110pax4 maint manual
TRANSCRIPT
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Zebra110PAX4
Print Engine
Maintenance Manual
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Customer Order # 57515L-001
Manufacturer Part # 57515L-001 Rev. 1
2005 ZIH Corp.
The copyrights in this manual and the label print engine described therein areowned by Zebra Technologies Corporation. Unauthorized reproduction of thismanual or the software in the label print engine may result in imprisonment of upto 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; ElementEnergy EqualizerCircuit; E3; and AGFA fonts.
Software ZIH Corp. All rights reserved worldwide.
ZebraLink and all product names and numbers are trademarks, and Zebra, theZebra logo, ZPL, ZPL II, Element Energy Equalizer Circuit, and E3 Circuit areregistered trademarks of ZIH Corp. All rights reserved worldwide.
CG Triumvirate is a trademark of AGFA Monotype Corporation. All rights
reserved worldwide. CG Triumvirate(tm) font AGFA Monotype Corporation.Intellifontportion AGFA Monotype Corporation. All rights reservedworldwide. UFST is a registered trademark of AGFA Monotype Corporation. Allrights reserved worldwide.
All other brand names, product names, or trademarks belong to their respectiveholders.
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Contents
About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Document Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Print Engine Exterior View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Indicator Lights (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Agency Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Communications Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Zebra Programming Language (ZPL II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Bar Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Printing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Standard Print Engine Font Matrices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applicator Pin Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Print Engine Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Print Engine Assembly Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Peel Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ribbon Tension Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DC Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Peel Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Applicator Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unpack and Inspect the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Report Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Store the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connect the Print Engine to a Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Optional Print Servers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DB-15 Applicator Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Interface Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Data Cable Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Media and Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Types of Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Load Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove Used Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Parameters Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Enter Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Exit Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Print Quality Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Prepare for Making Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Printhead Parallelism Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Printhead Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Printhead Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Strip Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Ribbon Sensor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Reflective Media Sensor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Upper Pinch Roller Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Adjusting the Elastomer Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Media Tracking Cam Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Routine Referral Procedures (RRPs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Print System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Printhead Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Printhead Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Toggle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Compound Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Stepper Motor Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Ribbon Take-Up Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Ribbon Supply Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Roller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Pinch Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Peel Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Auxiliary Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
PCMCIA Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Wireless PCMCIA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Compact Flash and PCMCIA Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Print Server Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Main Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Applicator Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
AC Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Exterior Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Door-Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
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5 Maintenance and Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
A Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Parallel Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Serial Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
RS-232 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Applicator Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Applicator Interface Connector Pin Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Jumper Configurations for +5 V I/O Applicator Interface Board . . . . . . . . . . . . . . . . 320
Proprietary Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Printer Software and Firmware License Agreement . . . . . . . . . . . . . . . . . . . . 329Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xii
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
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About Th is Document
Who Should Use This Document
Who Should Use This Document
This Maintenance Manual is intended for use by any person who needs to perform routine
maintenance, upgrade, or troubleshoot problems with the print engine.
How This Document Is Organized
The Maintenance Manual is set up as follows:
Section Description
About This Documenton page ix This section provides you with contact
information, document structure and organization,
and additional reference documents.
System Descriptionon page 1 This chapter provides an overview of the print
engine and its components. Specifications of theprint engine and a brief explanation of each main
component and its function are included.
Operationson page 27 This chapter provides the tasks that you must
complete and the issues that you must consider
before you load and configure your print engine.
Troubleshootingon page 89 This section contains tables showing symptom,
diagnosis, and action columns. These tables help
the technician to diagnose print engine faults and
determine the repair needed.
Preventive and Corrective
Maintenanceon page 107
This section provides various levels of print
engine maintenance required for optimumperformance. This section also provides
information on cleaning and general maintenance,
replacement of major assemblies, and mechanical
adjustments.
Maintenance and Assembly Drawings
on page 267
This section contains mechanical assembly
drawings and parts lists. Included are illustrations
of parts and assemblies common to all 110PAX4
models, as well as their part numbers.Maintenance kits and their contents are also listed.
Data Portson page 313 This appendix describes the standard
communication ports available to connect the print
engine to your computer or network.
Glossaryon page 335 The glossary provides a list of common terms.
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Abou t Th is Document
Contacts
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual xi
Contacts
You can contact Zebra Technologies at any of the following:
Visit us at: http://www.zebra.com
Our Mailing Addresses:
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, Illinois 60061.3109 U.S.A
Telephone: +1 847.634.6700
Fax: +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
Fax: +44 (0)1494 450103
Support
You can contact Zebra support at:
Web Address: www.zebra.com/SS/service_support.htm
US Phone Number +1 847.913.2259
UK/International Phone Number +44 (0) 1494 768289
Note The web address is case-sensitive.
http://www.zebra.com/http://www.zebra.com/SS/service_support.htmhttp://www.zebra.com/SS/service_support.htmhttp://www.zebra.com/SS/service_support.htmhttp://www.zebra.com/http://www.zebra.com/ -
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xii 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
About Th is Document
Document Conventions
Document Conventions
The following conventions are used throughout this document to convey certain information:
Al ternate 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.
Command Line Examples All command line examples appear in Couri er New font.For example, type the following to get to the Post-Install scripts in the bi ndirectory:
Zt ool s
Files and Directories All file names and directories appear in Couri er Newfont. Forexample, the Zebra. t ar file and the / root directory.
Cautions, Important, Note, and Example
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 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.
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Abou t Th is Document
Related Documents
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual xiii
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 thegraphic. Figure 1provides an example.
