer to ignore the listed EPL commands.
Default Value: DISABLED
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
SENSOR PROFILE Print Sensor Profile
Use the sensor profile (Figure 26) to troubleshoot registration problems
that may occur if the media sensor detects preprinted areas on the media or
if it experiences difficulty in determining web location. To adjust the
sensitivity of the media and/or ribbon sensors, use Calibrate Media and
Ribbon Sensors on page 72.
Note • The ribbon portion of the label appears only for printers
that have the Thermal Transfer option installed.

Figure 26 • Sensor Profile

To select this parameter:

1. Press ENTER to start this standard calibration procedure and print a
media sensor profile.

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Table 11 • Printer Parameters, Level 3 (Page 8 of 9)

Parameter Explanation
MEDIA/RIBBON Calibrate Media and Ribbon Sensors
CALIBRATE Use this procedure to adjust the sensitivity of the printer’s sensors. In a
(Thermal Transfer only) printer that has the Thermal Transfer option installed, both media and
MEDIA CALIBRATE ribbon sensors are adjusted. In a Direct Thermal printer (no Thermal
(Direct Thermal only) Transfer option installed), only media sensors are adjusted, and the LCD
displays for ribbon do not appear in this procedure.
Important • This procedure must be followed exactly as presented.
All of the steps must be performed even if only one of the sensors
requires adjustment. You may press the left arrow at any step in this
procedure to cancel the procedure.
How to select this parameter:
1. Press ENTER to start the calibration procedure.
The LOAD BACKING/REMOVE RIBBON prompt displays.
2. Open the printhead.
3. Remove approximately 8 in. (203 mm) of labels from the backing,
and pull the media into the printer so that only the backing is between
the media sensors.
4. Remove the ribbon (if used).
5. Press the right arrow to continue.
The message CALIBRATING PLEASE WAIT displays.
The printer adjusts the scale (gain) of the signals that it receives from
the media and ribbon sensors. On the sensor profile, this essentially
corresponds to moving the peak of the graph up or down to optimize
the readings for your application.
RELOAD ALL displays.
6. Reload the media and ribbon (if used).
7. Close the printhead.
8. Press the right arrow to continue.
The message CALIBRATING PLEASE WAIT displays.
The printer does a calibration; during this process, the printer
determines the label length. To see the new readings on the new scale,
print a sensor profile.

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Table 11 • Printer Parameters, Level 3 (Page 9 of 9)

Parameter Explanation
LANGUAGE Select the Display Language
This parameter allows you to display the control panel in the language of
your choice. As soon as you select a language, all parameters are
displayed in that language. Save changes as you exit Setup mode to save
the language setting.
Selections: English (ENGLISH), Spanish (ESPANOL), French
(FRANCAIS), German (Deutsch), Italian (ITALIANO), Norwegian
(NORSK), Portuguese (PORTUGUES), Swedish (SVENSKA), Danish
(DANSK), Spanish2 (ESPANOL2), Dutch (NEDERLANDS), Finnish
(SUOMI), and Japanese.
Default Value: ENGLISH
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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ZebraNet® Wired and Wireless Print Server LCD Displays

The menu options shown in Table 12 display only if you have the ZebraNet PrintServer II, or
10/100 PrintServer, or Wireless Print Server installed and are operating in ZPL or EPL mode.
These parameters are considered part of Level 3.

Table 12 • Print Server LCD Displays (Page 1 of 2)

Parameter Explanation
OBTAIN IP ADDRESS Obtain an IP Address
Selects the method by which an IP address will be assigned to the printer.
Selections: AUTO SELECT (dynamic), PERMANENT (user-specified)
Default Value: AUTO SELECT
To modify this parameter:
• Press the up or down arrow to scroll through the selections.
CHANGE IP ADDRESS Change the Printer’s IP Address
This parameter can be modified only when PERMANENT is selected for
OBTAIN IP ADDRESS.
Selections: 0 to 255 for each field
Default Value: 0.0.0.0
Note • Leading zeroes are not shown in the address. If an IP
address contains more digits than can be displayed at one time, use
the left or right arrows to scroll through the digits.
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
CHANGE SUBNET Change the Subnet
This parameter can be modified only when PERMANENT is selected for
OBTAIN IP ADDRESS.
Selections: 0 to 255 for each field
Default Value: 0.0.0.0
Note • Leading zeroes are not shown in the address. If an IP
address contains more digits than can be displayed at one time, use
the left or right arrows to scroll through the digits.
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.

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Table 12 • Print Server LCD Displays (Page 2 of 2)

Parameter Explanation
CHANGE GATEWAY Change the Gateway
This parameter can be modified only when PERMANENT is selected for
OBTAIN IP ADDRESS.
Selections: 0 to 255 for each field
Default Value: 0.0.0.0
Note • Leading zeroes are not shown in the address. If an IP
address contains more digits than can be displayed at one time, use
the left or right arrows to scroll through the digits.
To modify this parameter:
• To increase the value, press the up arrow.
• To decrease the value, press the down arrow.
CHANGE IP PROTOCOL Change the IP Protocol
Determines the method(s) by which the print server (wired or wireless)
receives the IP address from the server.
This parameter can be modified only when AUTO SELECT is selected
for OBTAIN IP ADDRESS.
Selections: ALL, GLEANING ONLY, RARP, BOOTP, DHCP,
DHCP AND BOOT
Default Value: ALL
To modify this parameter:
• Press the up or down arrow to scroll through the selections.

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Notes • ___________________________________________________________________

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 5
Routine Maintenance

This section provides routine cleaning and maintenance procedures.

Contents
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clean the Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clean the Printhead and Platen Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Clean the Media Compartment and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Clean the Peel-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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Lubrication

Lubrication
No lubrication is needed for this printer.

Caution • Some commercially available lubricants will damage the finish and the
mechanical parts if used on this printer.

Cleaning Procedures

Important • Zebra is not responsible for damage caused by the use of cleaning fluids on this
printer.

Specific cleaning procedures are provided on the following pages. Table 13 shows the
recommended cleaning schedule.
.

Table 13 • Recommended Cleaning Schedule

Area Method Interval

Printhead Solvent* Direct Thermal Mode: After every roll of
Platen roller Solvent* media (or 500 feet of fanfold media).
Thermal Transfer Mode: After every roll of
Media sensors Air blow
ribbon or three rolls of media.
Ribbon sensor Air blow These intervals are intended as guidelines only.
Media path Solvent* You may have to clean more often, depending
upon your application and media.
Ribbon path Solvent*
Pinch roller. (part of Peel-Off option) Solvent*
Tear-off/peel-off bar Solvent* Once a month.
Take label sensor Air blow Once every six months.
* Zebra recommends using Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl and
10% deionized water)

Clean the Exterior

You may clean the exterior surfaces of the printer with a lint-free cloth and a small amount of a
mild detergent, if necessary. Do not use harsh or abrasive cleaning agents or solvents.

