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Zebra 400 User Manual

Zebra technologies user's guide printers 400, 600
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®
S
S
For the Zebra
400™ and
600™ Printers
Customer order # 44885L
Manufacturer part # 44885LB Rev. 2
User's
Guide

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Table of Contents
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  Summary of Contents for Zebra 400

  • Page 1 ® For the Zebra 400™ and 600™ Printers Customer order # 44885L Manufacturer part # 44885LB Rev. 2 User’s Guide...
  • Page 2 Proprietary Statement Product Improvements FCC Compliance Statement NOTE: NOTE: Canadian DOC Compliance Statement Liability Disclaimer No Liability for Consequential Damage Copyrights...
  • Page 3 I have determined that the Zebra printers identified as the Stripe Series 400 and 600 manufactured by: Zebra Technologies Corporation 333 Corporate Woods Parkway Vernon Hills, Illinois 60061-3109 U.S.A. have been shown to comply with the applicable technical standards of the FCC...
  • Page 5: Table Of Contents

    Introduction Unpacking ........1 Reporting Damage......1 Site Requirements .
  • Page 6 S400 & S600 User’s Guide Printing a Test Label ......18 Connecting the Printer and Computer ....18 RS-232 Interface Requirements .
  • Page 7 Resetting Factory Defaults ..... . . 46 Resetting Communications Parameters ....46 Resetting Ribbon Parameters .
  • Page 8 S400 & S600 User’s Guide...
  • Page 9: Introduction

    Congratulations! You have just purchased a high-quality thermal label printer manufactured by the industry leader in quality, service, and value. For over 25 years, Zebra Technologies Corporation has provided customers with the highest caliber of products and support. This user's guide provides all the information you will need to operate the printer on a daily basis.
  • Page 10: Site Requirements

    S400 & S600 User’s Guide Site Requirements CAUTION: To insure that the printer has proper ventilation and cooling, do not place any padding or cushioning material under the unit, because this restricts air flow. This printer may be installed on any solid, level surface of sufficient size and strength to accommodate the physical dimensions and weight of the unit.
  • Page 11: Peel-Off Mode

    Figure 2 Cutter Module Figure 3 S400 & S600 User’s Guide This printer (Figure 2) operates in Peel-Off mode. In Peel-Off, backing material is peeled away from the label as it is printed. After this label is removed from the printer, the next one is printed.
  • Page 12: Printer Overview

    S400 & S600 User’s Guide Media Access Cover Ribbon Supply Spindle Ribbon Take-up Spindle Media Supply Hanger Media Supply Guide Media Guide Front Cover Tear Plate Printhead Figure 4 Control Panel Platen Roller AC Power Cable Connection Parallel Interface Serial Interface Fuse Power On/Off Switch Head Open Lever...
  • Page 13: Getting Ready To Print

    AC Power Cable The AC power cable has a three-prong female connector on one end (see Figure 5). This connector must be plugged into the mating connector on the left side of the printer. See Figure 6. The connector at the other end of the AC power cable will be one of the following: US Standard 110 VAC three-prong plug Great Britain Standard 230 VAC three-prong plug...
  • Page 14 S400 & S600 User’s Guide RS-232 (Serial) Interface Parallel Interface AC Power Cable Connection Figure 6 Power On/Off Switch Fuse...
  • Page 15: Loading The Media

    Loading the Media Media widths and thicknesses vary between applications. To maintain print quality from one application to another, refer to “Print Quality Adjustments” in Routine Care and Adjustments. NOTE: Zebra recommends using media that is outside wound (you can see the labels on the outside of the roll).
  • Page 16: Fanfold Media

    S400 & S600 User’s Guide 4. Adjust the media supply guide and the media guide against the outer edge of the media. These guides must not cause pressure or excessive drag on the media. 5. Close the head open lever, and see “Adjusting the Media Sensor” later in this chapter to adjust the media sensor position.
  • Page 17: Peel-Off Mode

    Peel-Off Mode (Optional) Refer to Figure 9 and follow the procedure below. 1. Slide the media supply guide (a), media guide (b), and the outer edge guides on both the platen guide rod (c) and the lower guide rod (d) as far out from the printer frame as possible.
  • Page 18: Removing The Label Backing Material