Figure 1 Sample Figure with Callouts
Related Documents
The following documents and CDs might be helpful references:
Tools Tells you what tools you need to complete a given task.
1 SETUP/EXITbutton
2 CALIBRATE button
21
57512L-001 110PAX4 User Guide
57511-001 PAX4 Series User CD
57515L-001 110PAX4 Print Engine Maintenance Manual
57513L-001 110PAX4 Quick Reference Guide
49560 PAX4 Maintenance Manual CD
45541L ZPL Programming Guide Vol. 1
45542L ZPL Programming Guide Vol. 2
45631 ZPL II Programming Guide CD
45537L ZebraNet PrintServer II User and Reference Guide
45630 ZebraNet PrintServer II CD
47619L ZebraNet 10/100 Print Server User Guide
45638 ZebraNet 10/100 Print Server CD
13422L ZebraNet Wireless Print Server User Guide
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xiv 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
About Th is Document
Related Documents
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 1
System Description
This chapter provides an overview of the print engine and its components. Specifications of
the print engine and a brief explanation of each main component and its function are included.
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel Indicator Lights (LEDs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Communications Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Zebra Programming Language (ZPL II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bar Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Media Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ribbon Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Standard Print Engine Font Matrices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applicator Pin Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Print Engine Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Print Engine Assembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Peel Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ribbon Tension Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Contents (Continued)
2 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
System Descripti on
AC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Media Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Peel Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Applicator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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System Description
General
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 3
General
This technical service guide contains information about service and maintenance of Zebras
110PAX4 print engine. The 110PAX4thermal transfer print engine consists of the 203 dot/inch
and the 300 dot/inch models.
All models are available in right-hand and left-hand configurations. They are versatile,
pressure-sensitive label print engines designed to print high-quality bar codes, various sizes
and styles of alphanumeric characters, and graphics in thermal transfer mode.
All print engines have the flexibility to meet a variety of applications. The Zebra Programming
Language (ZPL II) allows the programmer to format the printed material. ZPL II is transparent
to protocol converters and allows for easy integration of the 110PAX4 print engines into most
systems and host main frames.
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System Descripti on
Print Engine Exterior View
Print Engine Exterior View
Print engines are available in a right-hand configuration (media moves from left to right,
Figure 1) and a left-hand configuration (media moves from right to left, Figure 2).
Figure 1 Right-Hand (RH) Print Engine
Figure 2 Left-Hand (LH) Print Engine
1 Media Door
2 Front Panel
3 Power Switch
2
3
1
2
3
1
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System Description
Front Panel
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 5
Front Panel
All controls and indicators for the print engine are located on the front of the print engine on
the front panel (Figure 3). The Liquid Crystal Display (LCD) shows operating status and
feature parameters. The front panel buttons are used to control the print engine operations and
to set parameters. The front panel lights (LEDs) indicate the print engines status.
Figure 3 Front Panel
Front Panel Buttons
The front panel buttons are shown in Table 1.
1Buttons
2 LCD
3 Lights/LEDs
2 1 31
Table 1 Front Panel Buttons
Button Description/Function
BLACK OVALS The two black ovals are used to change values for the parameter displayed on the
LCD. Common uses include increasing or decreasing a value, answering yes or no,
indicating ON or OFF, and scrolling through choices.
PREVIOUS Scrolls the LCD to the previous parameter.
NEXT Scrolls the LCD to the next parameter.
SETUP/EXIT Enters and exits Setup mode.
PAUSE Stops and restarts the printing process or removes error messages and clears the LCD.
When the print engine is paused, the PAUSE light is on.
If the print engine is idle, it enters Pause mode immediately.
If the print engine is printing, the label is completed before the printing processstops.
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System Descripti on
Front Panel
Front Panel Indicator Lights (LEDs)
The front panel lights are described in Table 2.
CANCEL CANCEL functions only in PAUSE mode. Pressing CANCEL 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 print engines entire label format memory, press and hold CANCEL until
the DATA light turns off.
FEED Feeds a blank label.
If the print engine is idle or paused, the label is fed immediately.
If the print engine is printing, the label is fed after the current batch finishes
printing.
CALIBRATE CALIBRATE functions only in PAUSE mode. Press CALIBRATE to recalibrate for
proper media length, to set media type (continuous/noncontinuous), and to set print
method (direct thermal/thermal transfer).
Table 1 Front Panel Buttons (Continued)
Button Description/Function
Table 2 Front Panel Lights
LED OFF Indicates ON Indicates FLASHING Indicates
POWER
(Green)
Print engine is
OFF, or no powerto print engine.
Power switch is ON, and power is
being supplied to print engine.
PAUSE
(Yellow)
Normal operation. One of the following:
Print engine is paused because of
an error condition (printhead,
ribbon, or paper error). Usually
occurs in conjunction with
another LED.
PAUSE was pressed.
A pause was requested from the
Applicator Port.
A pause was received as part of
the label format.
DATA
(Green)
No data being
received or
processed.
Data is processing or printing is
taking place. No data is being
received.
Print engine is receiving data
from or sending status
information to the host computer.
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System Description
Front Panel
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 7
MEDIA
(Yellow)
Normal operation.
Media properly
loaded.
Out of media. (Print engine is
paused, LCD displays error
message, and PAUSE light is ON).
RIBBON
(Yellow)
Normal operation.
Ribbon properly
loaded.