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Cleaning Procedures

Clean the Printhead and Platen Roller

You can minimize printhead wear and maintain print quality with regular preventive measures.
Over time, the movement of media or ribbon across the printhead wears through the protective
ceramic coating, exposing and eventually damaging the print elements (dots). To avoid
abrasion:
• Clean the printhead frequently, and use well-lubricated thermal transfer ribbons with
backings optimized to reduce friction.
• Minimize printhead pressure and burn temperature settings by optimizing the balance
between the two.
• Ensure that the thermal transfer ribbon is as wide or wider than the label media to prevent
exposing the elements to the more abrasive label material.

For best results, clean the printhead after changing every roll of ribbon. Inconsistent print
quality, such as voids in the bar code or graphics, may indicate a dirty printhead.

Note • The printer can remain on while you are cleaning the printhead. In this way, all label
formats, images, and all temporary parameter settings stored in the printer’s internal memory
are saved. In addition, keep the peel engaged while cleaning the platen roller (media must be
unloaded to do this) to reduce the risk of bending the tear-off/peel-off bar.

Figure 27 • Cleaning the Printhead and Platen Roller

1 Printhead assembly
2 Platen roller

Caution • Observe proper electrostatic safety precautions when handling any

static-sensitive components such as circuit boards and printheads.

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Cleaning Procedures

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to
cool.

To clean the printhead and platen roller, complete these steps:

1. Open the printhead assembly.

2. Remove the media and ribbon.

3. Using the swab from the Preventive Maintenance Kit (part number 47362) or a solution of
90% Isopropyl alcohol and 10% deionized water and a cotton swab, wipe along the brown
strip on the printhead assembly from end to end. Allow the solvent to evaporate.

4. While manually rotating the platen roller, clean it thoroughly with the swab. Allow the
solvent to evaporate.

5. Reload media and ribbon, and close the printhead assembly.

Note • If performing this procedure does not improve print quality, 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
reseller for more information.

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 Routine Maintenance 81
Cleaning Procedures

Clean the Media Compartment and Sensors

To clean the media compartment and sensors, complete these steps:

1. Brush or vacuum any accumulated paper lint and dust away from the media and ribbon
paths.

2. Brush or vacuum any paper lint and dust away from the sensors (see Figure 28).

Figure 28 • Cleaning the Sensors

1 Take-label sensor
2 Ribbon sensor
3 Transmissive sensor
4 Reflective sensor

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82 Routine Maintenance
Cleaning Procedures

Clean the Peel-Off Assembly

The Peel-Off option is required.

Caution • Observe proper electrostatic safety precautions when handling any

static-sensitive components such as circuit boards and printheads.

Caution • The printhead may be hot and could cause severe burns. Allow the printhead to
cool.

If adhesive buildup affects peel-off performance, complete these steps:

1. Press the printhead release latch to open the printhead assembly.

2. Lift the printhead until it latches open.

3. Open the peel assembly by pivoting the module toward you.

4. Remove any media backing to expose the pinch roller.

5. While manually rotating the pinch roller, clean it thoroughly with the swab from the
Preventive Maintenance Kit (part number 47362) or a solution of 90% Isopropyl alcohol
and 10% deionized water and a cotton swab. Allow the solvent to evaporate.

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Cleaning Procedures

6. Use the swab to remove excess adhesive from the tear-off/peel-off bar. Allow the solvent
to evaporate.

Important • Apply minimum force when cleaning the tear-off/peel-off bar. Excessive
force can cause the tear-off/peel-off bar to bend, which could have a negative effect on
peel performance.

7. Close the printhead assembly and the media door.

The printer is ready to operate.

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Cleaning Procedures

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

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 6
Troubleshooting

This section provides information about errors that you might need to troubleshoot. Assorted
diagnostic tests are included.

Contents
Troubleshooting Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LCD Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Memory Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Calibration Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Communications Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Miscellaneous Printer Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Printer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Power-On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CANCEL Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
PAUSE Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
FEED Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
FEED and PAUSE Self Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Communications Diagnostics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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86 Troubleshooting
Troubleshooting Checklists

Troubleshooting Checklists
If an error condition exists with the printer, review this checklist:
‰ Is there an error message on the LCD? If yes, see LCD Error Messages on page 87.
‰ Are noncontinuous labels being treated as continuous labels? If yes, see Calibrate Media
and Ribbon Sensors on page 72.
‰ Is the CHECK RIBBON light on when ribbon is loaded properly, or are noncontinuous
labels being treated as continuous labels? If yes, see Calibrate Media and Ribbon Sensors
on page 72.
‰ Are you experiencing problems with print quality? If yes, see Print Quality Problems
on page 90.
‰ Are you experiencing communications problems? If yes, see Communications Problems
on page 94.

If the labels are not printing or advancing correctly, review this checklist:
‰ Are you using the correct type of labels? Review the types of label in Types of Media
on page 25.
‰ Does the printhead need to be adjusted? See Adjust Printhead Pressure on page 49 for
more information.
‰ Do the sensors need to be calibrated? See Calibrate Media and Ribbon Sensors
on page 72 for more information.

If none of the above suggestions correct the problem, review this checklist:
‰ Perform one or more of the self-tests given in Printer Diagnostics on page 97. Use the
results to help identify the problem.
‰ If you are still having problems, see Contacts on page 3 for customer support information.

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 Troubleshooting 87
LCD Error Messages

LCD Error Messages

The LCD displays messages when there is an error. See Table 14 for LCD errors, the possible
causes, and the recommended solutions.

Table 14 • LCD Error Messages

LCD Display/
Possible Cause Recommended Solution
Printer Condition
Ribbon is loaded, but the printer is Ribbon is not required with direct
WARNING set for direct thermal mode. thermal media. Remove ribbon unless
RIBBON IN you are using it to protect the
printhead. This error message will not
The ALERT light flashes. affect printing.
Media is not loaded or is loaded Load media correctly.
ALERT incorrectly.
PAPER OUT
Misaligned media sensor. Check position of the media sensor.
The printer stops and the The printer is set for Install proper media type, or reset
ALERT light flashes. noncontinuous media, but printer for current media type and
continuous media is loaded. perform calibration.
The printhead is not fully closed. Close printhead completely.
ALERT
HEAD OPEN The head open sensor is not Call a service technician.
working properly.
The printer stops and the
ALERT light flashes.

WARNING Caution • The printhead may be hot enough to cause severe

HEAD TOO HOT burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when
The printer stops and the handling any static-sensitive components such as circuit boards
ALERT light flashes. and printheads.

The printhead is over temperature. Allow the printer to cool. Printing

automatically resumes when the
printhead elements cool to an
acceptable operating temperature.

