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Zebra R402 User Manual

Smart label printer and encoder
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R402
Smart Label Printer and Encoder
User s
'
Guide
980389-001 Rev. A

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Table of Contents
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  Summary of Contents for Zebra R402

  • Page 1: User S Guide

    R402 Smart Label Printer and Encoder User s Guide 980389-001 Rev. A...
  • Page 3: Proprietary Statement

    (including, without limitation, damages for loss of business profits, business interruption, loss of business information, or other pecuniary loss) arising out of the use of or the results of use of or inability to use such product, even if Zebra Technologies Corporation has been advised of the possibility of such damages.
  • Page 5: Table Of Contents

    Introduction Hello! ........... . . 1 What’s in the Box?.
  • Page 6 Operation & Options Thermal Printing ......... . . 19 Replacing Supplies.
  • Page 7 Resetting the Factory Default Values ......51 Communications Diagnostics ....... . . 51 Feed Button Modes .
  • Page 8 980389-001 Rev. A...
  • Page 9: Introduction

    Refer to the driver or software documentation for more information. The Zebra R402 printer, when connected to a host computer, functions as a complete system for printing and encoding “smart” labels, tickets, and tags. Introduction ®...
  • Page 10: What's In The Box

    What’s in the Box? Save the carton and all packing materials in case you need to ship or store the printer later. After unpacking, make sure you have all parts. Follow the procedures for inspecting the printer to familiarize yourself with printer parts so you can follow the instructions in this book.
  • Page 11: Inspecting The Printer

    Inspecting the Printer Look at the outside of the printer and make sure that all parts are present. Opening the printer To access the media compartment, you must open the printer. Pull the release levers towards you and lift the cover.
  • Page 12 INSPECTING THE PRINTER (continued) After opening the printer, check the media compartment.
  • Page 13: Closing The Printer

    Closing the printer Hold the top cover and press the cover lock to release. Lower the top cover. The ribbon carriage automatically folds up into place. Press down until the cover snaps closed.
  • Page 14: Reporting Damage

    If you discover damage or missing parts: Immediately notify and file a damage report with the shipping company. Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the printer and will not cover the repair of this damage under its warranty policy.
  • Page 15: Getting Started

    This section describes how to set up your printer for the first time and use the most common operating procedures for loading media in tear-off mode and loading ribbon. Modes of Printing You can operate this printer in two different modes: tear-off or peel-off. Standard tear-off mode allows you to tear off each label (or a strip of labels) after it is printed.
  • Page 16: Attaching Power Supply

    Attaching Power Supply Check the power supply to make certain it is appropriate for your input voltage. Warning: Use the Zebra-supplied power supply that came with your printer. Never operate the printer and power supply in an area where they can get wet. Serious personal injury could result! 1.
  • Page 17: Loading Roll Media

    Loading Roll Media When you load media, you must place the roll on the media hangers and then adjust the media guides. Placing the Roll in the Media Compartment Whether your roll media is inside or outside wound you load it into the printer the same way.
  • Page 18: Adjusting The Guides

    Adjusting the Guides The adjustable guides direct the media toward the platen and print head. 1. Open the media guides by turning the guide adjuster knob to the rear. 2. Thread the media through the guides. 3. Close the media guides by turning the guide adjuster knob to the front.
  • Page 19: Using The Media Adapter Plates

    Using the Optional Media Adapter Plates If your media roll has a larger diameter core, you can use an accessory (part number 105810-002) to adapt the core to the media holders. 1. Note which position will fit the diameter of the roll core. 2.
  • Page 20: Loading Ribbon

    Loading Ribbon You must use thermal transfer media (accepts wax and/or resin transferred off a ribbon) when you use a ribbon. When loading ribbon, you install the supply and take-up rolls, then tighten the ribbon on the carriage. Install the Ribbon Supply Roll Install the Take-Up Core Before following these steps, prepare the ribbon by removing its wrapping and...
  • Page 21: Attach And Tighten The Ribbon

    Attach and Tighten the Ribbon You must align the ribbon so that it will be taken straight onto the core. 1. Attach the ribbon to the take up core. Use the adhesive strip on new rolls; otherwise, use tape. 2. Turn the ribbon take-up gear counter-clockwise (top moves toward rear) to remove slack from the ribbon.
  • Page 22: Auto Calibration