Ribbon in while print engine is in
direct thermal mode, or no ribbon
loaded while print engine is in
thermal transfer mode. Print engine
is paused, LCD displays error
message, and PAUSE light is ON.
ERROR
(Orange)
No print engine
errors.
Print engine error exists. Check
the LCD for status.
Table 2 Front Panel Lights (Continued)
LED OFF Indicates ON Indicates FLASHING Indicates
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8 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
System Descripti on
Power On/Off Switch
Power On/Off Switch
The power on/off switch is located on the top of the print engine housing, as shown in
Figure 4. When this switch is placed in the ON (I) position, the POWER light turns on, and the
print engine automatically performs a Power-On Self Test (POST). For more information, see
Power-On Self Teston page 100.
Figure 4 Print Engine Power Switch
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System Description
General Specifications
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 9
General Specifications
Physical
For installation information, refer to the User Guide.
Environmental Conditions
Agency Approvals.
Height 11.8 in. (300 mm)
Width 9.6 in. (245 mm)
Depth 18.831 in. (478.31 mm)
Weight 36 lb. (16.3 kg)
Operating Temperature
Thermal Transfer
Direct Thermal
41F to 104F (5C to 40C)
32F to 104F (0C to 40C)
Non-condensing relative humidity
Operation
Storage
20% to 95%
5% to 95%
Storage temperature 40 F to 160 F (40 C to 71 C)
Agency Approvals IEC 60950-1
EN55022, Class A
EN61000-6-2
Product Markings cULus
CE Mark
FCC-A
ICES-003
VCCI
C-Tick
CCC
Gost-R
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System Descripti on
General Specifications
Electrical Specifications
Communications Specifications
Memory
Power Supply Universal Power Supply with power-factor correcting 90264VAC, 4763 Hz
Power Consumption
Idle
Printing
19 W
375 W (maximum)
Fuses 5 Amp, 250 VAC, 5 20 mm IEC style, as supplied with the
print engine
Parallel Interface Bidirectional high-speed Centronics Parallel (36-pin
connector)
IEEE 1284-compliant software protocol (standard)Serial Interfaces Serial RS-232C w/DTR hardware handshake via DB-9
connector (standard)
Serial RS-422/485 via 2- or 4-wire w/XON/XOFF
handshake on alternate pins of DB-9 connector (standard)
Configurable baud rates between 110 and 57.6K baud with
7 or 8 data bits, standard parity, 1 or 2 stop bits
Fused +5V @ 750 mA supplied at pin 9 of the DB-9
connector
Network Connections ZebraNet 10/100 PrintServer
Applicator Interface with
DC15F Connector
North America
Europe 5V I/O port
24-28V I/O port
Standard 10.0 MB RAM
2.0 MB Flash
Flash Options Up to 256 MB Compact Flash 32 MB PC memory card
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System Description
General Specifications
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 11
Zebra Programming Language (ZPL II)
Bar Codes
Communicates in printable ASCIIcharacters
Controlled via mainframe, mini, or PC
Downloadable graphics, scalable and
bitmap fonts, label templates and formats
Object copying between memory areas
(RAM and PC memory card)
Adjustable print cache
Data compression
Automatic memory allocation for
format while printing
Bit image data transfer and printing,
mixed text/graphics
Status messages to host upon request
Format inversion (white on black)
Mirror image printing
Four-position field rotation
(normal/0, 90, 180, and 270)
Slew command
Programmable label quantities with print
and pause control
Automatic serialization of fields
User-programmable password
Portable Data Terminal
In-Spec OCR-A and OCR-B
Bar code modulus X dimensions
Picket fence (non-rotated) orientation:
203 dpi = 0.0049 in. mil to 0.049 in.
300 dpi = 0.0033 in. mil to 0.033 in.
Ladder (rotated) orientation:
203 dpi = 0.0049 in. mil to 0.049 in.
300 dpi = 0.0039 in. mil to 0.039 in.
Linear bar codes
Code 11
Code 39
Code 93
Code 128 with subsets A/B C and
UCC Case Codes
ISBT-128
UPC-A
UPC-E
EAN-8
EAN-13
UPC and EAN 2 or 5 digit extensions
Plessey
Postnet
Standard 2 of 5
Industrial 2 of 5
Interleaved 2 of 5
LOGMARS
MSI
Codabar
RSS-14
Two-dimensional bar codes
Code 49
Maxi Code
PDF-417
QR Code
Codablock
DataMatrix
Micro-PDF417
Bar code ratios
2:1 7:3
5:2
3:1
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System Descripti on
Printing Specifications
Printing Specifications
Specification 112PAX4 113PAX4
Resolution 203 dots per inch
(8 dots per mm)
300 dots per inch
(12 dots per mm)
Dot size 0.0049 in. x 0.0049 in.
(0.125 mm x 0.125 mm)
0.0033 in. x 0.0039 in.