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88 Troubleshooting
LCD Error Messages

Table 14 • LCD Error Messages (Continued)

LCD Display/
Possible Cause Recommended Solution
Printer Condition

WARNING Caution • An improperly connected printhead data or power cable

HEAD COLD can cause this error message. The printhead may be hot enough to
cause severe burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when
The printer stops and the handling any static-sensitive components such as circuit boards
ALERT light flashes. and printheads.

The printhead is under Continue printing while the printhead

temperature. reaches the correct operating
temperature. If the error remains, the
environment may be too cold for
proper printing. Relocate the printer to
a warmer area.
The printhead data cable is not
Caution • Turn off (O) the
properly connected. printer before performing this
procedure. Failure to do so
can damage the printhead.
1. Turn Off (O) the printer.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.
4. Turn on (I) the printer.

HEAD ELE. BAD Caution • The printhead may be hot enough to cause severe
burns. Allow the printhead to cool.
Caution • Observe proper electrostatic safety precautions when
handling any static-sensitive components such as circuit boards
The printer stops. and printheads.

The print head is not installed.

Caution • Turn off (O) the
The printhead data cable is not printer before performing this
connected. procedure. Failure to do so
The printhead is bad. can damage the printhead.
1. Turn Off (O) the printer.
2. Disconnect and reconnect the data
cable to the printhead.
3. Ensure that the cable connector is
fully inserted into the printhead
connector.
4. Turn on (I) the printer.
5. If the problem persists, replace the
printhead.

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 Troubleshooting 89
Memory Errors

Memory Errors
The memory errors in Table 15 indicate that the printer does not have enough memory to
perform the function shown on the second line of the LCD.

Table 15 • Memory Errors

Problem/LCD Display Possible Cause Recommended Solution

Creating Bitmap You may do any of the following:
OUT OF MEMORY The bitmap size (label • Press PAUSE. Send a ~HM ZPL
CREATING BITMAP length/width) does not fit in command to the printer to display the
available memory. amount of free memory. Then redesign
Storing Bitmap the graphic/format to fit available
OUT OF MEMORY Not enough memory is memory, or remove items from memory
STORING BITMAP available to store the bitmap to create more space.
created. • Press PAUSE to skip the formatting step
in process and proceed to the next step.
Building Format
OUT OF MEMORY With the printer paused, press CANCEL.
Label is too complex.
BUILDING FORMAT The printer skips the current label
formatting process and goes to the next
Storing Format label.
OUT OF MEMORY Format is too large to fit in • Turn the printer Off (O) and then On (I)
STORING FORMAT available memory. to clear the printer’s memory.
Storing Graphic
OUT OF MEMORY The graphic image is too large
STORING GRAPHIC to fit in available memory.
Storing Font
OUT OF MEMORY Not enough memory available
STORING FONT to store the font.

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90 Troubleshooting
Print Quality Problems

Print Quality Problems

Table 16 identifies problems with print quality, the possible causes, and the recommended
solutions.

Table 16 • Print Quality Problems

Problem Possible Cause Recommended Solution

General print quality The printer is set at the For optimal print quality, set the print speed to
issues incorrect print speed. the lowest possible setting for your application
via control panel, the driver, or the software. See
Adjust Print Speed on page 63. You may wish to
perform the FEED Self Test on page 100.
You are using an incorrect Consult your authorized Zebra reseller or
combination of labels and distributor for information and advice.
ribbon for your application.
The printer is set at an incorrect For optimal print quality, set the darkness to the
darkness level. lowest possible setting for your application via
the control panel, the driver, or the software. See
Adjust Print Darkness on page 60. You may wish
to perform the FEED Self Test on page 100 to
determine the ideal darkness setting.
The printhead is dirty. Clean the printhead according to the instructions
in Clean the Printhead and Platen Roller
on page 79.
Caution • The printhead may be hot
enough to cause severe burns. Allow
the printhead to cool.
Caution • Observe proper electrostatic
safety precautions when handling any
static-sensitive components such as
circuit boards and printheads.

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Print Quality Problems

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Wrinkled ribbon Ribbon fed through the See Load Ribbon on page 41.
machine incorrectly.
Incorrect burn temperature. Set the darkness to the lowest possible setting for
good print quality. See Adjust Print Darkness
on page 60.
Incorrect or uneven pressure. Set the pressure to the minimum needed for good
print quality.
Media not feeding properly; Make sure that media is snug by adjusting the
“walking” from side to side. media guide, or call a service technician.
The strip plate needs adjusting. Call a service technician.

The printhead needs vertical Call a service technician.

adjustment.
The printhead and platen roller Call a service technician.
need to be realigned.
Long tracks of Print element damaged. Call a service technician.
missing print on
several labels
Wrinkled ribbon. See wrinkled ribbon causes and solutions in this
table.
Fine, angular gray Wrinkled ribbon. See wrinkled ribbon causes and solutions in this
lines on blank labels table.
Printing too light or Media or ribbon is not designed Replace supplies with those recommended for
too dark over the for high-speed operation. high-speed operation.
entire label Incorrect or uneven printhead Set the pressure to the minimum needed. See
pressure. Adjust Printhead Pressure on page 49.
Smudge marks on Media or ribbon not designed Replace supplies with those recommended for
labels for high-speed operation. high-speed operation.
Misregistration/skips Media sensor not positioned Perform media sensor position adjustment.
labels correctly.
The printer is not calibrated. Recalibrate the printer.
Improper label format. Use correct label format.
Misregistration and Media sensor is not positioned Place media sensor in proper position.
misprint of one to correctly.
three labels The platen roller is dirty. See Clean the Printhead and Platen Roller
on page 79.
Media does not meet Use media that meets specifications.
specifications.

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92 Troubleshooting
Print Quality Problems

Table 16 • Print Quality Problems (Continued)

Problem Possible Cause Recommended Solution

Vertical drift in A plus or minus 4 to 6 dot row 1. Calibrate the printer.
top-of-form position (approximately 0.5 mm) 2. Adjust the label top position setting. See
vertical drift is acceptable due Adjust Label Top Position on page 61.
to different tolerances of
mechanical parts and printer
modes.
The printer is out of calibration. Recalibrate the printer.
The platen roller is dirty. See Clean the Printhead and Platen Roller
on page 79.
Vertical image or The printer is using Configure the printer for non-continuous and run
label drift noncontinuous labels but is calibration routine, if necessary.
configured in continuous mode.
Incorrectly positioned media Ensure the media sensor is properly positioned to
sensor. read a single/consistent interlabel gap.
Improperly calibrated media See Calibrate Media and Ribbon Sensors
sensor. on page 72.
The platen roller is dirty. Clean the platen roller. See Clean the Printhead
and Platen Roller on page 79.
Improper printhead pressure Adjust the printhead pressure to ensure proper
settings (toggles). functionality.
Improperly loaded ribbon or Verify that the printer is loaded properly.
media.
Incompatible media. Ensure that the interlabel gaps or notches are 2 to
4 mm and consistently placed. Media must not
exceed minimum specifications for mode of
operation.
The bar code printed The bar code is not within Perform the FEED Self Test on page 100. Adjust
on a label does not specifications because the print the darkness or print speed settings as necessary.
scan. is too light or too dark.
Not enough blank space around Leave at least 1/8 in. (3.2 mm) between the bar
the bar code. code and other printed areas on the label and
between the bar code and the edge of the label.