    Auto Calibration NOTE: If you are using pre-printed labels, pre-printed label backing, or continuous media, see “Manual Calibration” on page 49. An auto calibration is performed when the printer is turned on (if media is loaded) or after a media error is cleared. When it is auto calibrating, the printer sets the sensor levels for, and determines the length of, the label you are using.
  • Page 23: Operator Controls

    Operator Controls Power Switch Press up to turn ON or down to turn OFF the printer. CAUTION: The power should be turned off before connecting or disconnecting the communications and power cables. Feed Button Forces the printer to feed one blank label. Takes the printer out of a “pause”...
  • Page 24: Printing A Test Label

    If you cannot get this label to print, refer to Troubleshooting on page 43. PRI NTER CONFI GURATI ON Zebr a Tec hnol ogi es ZTC R402- 200dpi ....DARKNESS +000 .
  • Page 25: Hooking Up The Printer And Computer

    Hooking Up the Printer and Computer This printer comes with a bidirectional parallel data interface. You must supply the required interface cable for your application. CAUTIONS:Keep the power switch in the OFF position when attaching the interface cable. The power supply barrel connector must be inserted into the power supply receptacle on the back of the printer before connecting or disconnecting the com- munications cables.
  • Page 26: Communicating With The Printer

    Communicating with the Printer When using the parallel port, typically there is no setup is required once the cable is plugged in. If you should encounter any problems, consult the user’s guide that came with your computer. Adjusting the Print Width Print width must be calibrated when: You are using the printer for the first time.
  • Page 27: Operation & Options

    Operation & Options This section helps you get the most from your printer. You must use programming to control many of the printer’s functions. A few examples: The ~JL command controls label length. The ^XA^MTD^XZ command changes the printing mode to direct thermal;...
  • Page 28: Replacing Supplies

    Replacing Supplies If labels or ribbon run out while printing, leave the printer power on while reloading (data loss results if you turn off the printer). After you load a new label or ribbon roll, the printer flashes double-green until you press the Feed button to restart .
  • Page 29: Printing In Peel-Mode

    Printing in Peel-Mode The optional dispenser allows you to print in “peel-mode” where the label backing follows a different path and the labels are presented one at a time for subsequent placement. Before using peel-mode, you must send the programming commands ^XA ^MMP ^XZ ^XA ^JUS ^XZ to the printer.
  • Page 30: Printing On Fan-Fold Media

    Printing on Fan-Fold Media Lock-down Printing on fan-fold media requires you to set both the media hangers and the media guides in position. 1. Open the top cover. Screw 2. With a sample of your media, adjust the media hangers to the width of the media.
  • Page 31: Rfid Guidelines

    RFID Guidelines The Zebra R402 Smart Label Printer and Encoder serves as dynamic tool for both printing and programming smart labels, tickets and tags. Smart labels are usually made from two components, media and a RFID (radio frequency identification) transponder. The media will usually be comprised of synthetic- or paper-based material that can be printed upon using direct thermal or thermal transfer printing techniques.
  • Page 32: Supported Transponders

    RFID IC used. It is important to use media and tags that have been specifically designed for use in the R402. Failure to do so may result in the inability to read or program the embedded RFID tags.
  • Page 33: Texas Instruments Tag-It™ Transponders

    Texas Instruments Tag-it™ Transponders Texas Instruments transponders are high frequency (13.56MHz) RFID devices. Each transponder has 256 bits of memory. Data is segmented into 4 byte (32 bit) blocks that are uniquely addressable, for a total of 8 blocks. Each memory block is lockable using the write protect function during the writing process.
  • Page 34: Philips I•Code Transponders

    Philips I•Code Transponders Philips I•Code transponders are high frequency (13.56MHz) RFID devices. Each transponder has 512 bits of memory. Data is segmented into 4 byte (32 bit) blocks that are uniquely addressable for a total of 16 blocks. Each memory block is lockable using the write protect function during the writing process.
  • Page 35: Inside Technologies Picotag® Transponders

    Inside Technologies Picotag® Transponders Inside Technologies Picotag® transponders are high frequency (13.56MHz) RFID devices. Each transponder has 2048 bits of memory. Data is segmented into 8 byte (64 bit) blocks that are uniquely addressable for a total of 31 blocks. Blocks 6 to 12 are lockable using the write protect function during the writing process.
  • Page 36: Iso-15693 Transponders

    For these reasons, the R402 may not be compatible with every manufacturers ISO-15693 transponders. Contact your technical support representative for...
  • Page 37: Zpl Ii Commands For Rfid