(0.084 mm x 0.100 mm)
First dot location(from inside media edge) 0.093 in. (2.4 mm)
0.035 in. (0.89 mm)
0.093 in. (2.4 mm)
0.035 in. (0.89 mm)
Maximum print width 4.1 in. (104 mm) 4.2 in. (106 mm)
Maximum print length(with full width media)
Non-continuous
Continuous
39 in. (990 mm)
150 in. (3.810 mm)
39 in. (990 mm)
100 in. (2,540 mm)
Programmable constant printing speeds
(per second)
2.4 in. (61 mm)
3 in. (76 mm)
4 in. (102 mm)
5 in. (127 mm)
6 in. (152 mm)
7 in. (178 mm)
8 in. (203 mm)
9 in. (229 mm)
10 in. (254 mm)
11 in. (279 mm)
12 in. (305 mm)
2.9 in. (74 mm)
3 in. (76 mm)
4 in. (102 mm)
5 in. (127 mm)
6 in. (152 mm)
7 in. (178 mm)
8 in. (203 mm)
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System Description
Media Specifications
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 13
Media Specif ications
Media width
(label and
liner)
Minimum 0.625 in (16 mm)
Maximum 4.5 in. (114 mm)
Label length Minimum Applicator mode 0.5 in. (12.7 mm) with backfeed on
0.25 in. (6 mm) with backfeed off
Tear-off mode 0.5 in. (12.7 mm) with backfeed on
0.25 in. (6 mm) with backfeed off
Registration tolerance
(not including label/liner
position tolerances)
Vertical
(concurrent labels)
0.040 in. (1.0 mm)
(in Applicator mode)
Horizontal 0.040 in. (1.0 mm)
Total thickness (including liner) 0.0058 in. to 0.010 in. (0.148 mm to 0.256 mm)
Interlabel Gap
(Transmissive Sensor)
Minimum 0.079 in. (2 mm)
Preferred 0.118 in. (3 mm)
Maximum 0.157 in. (4 mm)
Notch Size (W x L) 0.25 in. x 0.12 in. (6 mm x 3 mm)
Position On inside edge,
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14 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
System Descripti on
Ribbon Specifications
Ribbon Specifications
Standard Print Engine Font Matrices
Bit mapped fonts A, B, D, E, F, G, H, and GS are expandable up to 10 times, height and width
independent. However, fonts E and H (OCR-B and OCR-A) are not in spec when expanded.
The Scalable Smooth Font (CG Triumvirate Bold Condensed) is expandable on a dot-by-dot
basis, height and width independent, while maintaining smooth edges, to a maximum of 1500
1500 dots.
IBM Code Page 850 International characters are available in fonts A, B, D, E, F, G, and
through software control.
Thickness 4.5 microns
Width(wound coated side out) 1.0 in. to 4.2 in. (25.4 mm to 107 mm)
Maximum length 2955 ft. (900 m)
Roll size
Inner core diameter
Maximum roll size
1.0 in. (25.4 mm)
4.2 in. (107 mm)
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System Description
Standard Print Engine Font Matrices
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 15
Table 3 Font Matrix for 8 dot/mm (203 dpi) Prin theads
Font
Matrix Type* Character Size
Height WidthBaseline
Dots
Inter-
Character
Gap
Cell
Width
Font
Matrix
Inches Millimeters
Height WidthChar/
Inch
Height WidthChar/
mmA 9 5 7 1 6 U-L-D 0.044 0.030 33.87 1.13 0.75 1.33
B 11 7 11 2 9 U 0.054 0.044 22.58 1.38 1.13 0.89
C,D 18 10 14 2 12 U-L-D 0.089 0.059 16.93 2.25 1.50 0.67
E 28 15 23 5 20 OCR-B 0.138 0.098 10.16 3.50 2.50 0.40
F 26 13 21 3 16 U-L-D 0.128 0.079 12.70 3.25 2.00 0.50
G 60 40 48 8 48 U-L-D 0.295 0.236 4.23 7.50 6.00 0.17
H 21 13 21 6 19 OCR-A 0.103 0.094 10.69 2.63 2.38 0.42
GS 24 24 24 2 26 SYMBOL 0.118 0.128 7.82 3.00 3.25 0.31
P 20 18 N/A N/A N/A U-L-D 0.098 0.089 N/A 2.50 2.25 N/A
Q 28 24 N/A N/A N/A U-L-D 0.138 0.118 N/A 3.50 3.00 N/A
R 35 31 N/A N/A N/A U-L-D 0.172 0.153 N/A 4.38 3.88 N/A
S 40 35 N/A N/A N/A U-L-D 0.197 0.172 N/A 5.00 4.38 N/A
T 48 42 N/A N/A N/A U-L-D 0.236 0.207 N/A 6.00 5.25 N/A
U 59 53 N/A N/A N/A U-L-D 0.290 0.261 N/A 7.38 6.63 N/A
V 80 71 N/A N/A N/A U-L-D 0.394 0.349 N/A 10.00 8.88 N/A
0 Default: 15 x 12 U-L-D Scalable
*U = Uppercase, L = Lowercase, D = Descenders
Table 4 Font Matrix for 12 dot/mm (300 dpi) Printheads
Font
Matrix Type* Character Size
Height WidthBaseline
Dots
Inter-
Character
Gap
Cell
Width
Font
Matrix
Inches Millimeters
Height WidthChar/
InchHei ght Width
Char/
mmA 9 5 7 1 6 U-L-D 0.030 0.020 50.00 0.76 0.51 1.97
B 11 7 11 2 9 U 0.037 0.030 33.33 0.93 0.76 1.31
C, D 18 10 14 2 12 U-L-D 0.060 0.040 25.00 1.52 1.02 0.98
E 41 20 32 6 26 OCR-B 0.137 0.087 11.54 3.47 2.20 0.45
F 26 13 21 3 16 U-L-D 0.087 0.053 18.75 2.20 1.35 0.74
G 60 40 48 8 48 U-L-D 0.200 0.160 6.25 5.08 4.06 0.25
H 30 19 30 9 28 OCR-A 0.100 0.093 10.71 2.54 2.37 0.42
GS 24 24 24 2 26 Symbol 0.080 0.087 11.54 2.03 2.20 0.45
P 20 18 N/A N/A N/A U-L-D 0.067 0.060 N/A 1.69 1.52 N/A
Q 28 24 N/A N/A N/A U-L-D 0.093 0.080 N/A 2.37 2.03 N/A
R 35 31 N/A N/A N/A U-L-D 0.117 0.103 N/A 2.96 2.62 N/A
S 40 35 N/A N/A N/A U-L-D 0.133 0.117 N/A 3.39 2.96 N/AT 48 42 N/A N/A N/A U-L-D 0.160 0.140 N/A 4.06 3.56 N/A
U 59 53 N/A N/A N/A U-L-D 0.197 0.177 N/A 5.00 4.49 N/A
V 80 71 N/A N/A N/A U-L-D 0.267 0.237 N/A 6.77 6.01 N/A
*U = Uppercase, L = Lowercase, D = Descenders
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System Descripti on
Applicator Pin Interface
Applicator Pin Interface
Table 5 110PAX4 Applicator Pin Interface
Pin
#
Signal
Name
Signal
Type Functional Description
1* SIGNAL GROUND
(+5V Return)
Ground JP1 IN Ground return for Internal +5 power source and is
available here for remote opto-isolators, if required.