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 Troubleshooting 93
Calibration Problems

Calibration Problems
Table 17 identifies problems with calibration, the possible causes, and the recommended
solutions.

Table 17 • Calibration Problems and Solutions

Problem Recommended Solution

Loss of printing registration on Ensure that the media guides are properly positioned.
labels.Excessive vertical drift in top-of-form Set the printer for the correct media type (non-continuous or
registration. continuous). See Set Media Type on page 62 .
Clean the platen roller according to the instructions in Clean
the Printhead and Platen Roller on page 79.
Auto Calibrate failed. Ensure that media and ribbon are loaded correctly.
Ensure that the sensors are clean and properly positioned.

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94 Troubleshooting
Communications Problems

Communications Problems
Table 18 identifies problems with communications, the possible causes, and the recommended
solutions.

Table 18 • Communications Problems

Problem Possible Cause Recommended Solution

A label format was sent to The communication Check the printer driver or software
the printer but was not parameters are incorrect. communications settings (if applicable).
recognized. Make sure you are using the correct
communication cable. See Data Cable
Requirements on page 24 for the requirements.
If a driver is used, check the driver
communication settings for your connection.
A label format was sent to The serial communication Ensure that the flow control settings match.
the printer. Several labels settings are incorrect. Check the communication cable length. See
print, then the printer Data Cable Requirements on page 24 for
skips, misplaces, misses, or requirements.
distorts the image on the
label. Check the printer driver or software
communications settings (if applicable).
A label format was sent to The prefix and delimiter Verify the prefix and delimiter characters. See
the printer but was not characters set in the printer Set Command Character on page 68 and Set
recognized. No printing do not match the ones in the Delimiter Character on page 68 for the
occurs. label format. requirements.
Incorrect data is being sent Ensure that the label format being used
to the printer. matches the operating language of the printer.
See Printer Language Modes on page 14.

Check the communication settings on the

computer. Ensure that they match the printer
settings.
If the problem continues, check the label
format.

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 Troubleshooting 95
Miscellaneous Printer Problems

Miscellaneous Printer Problems

Table 19 identifies miscellaneous problems with the printer, the possible causes, and the
recommended solutions.

Table 19 • Miscellaneous Printer Problems

Problem Possible Cause Recommended Solution

The LCD displays a The language parameter was Perform the procedure in Select a Display
language that I changed through the control Language on page 59.
cannot read panel or a firmware command.

Broken or melted Darkness setting too high. 1. Reduce the darkness setting.
ribbon 2. Clean the printhead thoroughly.
Ribbon tension Ribbon core is not standard size Replace ribbon with one that has a standard core
dancer(s) oscillate and is slipping on the spindle. size.
erratically
The LCD is missing The LCD may need replacing. Call a service technician.
characters or parts of
characters
Changes in Parameters are set incorrectly. 1. Set parameters and save permanently.
parameter settings 2. Turn the printer power Off (O) and then
did not take effect On (I).
A command turned off the Refer to the Programming Guide for the printer
ability to change the parameter. language being used, or call a service technician.

A command changed the Refer to the Programming Guide for the printer
parameter back to the previous language being used, or call a service technician.
setting.
If the problem continues, there Call a service technician.
may be a problem with the
main logic board.
The printer fails to The printer was not calibrated Perform the calibration procedure in Calibrate
calibrate or detect the for the label being used. Media and Ribbon Sensors on page 72.
top of the label. The printer is configured for Set the media type to noncontinuous media. See
continuous media. Set Media Type on page 62.
The driver or software Driver or software settings produce commands
configuration is not set that can overwrite the printer configuration.
correctly. Check the driver or software media-related
setting.
Non-continuous The printer is configured for Set the media type to noncontinuous media. See
labels are being continuous media. Set Media Type on page 62.
treated as continuous The printer was not calibrated Perform the calibration procedure in Calibrate
labels. for the media being used. Media and Ribbon Sensors on page 72.

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96 Troubleshooting
Miscellaneous Printer Problems

Table 19 • Miscellaneous Printer Problems (Continued)

Problem Possible Cause Recommended Solution

All lights are on, but Internal electronic or firmware Call a service technician.
nothing displays on failure.
the LCD, and the
printer locks up.
The printer locks up Main logic board failure. Call a service technician.
while running the
Power-On Self Test.

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 Troubleshooting 97
Printer Diagnostics

Printer Diagnostics
Self tests and other diagnostics provide specific information about the condition of the printer.
The self tests produce sample printouts and provide specific information that helps determine
the operating conditions for the printer. The most commonly used are the Power-On and the
CANCEL self tests.

Important • Use full-width media when performing self tests. If your media is not wide
enough, the test labels may print on the platen roller.

Each self test is enabled by pressing a specific control panel key or combination of keys while
turning the power On (I). Keep the key(s) pressed until the first indicator light turns off. The
selected self test automatically starts at the end of the Power-On Self Test.

Note •
• When performing these self tests, do not send data to the printer from the host.
• If your media is shorter than the label to be printed, the test label continues on the next
label.
• When canceling a self test prior to its actual completion, always reset the printer by turning
the printer power Off (O) and then On (l).

Power-On Self Test

A Power-On Self Test (POST) is performed each time the printer is turned On (l). During this
test, the control panel lights (LEDs) turn on and off to ensure proper operation. At the end of
this self test, only the POWER LED remains lit. When the Power-On Self Test is complete, the
media is advanced to the proper position.

To initiate the Power-On Self Test, complete these steps:

1. Turn On (I) the printer using the power switch located to the side of the control panel.
The POWER LED illuminates. The other control panel LEDs and the LCD monitor the
progress and indicate the results of the individual tests. All messages during the POST
display in English; however, if the test fails, the resulting messages cycle through the
international languages as well.

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98 Troubleshooting
Printer Diagnostics

CANCEL Self Test

The CANCEL self test prints a configuration label (Figure 29).

To perform the CANCEL Self Test, complete these steps:

1. Turn Off (O) the printer.

2. Press and hold CANCEL while turning the printer On (I). Hold CANCEL until the first
control panel light turns off.
A printer configuration label prints (Figure 29).

Figure 29 • Configuration Label

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 Troubleshooting 99
Printer Diagnostics

PAUSE Self Test

This self test can be used to provide the test labels required when making adjustments to the
printer’s mechanical assemblies or to determine if any printhead elements are not working.
Figure 30 shows a sample printout.