    S400 & S600 User’s Guide 8. To hold the media against the spindle, place the hold down hook over the backing and insert both ends into the small slots in the round plate at the far end of the spindle. Again, rotate the backing rewind spindle counterclockwise to remove any slack in the backing material.
  • Page 19: Cutter Mode

    S400 & S600 User’s Guide Cutter Mode (Optional) To insure proper media loading, follow the directions for the Tear-Off Mode with the exception that the end of the media must be positioned on top of the platen roller. See Figure 10. With the end of the media positioned directly on top of the platen roller (a), close the head open lever.
  • Page 20: Loading The Ribbon

    S400 & S600 User’s Guide Loading the Ribbon Before you load the ribbon, make sure the ribbon supply spindle is adjusted properly. Ribbon Supply Spindle: Normal Position In the normal position, the “dual-tension” ribbon supply spindle provides the desired amount of ribbon back tension for different ribbon widths. To place the spindle in the normal position, firmly pull the spindle end cap (a) until it clicks into place, as shown in Figure 11.
  • Page 21: Ribbon Loading Instructions

    Ribbon Loading Instructions NOTES: Zebra recommends the use of ribbon that is wider than the media. The smooth backing of the ribbon protects the printhead from wear and premature failure due to excessive abrasion. (For the direct thermal print method, ribbon is not used and should not be loaded in the printer.) Zebra recommends the use of ribbon that is outside wound (the ink side is on the outside of the roll).
  • Page 22: Ribbon Removal

    S400 & S600 User’s Guide Ribbon Removal Refer to Figure 12. When it’s time to change the ribbon, cut the ribbon where it is stretched between the upper ribbon guide arm and the takeup spindle. To remove ribbon from the takeup spindle, press the release button (d) and slide the ribbon off the spindle.
  • Page 23: Adjusting The Media Sensor

    S400 & S600 User’s Guide Adjusting the Media Sensor This adjustment aligns the position of the light sensor with the notch or edge of the label, so the printer can determine the correct label size. See Figure 13. With the printhead open, look through the side of the print mechanism and locate the media sensor adjustment lever (a).
  • Page 24: Auto Calibration

    S400 & S600 User’s Guide Auto Calibration This procedure occurs whenever the printer is turned on or the printhead is opened and closed. During this procedure, the printer automatically determines the media type, label length, media and ribbon sensor settings, and printing method (direct thermal or thermal transfer).
  • Page 25: Front Panel Leds

    If the button is pressed, the label format that is currently printing is canceled. If pressed when no label format is printing, then the next format to be printed is canceled. Press for at least three seconds to cancel all label formats the printer has received and return the printer to an idle state.
  • Page 26: Ac Power On/Off Switch

    S400 & S600 User’s Guide AC Power ON/OFF Switch This switch is located on the left side of the printer near the AC power cord and fuse (see Figure 6). The AC power switch should be turned off before connecting or disconnecting any cables. Turning the switch on activates the printer and causes it to perform a Power ON Self Test, which can take up to 30 seconds, as it begins operation.
  • Page 27: Parallel Interface Requirements

    For pinout information, as well as information on how to interconnect to either a DTE or DCE device, refer to the Appendix. Parallel Interface Requirements Refer to Figure 6. An IEEE 1284 compatible bi-directional parallel data cable is required when this communication method is selected. The required cable must have a standard 36-pin parallel connector on one end, which is plugged into the mating connector located inside the access opening on the left side of the printer.
  • Page 28: Autobaud

    S400 & S600 User’s Guide length, no parity, 1 stop bit, and XON/XOFF), press and hold the PAUSE, FEED, and MODE buttons while turning on the printer, then release the buttons when the CALIBRATE LED goes out. All of the LEDs will go on, while the DARKEN, POSITION, and CALIBRATE LEDs will flash.
  • Page 29: Routine Care And Adjustments

    Routine Care and Adjustments Cleaning CAUTION: Use only the cleaning agents indicated below. Zebra Technologies Corporation will not be responsible for any other products be- ing used on this printer. No lubricants are needed. The following table provides a brief cleaning schedule. Specific cleaning procedures are provided on the following pages.
  • Page 30 S400 & S600 User’s Guide Figure 15...
  • Page 31: Cleaning The Exterior