(JP2 IN)
JP1 OUT Ground return for External +5V power source.
(JP2 OUT)
1* SIGNAL GROUND
(+24-28V Return)
Ground Customer must provide this external power.
2* +5V
(Fused at 750 mA)
Power JP2 IN Internal +5V power source supplies power to
internal opto-isolators and is available here for remote opto-isolators, if required. (JP1 IN)
JP2 OUT External +5V power source must be connected
here to supply power to internal opto-isolators.
2* +24-28V
(Fused at 750 mA)
Power Customer must provide this external power.
3 START PRINT Input PULSE MODE The label printing process begins on the
HIGH to LOW transition of this signal, if a format is ready.
Deassert this signal HIGH to inhibit printing a new label.
LEVEL MODE Assert LOW to enable print engine to
begin printing if a format is ready. The print engine prints anew label as long as the signal is asserted. When deasserted,
the currently printing label is completed and the print engine
stops and waits for this input to be reasserted LOW.
4 FEED Input When the print engine is in an Idle state or in Pause, assert
this input LOW to trigger repeated feeding of blank labels.
Deassert HIGH to stop feeding blank labels and to register to
the top of the next label.
5 PAUSE Input To toggle the current Pause state, this input must be asserted
LOW for 200 milliseconds or until the SERVICE
REQUIRED output (pin 10) changes state.
6 REPRINT Input If the REPRINT feature is enabled, this input must be
asserted LOW to cause the print engine to reprint the last
label. (See the Configuration and Calibration Section.)
If the REPRINT feature is disabled, this input is ignored.
7 +28 VDC
(Fused at 500 mA)
Power Interface Power Supply supplies power to external sensors
as required.
* Applicator Boards are provided with separate part numbers for the +5V version and the +24-28V version.
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System Description
Applicator Pin Interface
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 17
8 POWER GROUND
(+28 VDC return)
Ground Interface Power Ground
9 RIBBON LOW Output If the RIBBON LOW feature is enabled and the amountof ribbon remaining on the supply spool is below a
specific threshold level, this output is asserted HIGH.
If the RIBBON LOW feature is disabled, this output lead
is disabled.
(See the Configure and Calibration Section.)
10 SERVICE
REQUIRED
Output If the media cover or printhead is open, the ribbon or
media is out, the print engine is paused, or an operational
fault has occurred, this output is asserted LOW.
If the applicator RESYNCH mode is set to Error Mode,
this signal also asserts low for a resynch error.
11 END PRINT Output OFF: Applicator Port is Off.
MODE 1: Asserted LOW only while the print engine is
moving the label forward; otherwise deasserted HIGH.
MODE 2: Asserted HIGH only while the print engine is
moving the label forward; otherwise deasserted LOW.
MODE 3: (Default) Asserted LOW for 20 milliseconds
when a label has been completed and positioned. Not
asserted during continuous printing.
MODE 4: Asserted HIGH for 20 milliseconds when a labelhas been completed and positioned. Not asserted during
continuous printing.
12 MEDIA OUT Output Asserted LOW when media is out.
13 RIBBON OUT Output Asserted LOW when ribbon is out.
14 DATA READY Output Asserted LOW when sufficient data has been received to
begin printing the next label.
Deasserted HIGH whenever printing stops after the
current label due to either a PAUSE condition or the
absence of a label format.
15 SPARE Output To be determined
Table 5 110PAX4 Applicator Pin Interface (Continued)
Pin
#
Signal
Name
Signal
TypeFunctional Description
* Applicator Boards are provided with separate part numbers for the +5V version and the +24-28V version.
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System Descripti on
Print Engine Options
Print Engine Options
Internal and External ZebraNet 10/100 Print Server
Advanced counter
8 MB, 32 MB PCMCIA Flash Card
Additional fonts available on PCMCIA Flash Cards
32 MB, 64 MB, 128 MB, 256 MB Compact Flash Memory Card
Wireless option (provides socket for PCMCIA Radio Card)
Firmware support for downloadable TrueType fonts
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System Description
Main Print Engine Assembly Locations
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 19
Main Print Engine Assembly Locations
Platen Roller
See Figure 5. The platen roller provides the frictional force to drive media under the printhead.It also provides the compliant surface that resists the printhead pressure necessary for
conventional thermal transfer printing. It is driven by the print engines stepper motor through
two drive belt stages.