To perform a PAUSE self test, complete these steps:

1. Turn Off (O) the printer.

2. Press and hold PAUSE while turning the power On (I). Hold PAUSE until the first control
panel light turns off.
• The initial self test prints 15 labels at the printer’s slowest speed, and then
automatically pauses the printer. Each time PAUSE is pressed, an additional 15 labels
print. Figure 30 shows a sample of the labels.

Figure 30 • PAUSE Test Label

• While the printer is paused, pressing CANCEL alters the self test. Each time PAUSE is
pressed, 15 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a second time.
Each time PAUSE is pressed, 50 labels print at the printer’s slowest speed
• While the printer is paused, pressing CANCEL again alters the self test a third time.
Each time PAUSE is pressed, 50 labels print at 6 in. (152 mm) per second.
• While the printer is paused, pressing CANCEL again alters the self test a fourth time.
Each time PAUSE is pressed, 15 labels print at the printer’s maximum speed.
• To exit this self test at any time, press and hold CANCEL.

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100 Troubleshooting
Printer Diagnostics

FEED Self Test

Different types of media may require different darkness settings. This section contains a
simple but effective method for determining the ideal darkness for printing bar codes that are
within specifications.

During the FEED self test, labels are printed at different darkness settings at two different print
speeds. The relative darkness and the print speed are printed on each label. The bar codes on
these labels may be ANSI-graded to check print quality.

During this test, one set of labels is printed at 2 ips, and another set is printed at 6 ips. The
darkness value starts at three settings lower than the printer’s current darkness value (relative
darkness of –3) and increase until the darkness is three settings higher than the current
darkness value (relative darkness of +3).

To perform a FEED self test, complete these steps:

1. Print a configuration label to show the printer’s current settings.

2. Turn Off (O) the printer.

3. Press and hold FEED while turning the power On (I). Hold FEED until the first control
panel light turns off.
The printer prints a series of labels (Figure 31) at various speeds and at darkness settings
higher and lower than the darkness value shown on the configuration label.

Figure 31 • FEED Test Label

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 Troubleshooting 101
Printer Diagnostics

4. See Figure 32 and Table 20. Inspect the test labels and determine which one has the best
print quality for your application. If you have a bar code verifier, use it to measure
bars/spaces and calculate the print contrast. If you do not have a bar code verifier, use your
eyes or the system scanner to choose the optimal darkness setting based on the labels
printed in this self test.

Figure 32 • Bar Code Darkness Comparison

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102 Troubleshooting
Printer Diagnostics

Table 20 • Judging Bar Code Quality

Print Quality Description

Too dark Labels that are too dark are fairly obvious. They may be
readable but not “in-spec.”
• The normal bar code bars increase in size.
• The openings in small alphanumeric characters may fill in
with ink.
• Rotated bar code bars and spaces run together.
Slightly dark Slightly dark labels are not as obvious.
• The normal bar code will be “in-spec.”
• Small character alpha numerics will be bold and could be
slightly filled in.
• The rotated bar code spaces are small when compared to
the “in-spec” code, possibly making the code unreadable.
“In-spec” The “in-spec” bar code can only be confirmed by a verifier,
but it should exhibit some visible characteristics.
• The normal bar code will have complete, even bars and
clear, distinct spaces.
• The rotated bar code will have complete, even bars and
clear, distinct spaces. Although it may not look as good as a
slightly dark bar code, the bar code will be “in-spec.”
• In both normal and rotated styles, small alphanumeric
characters look complete.
Slightly light Slightly light labels are, in some cases, preferred to slightly
dark ones for “in-spec” bar codes.
• Both normal and rotated bar codes will be in spec, but
small alphanumeric characters may not be complete.
Too light Labels that are too light are obvious.
• Both normal and rotated bar codes have incomplete bars
and spaces.
• Small alphanumeric characters are unreadable.

5. Note the relative darkness value and the print speed printed on the best test label.

6. Add or subtract the relative darkness value from the darkness value specified on the
configuration label. The resulting numeric value is the best darkness value for that specific
label/ribbon combination and print speed.

7. If necessary, change the darkness value to the darkness value on the best test label. See
Adjust Print Darkness on page 60.

8. If necessary, change the print speed to the same speed as on the best test label. See Adjust
Print Speed on page 63.

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 Troubleshooting 103
Printer Diagnostics

FEED and PAUSE Self Test

Performing this self test temporarily resets the printer configuration to the factory default
values. These values are active only until power is turned off unless you save them
permanently in memory. If the factory default values are permanently saved, a media
calibration procedure must be performed.

To perform a FEED and PAUSE self test, complete these steps:

1. Turn Off (O) the printer.

2. Press and hold FEED and PAUSE while turning the power On (I).

3. Hold FEED and PAUSE until the first control panel light turns off.
The printer configuration is temporarily reset to the factory default values. No labels print
at the end of this test.

Communications Diagnostics Test

Do not perform the following test until all configuration and calibration parameters have been
set. For configuration information, see Control Panel LCD Display on page 60.

This test is controlled from the control panel LCD display. See Hex Dump on page 69.
Figure 33 shows a typical printout from this test. Turn the printer power Off (O) and then back
On (I) to exit this self test and return to normal operation.

Note • This test label prints upside-down.

Figure 33 • Communications Diagnostics Test Label

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104 Troubleshooting
Printer Diagnostics

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

13290L-001 Rev. A S4M User Guide 10/21/05

 7
Specifications

This section provides the features of and specifications for the printer.

Contents
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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106 Specifications
General Specifications

General Specifications

General Specifications
Height 11.6 in. 295 mm
Width 10.7 in. 272 mm
Depth 18.8 in. 477 mm
Weight (without options) 27.2 lbs. 12.4 kg
Electrical 90–264 VAC, 47–63 Hz, 4 Amps (300 W)
Temperature Operating 40° to 104°F 5° to 40°C
Storage –40° to 140°F –40° to 60°C
Relative Humidity Operating 20% to 85%, non-condensing
Storage 5% to 85%, non-condensing
Communication Interface • RS-232/CCITT V.24 serial data interface; 110 to
115000 baud, parity, bits/character, 7 or 8 data
bit, and XON-XOFF, RTS/CTS or DTR/DSR
handshake protocol required. 750mA at 5 V
from pins 1 and 9.
• USB 1.1 data interface
• One of the following:
• 8-bit parallel data interface; supports IEEE
1284 bidirectional parallel; nibble mode
compliant.
• 10/100 internal Ethernet
• 802.11b wireless card support

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 Specifications 107
Agency Approvals

Agency Approvals
Agency Approvals • IEC60950-1
• EN55022: Class B
• EN55024
• EN61000-3-2,-3-3
Product Markings • cULus
• CE Marking
• FCC-B
• ICES-003
• VCCI
• C-Tick
• NOM
• CCC
• GOST-R
• S-Mark (Argentina)
• MIC
• BSMI