    S400 & S600 User’s Guide Cleaning the Exterior The exterior surfaces of the printer may be cleaned with a lint-free cloth. Do not use harsh or abrasive cleaning agents or solvents. If necessary, a mild detergent solution or desktop cleaner may be used sparingly. Cleaning the Interior Remove any accumulated dirt and lint from the interior of the printer using a soft bristle brush and/or vacuum cleaner.
  • Page 32: Cleaning The Cutter Module

    S400 & S600 User’s Guide 2. Open the printhead (a) by moving the head open lever (b) to the open position. 3. Remove the media and ribbon (if present). 4. With a swab, wipe the print elements (c) from end to end (the print ele- ments are the grayish/black strip just behind the chrome strip.) Allow a few seconds for the solvent to evaporate.
  • Page 33 S400 & S600 User’s Guide Figure 17 Figure 18...
  • Page 34 S400 & S600 User’s Guide Figure 19 Figure 20...
  • Page 35 II. Disassembling the cutter module. See Figure 20. Hold the cutter module as illustrated. Put your thumbs on the two wire spring loops (a) and your index fingers on the top of the rear cutter blade guard (b). It may help to lay the cutter module on a table or other surface throughout this process.
  • Page 36 S400 & S600 User’s Guide CUTTER CUTTER SIDE PANEL SIDE PANEL Figure 21 Figure 22...
  • Page 37 V. Reinstalling the cutter module. See Figure 19. Position the cutter module above the cutter mounting posts (a). Press down on the cutter module until the mounting slots (b) engage the mounting posts on the printer. 2. See Figure 18. Tighten the mounting screw (b) in a clockwise direction to hold the cutter module in position.
  • Page 38: Lubrication

    S400 & S600 User’s Guide Lubrication No lubricating agents of any kind are required on this printer. Some commercially available lubricants will damage the finish if used. AC Power Fuse Replacement A user-replaceable AC power fuse (see Figure 6) is located just to the left of the power on/off switch.
  • Page 39: Mechanical Adjustments

    Mechanical Adjustments This printer has been designed with minimal operator adjustments required. Print Quality Adjustments When changing from one media/ribbon combination to another, only slight changes in print darkness or toggle pressure may be required. For these situations, refer to the toggle pressure adjustment in this chapter. I.
  • Page 40 S400 & S600 User’s Guide The pressure applied by the toggle assembly may need to be increased or reduced when different thicknesses or widths of media are used in the printer. NOTE: Before increasing toggle pressure to achieve darker print darkness, perform the print quality adjustments.
  • Page 41: Media Rest Position Adjustment

    Media Rest Position Adjustment This procedure sets the end-of-label position relative to the Tear-Off plate or cutter. Adjust this if your label is not being torn or cut at the correct point. 1. Briefly press the MODE button twice. The PAUSE and POSITION LEDs turn on.
  • Page 42: Backing Rewind Power Roller Adjustment

    S400 & S600 User’s Guide Backing Rewind Power Roller Adjustment (PEEL-OFF OPTION REQUIRED) NOTE: This roller is only present on printers with the Peel-Off option. Zebra presets this roller during manufacture for proper operation with most applications. Only adjust this roller when necessary. In the Peel-Off mode, proper media tracking is critical.
  • Page 43 S400 & S600 User’s Guide Figure 24 illustrates an improperly adjusted backing rewind power roller (a). On the left side, the backing material (b) is not contacting the power roller. The backing has more tension on the right edge (c) than on the left edge (d).
  • Page 44 S400 & S600 User’s Guide...
  • Page 45: Troubleshooting