Figure 5 Platen Roller
Platen Roller
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System Descripti on
Main Print Engine Assembly Locations
Peel Roller Assembly
See Figure 6. The 110PAX4 Series peel roller assembly is located farther away from previous
assemblies, allowing the label sensors to be located closer to the print line. The assembly
consists of a spring-loaded knurled roller in a pivoting frame that can be unlatched to allow
media liner loading.
The supported pivoting frame is around inboard and outboard pins. In the latched position, the
knurled roller is in position for the media liner to achieve a wrap angle around the elastomer
peel roller. This increases the driving force on the liner that assists in reducing liner slack and
improves label peeling.
Figure 6 Peel Roller Assembly
PeelRollerLatch
Peel RollerBracket AssemblyMounting Screw
Peel RollerBracket Assembly
Open/Close
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System Description
Main Print Engine Assembly Locations
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 21
Ribbon Tension Control Assembly
See Figure 7. The ribbon tension control assemblys main function is to provide appropriate
output to the DC motors on the ribbons supply and take-up spindles in response to ribbon
dancer arm movement to control the ribbons tension.
Figure 7 Ribbon Tension Contro l Assembly
A magnet is attached to each dancer arm. In the center of each magnets path is a fixed locationHall effect sensor mounted on the main frame. As the dancer arm moves in response to
changes in the ribbons tension, the magnetic flux varies, causing the output voltage to vary
accordingly. The voltage is processed by the ribbon/tension control subsystems electronics
and provides the appropriate signals to the motor control board for the DC motors and thereby
the ribbons tension.
Ribbon SupplySpindle Assembly
Ribbon Take-UpSpindle Assembly
Lower DancerAssembly
Upper DancerAssembly
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System Descripti on
Main Print Engine Assembly Locations
DC Power Supply Assembly
See Figure 8. The DC power supply provides power for the printhead, the +5V system power,
and the stepper motor drive circuit.
Figure 8 DC Power Supply Assembly (RH Shown)
AC Power Supply Assembly
See Figure 9. This modified board contains a transformer and choke to allow +32 VDC to be
generated for use by the printhead
Figure 9 AC Power Supply Board
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System Description
Main Print Engine Assembly Locations
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 23
Drive System
See Figure 10. The 110PAX4 drive system uses a series of pitch timing belts and pulleys. The
staged belt drive systems consist of one stage from stepper motor to a compound pulley and
another serpentine stage from the compound pulley to the pinch and peel rollers. The final
stage is from the compound pulley to the platen shaft.
The serpentine belt uses a stationary backside idler pulley to maximize timing belt wrap angle
around the pinch and peel roller pulleys. The serpentine belt also uses a spring-loaded
backside idler pulley to maintain belt tension during backfeed. Both serpentine and platen
shaft belts are constantly pretensioned by means of an extension spring.
Figure 10 Drive System
Auxiliary Pulley
Platen Pulley
CompoundPulley
Stepper MotorPulley
Stepper BeltTensioner
IdlerPulley
Slack SideIdler Pulley
Peel Roller Pulley
Pinch Roller Pulley
Auxiliary PulleyStepper BeltTensioner
Stepper MotorPulley
IdlerPulley
Pinch Roller Pulley Platen Pulley
Slack SideIdler Pulley
Peel Roller Pulley
Right-HandPrint Engine
Left-HandPrint Engine
CompoundPulley
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System Descripti on
Main Print Engine Assembly Locations
Media Sensor
See Figure 11. The media sensor uses an LED array in a fixed location under the media with a
moveable photo transistor above the media in line with the LED array. The black mark sensor
is on the same board as the LED array.
Figure 11 Media Sensor
There are seven LEDs in the array and one black mark sensor on the lower media sensor board
inside the pinch roller assembly. The LED array and black mark sensor are pointed upward at
the back of the media. In operating position, the photo transistor is on the upper media sensor
board inside the channel pinch roller assembly. The photo transistor is pointing downward
toward the top of the media.
ReflectiveMedia Sensor
TransmissiveMedia Sensor
TransmissiveMedia Sensor
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System Description
Main Print Engine Assembly Locations
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 25
Peel Bar
See Figure 12. The peel bar creates a sharp edge over which the media liner is tensioned to
separate and present the label to the applicators label transport mechanism.
Figure 12 Peel Bar
Applicator Interface
See Figure 13. The applicator interface allows the print engine to be controlled by and its
status monitored from an external program logic controller (PLC).
Figure 13 Applicator Interface
Peel Bar
ApplicatorInterface
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System Descripti on
Main Print Engine Assembly Locations
Notes ___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
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57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 27
Operations
This chapter provides the tasks that you must complete and the issues that you must consider
before you load and configure your print engine.
If you have completed the tasks and resolved issues in the checklist inBefore You Begin
on page 29, use this chapter to load the print engine, to calibrate the print engine, and to print
configuration labels.
Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unpack and Inspect the Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Report Shipping Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Store the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Print Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install the Print Engine in an Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connect the Print Engine to a Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Cord Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Select a Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Optional Print Servers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DB-15 Applicator Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Interface Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Data Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Media and Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Types of Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Load Ribbon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove Used Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Parameters Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Enter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Contents (Continued)
28 110PAX4 Maintenance Manual 57515L-001 Rev. 1 2/2/05
Operations
Exit Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Changing Password-Protected Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Default Password Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Disable the Password Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Front Panel LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ZebraNetPrint Server LCD Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Calibrate the Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Toggle Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Printhead Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Power Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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Operations
Installation
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 29
Installation
Before You Begin
Review this checklist, and resolve any issues before you begin setting up your print engine.
Unpack and Inspect the Print Engine Have you unpacked the print engine andinspected it for damage? If you have not, see Unpack and Inspect the Print Engine
on page 30.
Install the Print Engine Have you considered what factors will affect how the printengine is installed into an applicator? Is the print engine mounted in an applicator? For
information, see Print Engine Installationon page 31.
At tach a Power Cord Do you have the correct power cord for your print engine? Ifyou are unsure, see Power Cord Specificationson page 38. To attach the power cord and
connect the print engine to a power source, see Connect the Print Engine to a Power
Sourceon page 37.
Connect to a Data Source Have you determined how the print engine will connect toa data source (usually a computer)? For more information, see Select a Communication
Interfaceon page 39.
Select Media Do you have the correct media for your application? If you are unsure,see Types of Mediaon page 42.
Select Ribbon Do you need to use ribbon, and is the appropriate ribbon available, ifneeded? If you are unsure, seeRibbonon page 50.
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Operations
Unpack and Inspect the Print Engine
Unpack and Inspect the Print Engine
When you unpack the print engine, save all packing materials and boxes. Inspect the print
engine for possible damage incurred during shipment.
Inspect the print engine 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
If you discover shipping damage upon inspection:
Immediately notify the shipping company of the damage, and file a damage report with
them.Zebra is not responsible for any damage incurred during shipment of the equipment
and does not repair this damage under warranty.
Keep all packaging material for shipping company inspection.
Notify your authorized Zebra reseller.
Store the Print Engine
If you are not placing the print engine into immediate operation, repackage it using the original
packing materials. You may store the print engine under the following conditions:
Temperature: 40 to 160F (40 to 71C)
Relative humidity: 5% to 95% non-condensing
Shipping
If you must ship the print engine, remove any ribbon from the spindles to avoid damaging the
print engine. Carefully pack the print engine 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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Operations
Print Engine Installation
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 31
Print Engine Installation
This section provides basic information for mounting the print engine into an applicator. The
illustrations in this section show the print engine from different angles and include
measurements and clearance needs.
Requirements
Stability When the print engine is mounted, the complete assembly must be physicallystable. When the print engine is loaded with ribbon and media, the equipment must not
become physically unstable.
Ventilation and Temperature Provide ventilation for the print engine mounting enclosure
to remove heat and ensure uninterrupted, trouble-free operation of the print engine. Ambient
air temperature surrounding the print engine must not exceed the following:
Temperature: 32 to 105F (0 to 41C)
Relative humidity: 20% to 95% non-condensing
Power Requirements Consider the current rating of the print engine during installation.
When power is applied to the print engine and the enclosing equipment, an overload condition
must not be created.
Grounding Requirements Maintain reliable grounding of the print engine. Pay particular
attention to the AC power supply connections so that earth ground is maintained through theAC power input connector.
Clearance for Cables and Connectors Allow ample space at the rear of the print engine
for electronic connectors and dressing of the following cables: IEC power cord, serial and/or
parallel host communication cable, optional host communication cable (Ethernet), and thediscrete signal (applicator) interface cable.
Power Cord Requirements The IEC power cord does not have a strain relief on the print
engine. If the operating characteristics of the applicator include vibration or strain on the
power cord, provide an appropriate clamping mechanism to avoid unintentional disconnection
of the power cord from the print engine.
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Operations
Print Engine Installation
Figure 14 Front View of Right-Hand Prin t Engine
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Operations
Print Engine Installation
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 33
Figure 15 Right Side View of Right-Hand Print Engine
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Operations
Print Engine Installation
Figure 16 Rear View of Right-Hand Print Engine
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Operations
Print Engine Installation
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 35
Figure 17 Top View of Right-Hand Print Engine
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Operations
Print Engine Installation
Install the Print Engine in an Applicator
This section provides the basic instructions for installing the print engine into an applicator.
To install the print engine into an applicator, complete these steps:
1. See Figure 18. Install the center mounting bolt into the center hole on the applicator.
2. Carefully place the keyhole on the center mounting bolt.
3. Install the four corner mounting screws to secure the print engine to the applicator.
Figure 18 Front View of 110PAX4 Print Engine in Applicator
Caution If the print engine is installed improperly, it could fall out of the applicator and
cause injury. The center mounting bolt and four mounting screws must be installed andsecured. See Figure 18for the location of the bolt and screws.
Note The keyhole and the center mounting bolt are designed to support the print engine
and assist in installing and removing the four mounting screws.
1 Mounting screws (four total)
2 Keyhole
3 Center mounting bolt (shown inside hole on applicator)
2 1
1
1
3
1
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Operations
Connect the Print Engine to a Power Source
57515L-001 Rev. 1 2/2/05 110PAX4 Maintenance Manual 37
Connect the Print Engine to a Power Source
The power supply in the print engine automatically detects the applied line voltage and works
in the 90 to 264 VAC, 47 to 63 Hz range.