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108 Specifications
Printing Specifications

Printing Specifications
Printing Specifications
Print resolution 203 dots/inch 8 dots/mm
300 dots/inch 12 dots/mm
Dot size 203 dpi 0.00492 in. x 0.00492 in. 0.125 mm x
(width x length) 0.125 mm
300 dpi 0.0033 in. x 0.0039 in. 0.084 mm x 0.099
mm
Maximum print 203 dpi 4.09 in. 104 mm
width 300 dpi 4.1 in. 106 mm
Bar code modulus 203 dots/inch 5 mil to 50 mil
(X) dimension 300 dots/inch 3.3 mil to 33 mil
Programmable 203 dots/inch Per second: Per second:
constant print speeds and 300 2 in. 51 mm
dots/inch 3 in. 76 mm
4 in. 102 mm
5 in. 127 mm
6 in. 152 mm

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 Specifications 109
Media Specifications

Media Specifications

Media Specifications
Label length Minimum (Tear-Off) 0.7 in. 17.8 mm
Minimum (Peel-Off) 0.5 in. 12.7 mm
Maximum 39 in. 991 mm
Label width Minimum 0.75 in. 19 mm
Maximum 4.5 in. 114 mm
Total thickness Minimum 0.003 in. 0.076 mm
(includes liner, if any) Maximum 0.010 in. 0.25 mm
Maximum roll outside 3-in. (76 mm) core 8 in. 203 mm
diameter 1-in. (25 mm) core 6 in. 152 mm
Inter-label gap Minimum 0.079 in. 2 mm
Preferred 0.118 in. 3 mm
Maximum 0.157 in. 4 mm
Ticket/tag notch size (width x length) 0.25 in. × 0.12 in. 6 mm × 3 mm
Hole diameter 0.125 in. 3 mm
Notch or hole position Minimum 0.15 in. 3.8 mm
(Centered from inner Maximum 2.25 in. 57 mm
media edge)
Density, in Optical Density Units (UDO) (black mark) > 1.0 ODU
Maximum media density < 0.5 ODU
Transmissive Sensor Fixed 7/16 in. (11 mm) from inside edge

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110 Specifications
Ribbon Specifications

Ribbon Specifications

Note • This section applies only to printers that have the Thermal Transfer option installed.

Ribbon must be wound with the coated side out.

Ribbon Specifications
Ribbon width Minimum >2 in.* 51 mm*
(Zebra recommends using ribbon at least as Maximum 4.3 in. 109 mm
wide as the media to protect the printhead
from wear.)
Standard lengths 2:1 media to ribbon roll 984 ft. 300 m
ratio
3:1 media to ribbon roll 1476 ft. 450 m
ratio
Ribbon core inside diameter 1 in. 25.4 mm
* Depending on your application, you may be able to use ribbon narrower than 2 in. (51 mm), as long as the ribbon is wider
than the media being used. To use a narrower ribbon, test the ribbon’s performance with your media to assure that you get the
desired results.

13290L-001 Rev. A S4M User Guide 10/21/05

 A
ZPL II Commands

This section provides the ZPL II commands that were added or changed for the S4M.

Contents
^KP Define Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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112 ZPL II Commands
^KP

^KP
Define Password
Description The ^KP command is used to define the password that must be entered to
access the control panel switches and LCD Setup mode. For more information about the
password structure in this printer, see Password Protection of Parameters on page 54.

Format ^KPa,b

This table identifies the parameters for this format:

Parameters Details
a = mandatory four-digit A password of 0000 for any level disables password checking for that level and
password all levels below it. The printer web pages assume the Level 3 password.
Accepted Values: Any four-digit number from 0000 to 9999
Default Value:
• Level 4—9999
• Level 3—1234
• Level 2—0000
• Level 1—0000
b = password level Accepted Values: 1, 2, 3, 4
Default Value: 3

Example • This example shows how to set a password of 5678 for level 3:
^XA
^KP5678,3
^XZ

Password-Protect All Parameters To password protect all parameters, send the

^KP ZPL II command with a password for each level.

Disable Passwords To disable the password-protection feature for a particular level and
those below it, set the password to 0000 using the ^KP ZPL II command. To reenable the
password-protection feature, send the ZPL II command with any non-zero number for a
password.

Return to Default Passwords If you forget your passwords, the printer can be returned to
the default factory settings, which makes the default passwords valid again. Use caution when
returning the passwords to their default values because this also sets all other printer
parameters back to their defaults.

To return the printer to the default factory settings using ZPL, send this command:
^XA
^JUF
^XZ

13290L-001 Rev. A S4M User Guide 10/21/05

 Proprietary Statement

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.

Product Improvements
Continuous improvement of products is a policy of Zebra Technologies. All specifications and
designs are subject to change without notice.

FCC Compliance Statement

This device complies with Part 15 rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference, and

2. This device must accept any interference received, including interference that may cause
undesired operation.

This equipment has been tested and found to comply with the limits for Class B Digital
Devices, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference when the equipment is operated in a residential
environment. This equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the product manuals, may cause harmful interference
to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television
reception, the user is encouraged to do one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.

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114 Proprietary Statement

• Consult the dealer or an experienced radio/TV technician for help.

The user is cautioned that any changes or modifications not expressly approved by Zebra
Technologies could void the user’s authority to operate the equipment. To ensure compliance,
this printer must be used with Shielded Communication Cables.

Canadian DOC Compliance Statement

This Class B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

Liability Disclaimer
Zebra Technologies takes steps to ensure that its published Engineering specifications and
manuals are correct; however, errors do occur. Zebra Technologies reserves the right to correct
any such errors and disclaims liability resulting therefrom.

Limitation of Liability
In no event shall Zebra Technologies 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, consequential damages including loss of
business profits, business interruption, or loss of business information) arising out of the use
of, the results of use of, or inability to use such product, even if Zebra Technologies has been
advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation or exclusion may
not apply to you.

13290L-001 Rev. A S4M User Guide 10/21/05

 C
Glossary

alphanumeric Indicating letters, numerals, and characters such as punctuation marks.

backfeed 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 operating the printer in Tear-Off and Applicator modes.

bar code A code by which alphanumeric characters can be represented by a series of

adjacent stripes of different widths. Many different code schemes exist, such as the universal
product code (UPC) or Code 39.

black mark A registration mark found on the underside of the print media that acts as a start-
of-label indication for the printer. (See continuous media.)

calibration (of a printer) A process in which the printer determines some basic
information needed to print accurately with a particular media and 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, and (if using non-continuous media)
the length of individual labels or tags.

character set The set of all letters, numerals, punctuation marks, and other characters that
can be expressed by a particular font or bar code.

check digit A character added to a bar code symbol that indicates to the scanner that it has
read the symbol correctly.

configuration The printer configuration is a group of operating parameters specific to the

printer application. Some parameters are user selectable, while others are dependent on the
installed options and mode of operation. Parameters may be switch selectable, control panel
programmable, or downloaded as ZPL II commands. A configuration label listing all the
current printer parameters may be printed for reference.

continuous media Label or tag-stock media that has no notch, gap, or web (media liner
only) to separate the labels or tags. The media is one long piece of material.