    If the printer operates in an abnormal fashion, consult the troubleshooting table below. The printer diagnostics following the troubleshooting table may also help you to determine the problem. The troubleshooting of some problems may be beyond the abilities of the operator.
  • Page 46 S400 & S600 User’s Guide Printer stops, PAUSE LED and PAPER/RIBBON LED both on. Printer stops, PAUSE LED on and PAPER/ RIBBON LED flashing. Printer stops, PAUSE LED on and PRINTHEAD LED flashing. Printer stops, PAUSE LED and PRINTHEAD LED both on. Printer will not successfully perform an auto calibration.
  • Page 47 Symptom Diagnosis CANCEL button DATA LED is single was pressed and flashing. a format was deleted. PAUSE LED and DATA LED alternately flashing, Firmware error. but all other LEDs on. Printer is DATA LED is flashing. receiving data. Printer sent a “stop DATA LED is slow transmitting”...
  • Page 48 S400 & S600 User’s Guide Truncated print, no print, or FEED button operates incorrectly while using non-continuous media. Fine gray lines on blank labels at angles. Long tracks of missing print on several labels. Wrinkled ribbon. In Peel-Off mode, skewed or stuck labels. Image is not positioned correctly and/or misprint of 1 to 3 labels.
  • Page 49 Symptom Diagnosis Parameters are set or saved incorrectly. Changes in parameter settings did not take If problem effect. continues, there may be a problem on the main logic board. When using wide ribbon (over 2.4"), the image gets lighter or smears Too much near the end of the roll back-tension on...
  • Page 50 S400 & S600 User’s Guide In cutter mode, skewed, stuck, improperly cut or partially cut labels. The cutter is jamming up with labels, or labels are being cut more than once. Labels are not being cut at all. Printing stops, PAPER/RIBBON, PAUSE, and CANCEL LEDs on.
  • Page 51: Printer Status Sensors

    Printer Status Sensors The printer contains several status sensors. These sensors alert the operator to various conditions by either stopping the printing or turning on an LED. Sensor What it Monitors Checks the open/ closed Printhead status of the printhead sensor lever.
  • Page 52 S400 & S600 User’s Guide Label Available Sensor Tear-Off/ Peel-Off Plate Edge Guide Mark Figure 25 Rewind Spindle Full Sensor Figure 26...
  • Page 53: Manual Calibration

    Manual Calibration Perform a manual calibration whenever you are using pre-printed media, if the printer is in manual calibration mode, or when the printer will not auto calibrate. During this procedure, the media type, label length, media and ribbon sensor settings, and printing method are determined. Media type is determined by sensing either continuous or non-continuous media as blank labels move through the printer.
  • Page 54: Resetting Printer Parameters

    S400 & S600 User’s Guide Resetting Printer Parameters Resetting Factory Defaults If it is ever necessary to reset all of the factory default values, press and hold the FEED and PAUSE buttons while turning on the power. Permanently save these values in memory by pressing the MODE button four times;...
  • Page 55: Printer Diagnostics

    Printer Diagnostics Power-On Self Test A Power-On Self Test (POST) is performed automatically each time the printer is turned on. This test checks for proper initialization of various electronic circuits and establishes starting parameters as those stored in the printer’s memory.
  • Page 56: Cancel Key Self Test

    S400 & S600 User’s Guide CANCEL Key Self Test This self test prints the printer’s configuration parameters (for example, printing darkness, label length, and media type) that are currently stored in configuration (Flash) memory. See Figure 27. To perform the CANCEL key self test: 1.
  • Page 57: Pause Key Self Test

    PAUSE Key Self Test This self test can be used to provide the test labels required when making adjustments to the printer’s mechanical assemblies. See Figure 28. To perform the PAUSE key self test: 1. Press the PAUSE button while turning on the printer. 2.
  • Page 58: Feed Key Self Test

    S400 & S600 User’s Guide FEED Key Self Test The results of this self test will be used to determine the best darkness setting for a specific media/ribbon combination. Refer to Figure 29. To perform the FEED key self test: 1.
  • Page 59: Mode Key Self Test

    S400 & S600 User’s Guide MODE Key Self Test This self test places the printer in a communications diagnostics mode. In this mode, the printer prints the ASCII characters and their corresponding hexadecimal values for any data received from the host computer. See Figure 30.
  • Page 60 S400 & S600 User’s Guide...
  • Page 61: Specifications

    NOTE: Printer specifications are subject to change without notice. NOTE: Your printer may not have all of the options described in these specifications. General Specifications Height Width Depth Weight (option-dependent) Electrical Agency approvals Operating Temperature Storage Operating Relative humidity Storage Communications Interface S400 &...
  • Page 62: Printing Specifications

    S400 & S600 User’s Guide Printing Specifications Printing Specifications Resolution Dot size (square) Maximum print width Print length Bar code modulus (“X”) dimension Programmable constant printing speeds DRAM memory Flash memory (E:) Ribbon Specifications Ribbon width (we recommend using ribbon at least as wide as the media to protect the printhead from wear).
  • Page 63: Media Specifications