    ZPL II Commands for RFID ^WT – Write Tag The format for the ^WT instruction is: ^WTb,r,m,w,s where ^WT = Write Tag command b = Block Number Default value: 0 Other values: 1 to n, where n is the maximum number of blocks for the tag This is the starting block number.
  • Page 38: Rt - Read Tag

    ^RT – Read Tag The format for the ^RT instruction is: ^RT#,b,n,f,r,m,s where ^RT = Read Tag command # = Number to be assigned to the Field Default value: 0 Other Values: 1 to 9999 b = Starting Block Number Default value: 0 Other values: 1 to n, where n is the maximum number of blocks for the tag...
  • Page 39 ^RT – Read Tag (continued) Example: This reads a block from a tag, and prints it on a label: ^FO20,120^A0N,60^FN1^FS ^FO20,100^A0N,20^FN2^FS ^RT1,0,7,3,0,5,0,0^FS ^RT2,0,2,2,0,5,0,0^FS The first ^RT command automatically detects the tag type, starting at block 7, reads three blocks of data in ASCII format. It will retry the command 5 times if necessary.
  • Page 40: Rs - Rfid Setup

    For these reasons, the R402 may not be compatible with every manufacturers ISO-15693 transponders. Contact your technical support representative for the latest list of supported ISO-15693 transponders.
  • Page 41: Ri - Rfid Get Tag Unique Id

    ^RI – RFID Get Tag Unique ID The format for the ^RI instruction is: ^RIn where n = field number to store the unique ID The unique ID will be read from the tag and available to print or return to the host computer. The example below reads the unique ID/serial number from a tag, and prints it on a label: ^FO100,100^A0N, 60^FN0^FS...
  • Page 42: Sample Of Rfid Programming

    Sample of RFID Programming ZPL II is Zebra Technologies Corporation’s Zebra Programming Language II label design language. ZPL II lets you create a wide variety of labels from the simple to the very complex, including text, bar codes, and graphics.
  • Page 43 Line # Type this label format ^WT6^FDZebra^FS ^FO100,100^A0n,60^FN0^FS ^FO100,200^A0n,40^FN1^FS ^RT0,6,2^FS ^RT1,6,2,1 Line 1 Indicates start of label format. Line 2 Writes the data “Zebra” to block 6 for the tag (one byte will spill into block 7, since we have 4 bytes/block. Line 3 Print field number ‘0’...
  • Page 45: Maintenance

    Cleaning Use only the cleaning agents indicated. Zebra Technologies Corporation will not be responsible for damage caused by any other cleaning materials used on this printer. Printer Part After allowing the print head to cool for approximately one minute, use 70% isopropyl alcohol on a cotton...
  • Page 46: Parts List

    Power Supply, 100V-240V Power Cord, U.S. 120V IEC320C13 (set of 5) PCBA, RFID Reader PCBA, Antenna, Type 2 Ribbon Core, 4” (set of 50) Accessory, Media Adapter Plates User’s Manual, R402 Manuals ZPL II Programmer’s Manual DESCRIPTION PART NUMBER 105910-052...
  • Page 48: Replacing The Print Head

    Replacing the Print Head In the event you need to replace the print head, make sure your work area is prepared by protecting against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer a conductive wrist strap for yourself.
  • Page 49: Assembly

    REPLACING THE PRINT HEAD (Continued) Assembly Cleaning the Print Head The new print head comes with the clip and ground screw attached. 1. Align the print head and bracket to plug the left and right connectors into the black and white wire bundles. 2.
  • Page 51: Troubleshooting

    What the Status Light is Telling You Status LED Condition and Color Solid Green Flashing Yellow Flashing Green Flashing Red Double Flashing Green Solid Yellow Alternately Flashing Green and Red Resolutions 1. The printer is not receiving power. Have you turned on the printer power? Check power connections from the wall outlet to the power supply, and from the power supply to the printer.
  • Page 52 3. The printer has failed its power on self test (POST). If this error occurs right after you turn on the printer, contact an authorized reseller for assistance. There is a shortage of memory. If this error occurs after you have been printing, turn the printer power off and on.
  • Page 53 7. The print head is under temperature. Continue printing while the print head reaches the correct operating temperature. The print head is over temperature. Printing will stop until the print head cools to an acceptable printing temperature. When it does, the printer will automatically resume operation.
  • Page 54: Print Quality Problems