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116 Glossary

core diameter The inside diameter of the cardboard core at the center of a roll of media or
ribbon.

diagnostics Information about which printer functions are not working that is used for
troubleshooting printer problems.

die-cut media A type of label stock that has individual labels stuck to a media liner. The
labels may be either lined up against each other or separated by a small distance. Typically the
material surrounding the labels has been removed. (See non-continuous media.)

direct thermal A printing method in which the printhead presses directly against the media.
Heating the printhead elements causes a discoloration of the heat-sensitive coating on the
media. By selectively heating the printhead elements as the media moves past, an image is
printed onto the media. No ribbon is used with this printing method. Contrast this with thermal
transfer.

direct thermal media Media that is coated with a substance that reacts to the application of
direct heat from the printhead to produce an image.

dynamic RAM The memory devices used to store the label formats in electronic form while
they are being printed. The amount of DRAM memory available in the printer determines the
maximum size and number of label formats that can be printed. This is volatile memory that
loses the stored information when power is turned off.

fanfold media Media that comes folded in a rectangular stack. Contrast this with roll media.

firmware This is the term used to specify the printer’s operating program. This program is
downloaded to the printer from a host computer and stored in FLASH memory. Each time the
printer power is turned on, this operating program starts. This program controls when to feed
the media forward or backward and when to print a dot on the label stock.

FLASH memory FLASH memory is non-volatile and maintains the stored information
intact when power is off. This memory area is used to store the printer’s operating program. In
addition, this memory can be used to store optional printer fonts, graphic formats, and
complete label formats.

Font A complete set of alphanumeric characters in one style of type. Examples include
CG Times™, CG Triumvirate Bold Condensed™.

ips (inches-per-second) The speed at which the label or tag is printed. Zebra printers can
print from 1 ips to 12 ips.

label An adhesive-backed piece of paper, plastic, or other material on which information is

printed.

label backing (liner) The material on which labels are affixed during manufacture and
which is discarded or recycled by the end-users.

liquid crystal display (LCD) The LCD is a back-lit display that provides the user with
either operating status during normal operation or option menus when configuring the printer
to a specific application.

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 Glossary 117

light emitting diode (LED) Indicators of specific printer status conditions. Each LED is
either off, on, or blinking depending on the feature being monitored.

lock-up This is the term generally used to describe a fault condition that, for no apparent
reason, causes the printer to stop working.

media Material onto which data is printed by the printer. Types of media include: tag stock,
die-cut labels, continuous labels (with and without media liner), non-continuous media,
fanfold media, and roll media.

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 used to indicate the start
of each label.

non-continuous media Media that contains an indication of where one label/printed

format ends and the next one begins. Examples are die-cut labels, notched tag-stock, and stock
with black mark registration marks.

non-volatile memory Electronic memory that retains data even when the power to the
printer is turned off.

notched media A type of tag stock containing a cutout area that can be sensed as a start-of-
label indicator by the printer. This is typically a heavier, cardboard-like material that is either
cut or torn away from the next tag. (See non-continuous media.)

print speed The speed at which printing occurs. For thermal transfer printers, this speed is
expressed in terms of ips (inches per second). Zebra offers printers that can print from 1 ips to
12 ips.

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 the
printhead, use the lowest print darkness setting (sometimes called burn temperature or head
temperature) and the lowest printhead pressure necessary to produce good print quality. In the
thermal transfer printing method, use ribbon that is as wide or wider than the media to protect
the printhead from the rough media surface.

registration Alignment of printing with respect to the top of a label or tag.

ribbon A band of material consisting of a base film coated with wax or resin “ink.” The
inked side of the material is pressed by the printhead against the media. The ribbon transfers
ink onto the media when heated by the small elements within the printhead. Zebra ribbons
have a coating on the back that protects the printhead from wear.

ribbon wrinkle A wrinkling of the ribbon caused by improper alignment or improper

printhead pressure. This wrinkle can cause voids in the print and/or the used ribbon to rewind
unevenly. This condition should be corrected by performing adjustment procedures.

roll media Media that comes supplied rolled onto a core (usually cardboard). Contrast this
with fanfold media.

supplies A general term for media and ribbon.

10/21/05 Rev. A
118 Glossary

symbology The term generally used when referring to a bar code.

tag A type of media having no adhesive backing but featuring a hole or notch by which the
tag can be hung on something. Tags are usually made of cardboard or other durable material.

tear-off A mode of operation in which the user tears the label or tag stock away from the
remaining media by hand.

thermal transfer A printing method in which the printhead presses an ink or resin coated
ribbon against the media. H eating the printhead elements causes the ink or resin to transfer
onto the media. By selectively heating the printhead elements as the media and ribbon move
past, an image is printed onto the media. Contrast this with direct thermal.

void A space on which printing should have occurred, but did not due to an error condition
such as wrinkled ribbon or faulty print elements. A void can cause a printed bar code symbol
to be read incorrectly or not at all.

13290L-001 Rev. A S4M User Guide 10/21/05

 Index

A B
active control panel buttons, 10 bar code list, 65
adhesive test for ribbon coating, 28 baud rate, 66
adjustments before you begin setup, 16
label left side, 61 black mark media
label top, 61 described, 25
print speed, 63 specifying, 62
print width, 63
printhead pressure, 49 C
reflective sensor, 47
cable requirements, 24
tear-off position, 61
calibration
agency approvals, 107
media and ribbon sensors, 72
ALERT light, 12
troubleshooting problems, 93
APL-D
Canadian DOC compliance, 114
set Module A storage device, 64
CANCEL button
set Module B storage device, 64
CANCEL self test, 98
setting compatibility mode, 63
function, 11
setting control codes, 64
CANCEL light, 12
APL-I
changing display language, 59
adjust label left position, 61
checklist
print settings, 65
before you begin, 16
print stored format, 66
troubleshooting, 86
print stored page, 66
cleaning
response format, 67
exterior of printer, 78
set printer resolution, 64
media compartment and sensors, 81
status response, 67
peel-off assembly, 82
arrow button functions, 11
printhead and platen roller, 79
auto calibration, 46
recommended cleaning schedule, 78
command character, 68