    Media Specifications Minimum Total media Maximum width Maximum (cutter installed) 4.0" Minimum Label length Maximum Minimum Total thickness Maximum (printhead (includes position may need to be liner) adjusted above 0.01") Core size Maximum roll diameter Minimum Inter-label Maximum Ticket/tag notch size (W x L) Media Handling Tear-off mode: Produced in strips Peel-off mode: Dispensed and peeled away from the liner...
  • Page 64: Options

    S400 & S600 User’s Guide Options 4 MB flash expansion 8 MB flash expansion *Peel-Off mode with backing-only rewind feature *Cutter with label catch tray Scalable and bitmap smooth fonts available for text Ethernet * Factory installed Contact your authorized Zebra distributor for information. Zebra Programming Language (ZPL II) Downloadable graphics (with data compression)
  • Page 65: Bar Codes

    Bar Codes Interleaved 2 of 5 (supports Codabar (supports ratios of ratios of 2:1 to 3:1, 2:1 to 3:1) Modulus 10 Check Digit) Code 11 LOGMARS Code 128 (supports serialization in all subsets and UCC Case Codes) Code 39 (supports ratios of Plessey 2:1 to 3:1) Code 93...
  • Page 66 S400 & S600 User’s Guide...
  • Page 67: Appendix

    RS-232 Connector Technical Information RS-232 Connector Pinouts Pin. No. Not used RXD (receive data) input to the printer TXD (transmit data) output from the printer DTR (data terminal ready) output from the printer -- controls when the host may send data Chassis ground DSR (data set ready) input to the printer RTS (request to send) output from the printer -- always in...
  • Page 68 S400 & S600 User’s Guide (RD) (TD) (DTR) (SG) (DSR) (RTS) Figure 31 CARRIER DETECT (CD) RECEIVE DATA (RD) TRANSMIT DATA (TD) DATA TERMINAL READY (DTR) SIGNAL GROUND (SG) DATA SET READY (DSR) REQUEST TO SEND (RTS) CLEAR TO SEND (CTS) Figure 32 (RD) (TD)
  • Page 69: Parallel Interface Technical Information

    Parallel Interface Technical Information Pin. No. 16-17 19-30 33-34 S400 & S600 User’s Guide Parallel Connector Pinouts Description nStrobe/Host Clk Data Bits 1-8 nACK/PtrClk Busy/Per Busy PError/ACK Data Req. Select/Xflag nauto Fd/Host Busy Not Used Ground +5V @ 1A Fused Ground nlnit nFault/nData Avail.
  • Page 70: Storage And Reshipping

    To ship the printer, carefully pack it in a suitable container to avoid damage during transit. Whenever possible, use the original container from the factory. A shipping container can be purchased from Zebra Technologies Corporation, if the original one has been lost or destroyed.
  • Page 71: Glossary

    alphanumeric Indicating letters, numerals, and characters such as punctuation marks. backfeed Backfeed is when the printer pulls the media and ribbon (if used) backward into the printer so that the beginning of the label to be printed is properly positioned behind the printhead. Backfeed occurs when you’re operating the printer in tear-off, peel-off, or cutter mode.
  • Page 72 S400 & S600 User’s Guide font A complete set of alphanumeric characters in one style of type. Example: Times, Helvetica. ips “inches-per-second” The speed at which the label or tag is printed. Zebra offers printers that can print from 2 ips to 12 ips. label An adhesive-backed piece of paper, plastic, or other material on which information is printed.
  • Page 73 ribbons also have a back coating that protects the printhead from damage. The ribbon transfers ink onto the media when heated by the printhead. ribbon wrinkle A wrinkling of the ribbon caused by improper alignment of the strip plate and/or printhead pressure. This wrinkle can be seen just above the strip plate.
  • Page 74 S400 & S600 User’s Guide...
  • Page 75: Index

    AC power cable ... 5 AC power fuse, replacing..30 Adjustments Backing rewind power roller . . 34 Label top position ..33 Media rest position .
  • Page 76 S400 & S600 User’s Guide Factory defaults, resetting ..46 Fanfold media loading ..8 Fonts Optional ... . . 57 Standard.
  • Page 77 Printer diagnostics CANCEL key self test ..48 FEED key self test ..50 MODE key self test ..51 PAUSE key self test ..49 Power-on self test .
  • Page 78 S400 & S600 User’s Guide...

This manual is also suitable for:

600Stripe s400Stripe s600