    Print Quality Problems No print on the label. You must use the correct media for the method of printing you require. When printing without a ribbon, you must use direct thermal media. When using ribbon, you must use thermal transfer media. The printer's ribbon sensor detects motion of the supply spindle.
  • Page 55 The printing does not start at the top of the label, or misprinting of one to three labels. The media may not be threaded under the media guides. Refer to “Loading the Media” on page 9. The printer needs to be calibrated. Refer to “Auto Calibration” on page The correct media sensor may not be activated.
  • Page 56: Rfid Symptoms

    RFID Symptoms RFID tags generally not programmed Is the printer set up correctly? Print a configuration label to verify RFID version. See “Auto Calibration” on page 14. Check if supported RFID media is loaded correctly. VOID messages are printed across media. Verify tag type is properly selected in ZPL II.
  • Page 57: Manual Calibration

    Manual Calibration Manual calibration is recommended whenever you are using pre-printed labels (or label backing) or if the printer will not correctly auto calibrate. 1. Turn on the printer power. 2. Remove approximately 4" (102 mm) of labels from a section of backing material.
  • Page 58: Troubleshooting Tests

    See “Auto Calibration” on page 14. PRI NTER CONFI GURATI ON Zebr a Tec hnol ogi es ZTC R402- 200dpi ....+000 ....
  • Page 59: Resetting The Factory Default Values

    Resetting the Factory Default Values Sometimes, resetting the printer to the factory defaults solves some of the problems. Follow the four-flash sequence instructions in “Feed Button Modes” on page 52. Communications Diagnostics If there is a problem transferring data between the computer and printer, try putting the printer in the communications diagnostics mode.
  • Page 60: Feed Button Modes

    Feed Button Modes Power Off Mode (Communications Diagnostics Mode) With the printer power off, press and hold the feed button while you turn on the power. The printer prints out a listing of its current configuration (see Figure 22). After printing the label, the printer will automatically enter a diagnostic mode in which the printer prints out a literal representation (see Figure 23) of all data subsequently received.
  • Page 61: Physical Specifications

    All specifications are subject to change without notice. Physical Specifications Size 7.8 inches wide / 6.8 inches tall / 9.4 inches long (depth) 200 mm wide / 173 mm tall / 240 mm long (depth) Weight 3.6 pounds / 1.6 kilograms Environmental Guidelines Operating temp.
  • Page 62: Media Specifications

    Media Specifications Width 1 to 4.25 inches / 25.4 to 108 millimeters) 1 to 2.25 inches / 25.4 to 57 millimeters (tag stock) Length 0.5 to 22 inches / 13 to 559 millimeters with standard memory 0.08 to 0.16 inch (2.0 to 4.0 millimeters) 0.118 inch / 3.0 millimeters recommended Thickness 0.003 to 0.007 inch / 0.08 to 0.18 millimeter...
  • Page 63 Font/Code Specifications Fonts CG Triumvirate Bold Condensed scalable smooth (0) Zebra fonts A-H, GS, P-V IBM Code Page 850 international Symbols 1D Bar Codes Codabar (supports ratios of 2:1 to 3:1) Code 11 Code 128/USD 8 (supports serialization in all subsets and UCC Case Codes) Code 39 (supports ratios of 2:1 to 3:1)
  • Page 64: Agency Approvals

    Agency Approvals The Thermal Printer Model R402, manufactured by Zebra Technologies Corporation, complies with the applicable requirements: Emissions and susceptibility: FCC 15.225, FCC Part 15 Class B, RSS-210, EN300-330, EN300-683, IECS-003, EN61000-3-2, EN61000-3-3. Safety: UL 1950 3 Ed., CSA C22.2 No. 950-95 3...
  • Page 65: Parallel Interface Technical Information

    Parallel Interface Technical Information Pin No. Description NStrobe/Host Clk Data Bits 1-8 nACK/PtrClk Busy/Per Busy PError/ACK Dat Req. Select/Xflag NAuto Fd/Host Busy Not Used 16-17 Ground +5 V @ 0.75 A Fused 19-30 Ground nInit NFault/nData Avail. 33-34 Not Used +5 V throught 1.8 K Ohms Resistor NSelectin/1284 active The maximum current available through the interface port is not to exceed a...
  • Page 67 adapter plates ....11 agencies ..... . . 56 attaching power .
  • Page 68 lubrication..... . 37 maintenance ....37 manual calibration .
  • Page 69 thermal printing ....19 thermal transfer....20 top cover, closing .