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120 Index

communication interfaces E
overview and location, 21 electrical noise, 24
types of connections, 22 electronics cover, 8
communications diagnostics test emulations, 14
overview, 103 ENTER button function, 11
selecting hex dump mode, 69 enter Setup mode, 52
communications problems, 94 error messages, 87
components of printer, 13 Error mode, 10
configuration external view of printer, 8
changing password-protected parameters, 54
viewing printer settings, 56
configuration label F
printing from control panel, 56 factory defaults, 70
printing using CANCEL self test, 98 fanfold media, 26
connect to power source, 19 FCC compliance, 113
contacts, 3 FEED button
continuous media FEED and PAUSE self test, 103
described, 26 FEED self test, 100
specifying, 62 function, 11
control character, 68 FEED light, 12
control panel firmware, 14
buttons, 10 Flash memory initialization, 70
LCD error messages, 87 font list, 65
LCD functions, 10 formats list, 65
lights, 12
location, 8 G
overview, 9
gap/notch, 62
parameters described, 60
general specifications, 106
customer service, 3

D H
handshaking protocol, 67
darkness adjustment, 60
HEAD COLD message, 88
data bits, 66
HEAD TOO HOT message, 87
data cable requirements, 24
hex dump mode, 69
data source
host handshake, 67
connections, 21
humidity requirements, 18
site selection, 18
default values
passwords, 54 I
resetting, 70 images list, 65
sensor selection, 62 initialize Flash memory, 70
define password, 112 inspect for shipping damage, 17
delimiter character, 68 interfaces
diagnostics, 97 IEEE 1284 bidirectional parallel, 23
direct thermal mode print servers, 24
media scratch test, 27 RS-232 serial, 22
setting through control panel, 70 USB 1.1, 23
display language selection, 59 international safety organization marks, 20
download firmware, 14 IP settings, 74

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 Index 121

L N
label length setting, 64 navigation through parameters, 52
label removal method, 63 network configuration label, 56
label sensor positioning, 47 non-continuous media
label top described, 25
printer cannot detect, 95 specifying, 62
labels did not print, 94
language selection O
available languages, 73
operating conditions, 18
procedure, 59
Operating mode, 10
LCD messages
optional print servers, 24
error messages, 87
ordering ribbon and media, 3
leave Setup mode, 52
override EPL commands, 71
left side adjustment, 61
override ZPL commands, 71
liability, 114
load factory defaults, 70
loading ribbon, 41 P
lubrication, 78 parallel port
overview, 23
M setting parallel communications, 65
parity, 67
manual calibration, 46
password
media
defaults, 54
continuous roll media, 26
define via ZPL, 112
fanfold, 26
password level 1 and 2 parameters, 60
non-continuous roll media, 25
password level 3 parameters, 65
ordering, 3
PAUSE button
specifications, 109
FEED and PAUSE self test, 103
specify type, 62
function, 11
types of media, 25
PAUSE self test, 99
media compartment
PAUSE light, 12
cleaning, 81
Pause mode, 10
components, 13
peel-off mode
media door, 8
cleaning peel-off assembly, 82
media loading
loading media, 36
peel-off mode, 36
position label sensor, 47
tear-off mode, 33
power
media scratch test, 27
connect to power source, 19
media sensor
power cord specifications, 20
calibrate, 72
site selection, 18
select sensor type, 62
POWER light, 12
sensor profile, 71
Power-On Self Test (POST), 97
media sensors
print configuration label
reflective sensor adjustment, 47
CANCEL self test, 98
transmissive sensor location, 47
from control panel, 56
MENU button function, 11
print darkness adjustment, 60

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122 Index

print modes RIBBON IN message, 87

load media for different modes, 30 ribbon sensor calibration, 72
specify label removal method, 63 roll media
print position adjustment, 61 described, 25
print quality troubleshooting, 90 routine cleaning schedule, 78
print rate, 63 RS-232 serial interface, 22
print server
options, 24 S
parameters, 74
sales, 3
viewing network settings, 56
saving changes to parameters, 52
print speed adjustment, 63
scratch test
print width adjustment, 63
media type, 27
printer components, 13
ribbon coated side, 28
printer diagnostics, 97
self tests, 97
printer interior, 13
CANCEL, 98
printer language modes, 14
communications diagnostics, 103
printer modes, 10
FEED, 100
printer passwords, 54
FEED and PAUSE, 103
printer resolution for APL-I, 64
PAUSE, 99
printhead
Power-On Self Test (POST), 97
cleaning, 79
sensors
pressure adjustment, 49
calibrate, 72
printing specifications, 108
media sensor profile, 71
product improvements, 113
reflective, 47
product markings, 107
select sensor type, 62
proprietary statement, 113
transmissive sensor location, 47
setting passwords, 54
R setup
Real-Time Clock (RTC) checklist, 16
set date, 69 unpack the printer, 17
set time, 69 Setup mode
reflective sensor defined, 10
adjustments, 47 entering and leaving, 52
selecting, 62 shipping
registration problems, 93 report damage, 17
relative humidity requirements, 18 reshipping the printer, 17
removal method for labels, 63 spacing requirements, 18
remove ribbon, 44 specifications
report shipping damage, 17 agency approvals and markings, 107
reset factory defaults, 70 general, 106
ribbon media, 109
adhesive test, 28 power cord, 20
determining coated side, 27 printing, 108
loading, 41 ribbon, 110
ordering, 3 specify media type, 62
removing, 44 speed adjustments, 63
scratch test, 28 storing the printer, 17
setting printer for use, 70 surface for the printer, 18
specifications, 110
when to use, 27

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 Index 123

T types of media
tag stock continuous roll media, 26
described, 25 fanfold media, 26
specifying, 62 non-continuous roll media, 25
tear-off mode
adjust tear-off position, 61 U
loading media, 33 unpack the printer, 17
technical support, 3 USB 1.1 port, 23
temperature requirements, 18
thermal transfer mode
media scratch test, 27 W
setting through control panel, 70 web media, 25
top of label wireless print server
adjust label top, 61 parameters, 74
printer cannot detect, 95 viewing network settings, 56
transmissive sensor
location, 47 Z
selecting, 62 Zebra Programming Language (ZPL)
troubleshooting ^KP, define password, 112
checklist, 86 command character, 68
communications problems, 94 control character, 68
diagnostic tests, 97 delimiter character, 68
LCD error messages, 87 override certain commands, 71
print quality problems, 90

10/21/05 S4M User Guide 13290L-001 Rev. A

124 Index

Notes • ___________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

13290L-001 Rev. A S4M User Guide 10/21/05

Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109 U.S.A.
Telephone: +1 847.634.6700
Facsimile: +1 847.913.8766

Zebra Technologies Europe Limited

Zebra House
The Valley Centre, Gordon Road
High Wycombe
Buckinghamshire HP13 6EQ, UK
Telephone: +44 (0) 1494 472872
Facsimile: +44 (0) 1494 450103

Zebra Technologies Asia Pacific, LLC

16 New Industrial Road
#05-03 Hudson TechnoCentre
Singapore 536204
Telephone: +65 6858 0722
Facsimile: +65 6885 0838

Part Number: 13290L-001

© 2005 ZIH Corp.