Refer to Figure 19. 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 print engine. If a power cable
was not included with your print engine, refer to Power Cord Specificationson page 38.
To connect the print engine to a power source, complete these steps:
1. Turn Off(O) the print engine power switch (located on the top of the print engine
housing).
2. Plug the power cord into the AC power connector on the rear of the print engine.
Figure 19 Power Connection
3. Plug the other end of the power cord into the power source.
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.
1 AC power connector
Left-Hand Right-Hand
1 1
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Operations
Connect the Print Engine to a Power Source
Power Cord Specifications
Depending on how your print engine 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 5 A, 250 V.
The chassis ground (earth) mustbe connected to ensure safety and reduce electromagnetic
interference. The third wire in the power cord grounds the connection (Figure 20).
Figure 20 Power Cord Specifications
The AC power plug and the IEC 320 connector must bear the certification mark of at least
one of the known international safety organizations shown in Figure 21.
Figure 21 International Safety Organization Marks
1 AC power plug for your country
2 3-conductor HAR cable
3 IEC 320 connector
4 Contact view of plug(a) neutral, (b) earth, (c) live
1 2 3 4
abc
+
R
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Operations
Select a Communication Interface
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Select a Communication Interface
The way that you connect your print engine to a data source depends on the communication
options installed in the print engine. SeeData Portson page 313for control signal
descriptions and other additional information.
Standard Connections
Refer to Figure 22. The print engine comes standard with both an Electronics Industries
Association (EIA) RS-232 serial interface (DB-9 connector) and an IEEE 1284 bidirectionalparallel interface. You may use either of these interface methods to send commands and label
formats from a host to the print engine.
Figure 22 Cable Connections
Caution Connecting a data communications cable while the power is ON may damage
the print engine.
Note You must supply all interface cables for your application. Refer to Data Cable
Requirementson page 41for specific cable requirements.
1 DB-15 applicator interface port
2 Parallel interface connector
3 DB-9 serial interface connector
e t- an g t- an
13
2
2
31
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Optional Print Servers
ZebraNet Wireless Print Server. For more information on this option, see theZebraNet
Wireless Print Server User Guide(part number 13422L-001).
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(part number 47619L-001).
DB-15 Applicator Interface Connector
A DB-15 Applicator Interface Connector provides communication between the print engine
and the associated applicator hardware. In some applications, control signal timing may be a
critical element in the performance of the print engine.
System Considerations
Communications Code The print engine sends and receives American Standard Code for
Information Interchange (ASCII). This code consists of 128 characters (256 for Code Page850) including uppercase and lowercase letters, numbers, punctuation marks, and various
control codes.
Interfaces The method of interfacing the print engine to a data source depends on the
communication options installed in the print engine and the host. The standard interfaces are
an RS-232 serial data port and an IEEE 1284 bidirectional parallel port.
Communication Specifications When communicating via an asynchronous serial dataport (RS-232), the baud rate, number of data and stop bits, the parity, and the XON/XOFF or
DTR control are user-selectable and should be set to match those of the host computer. When
communicating via the IEEE 1284 bidirectional parallel port, the previously mentioned
parameters do not apply. Refer to Changing Password-Protected Parameterson page 60toconfigure the communication parameters for the print engine.
Interface Considerations
RS-232 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 print
engine.
Disadvantages:Slower than the parallel connection; limited to 50 feet (15.24 m) of cable.
IEEE 1284 Bidirectional Parallel A common communication method available on most
PCs and other hosts.
Advantages:Fastest of the four communication interfaces; cables and connectors are
readily available from computer equipment stores and suppliers; two-way communication
between the host and the print engine; easy to connect.
Disadvantages:Shorter recommended cable length of 6 feet (1.83 m); many computers
are equipped with only one parallel port, allowing only one IEEE 1284 bidirectional
device to be connected at a time.
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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 print engines comply with FCC Rules and Regulations, Part 15 for Class A
Equipment using fully shielded, 6.5 ft. (2 m) data cables. Use of unshielded cables may
increase radiation above the Class B limits. Print engines comply with FCC Rules and
Regulations, Part 15, Subpart J, for Class A equipment, using fully-shielded 6-foot (2-meter)
data cables. Use of longer cables or unshielded cables may increase radiated emissions abovethe Class A limits.
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Media and Ribbon
Types of Media
The print engine can use various types of media (Table 1). We strongly recommend the use ofZebra-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 1 Types of Media
Media Type How It Looks Description
Non-Continuous Roll
Media
The media is wound on a core. Individual
labels are separated by a gap, notch, hole,
or black mark, which enables you to see
where one label ends and the next onebegins. When using media that has holes
or notches, position the media sensor
directly over a hole or notch. Figure 23
and Figure 24shows different types ofnon-continuous media.
Figure 23 Non-Continuous Web Media
Figure 24 Non-Continuous Black Mark Media
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Continuous
Roll Media
The media is wound on a core and is
without gaps, holes, notches, or black
marks. This allows the image to be printedanywhere on the label.
Fanfold Media The media is folded in a zigzag pattern.
RFID Smart Media
(for use with
RFID-capable print
engines only)
Each label has a radio frequency
identification (RFID) chip and antenna
inlay embedded between the label and the
liner. The media is made from the same
materials and adhesives as non-RFID
labels. The outline of the transponder
(which varies by manufacturer) can be
seen through the label. All smart labelshave memory that can be read, and many
have memory that can be encoded.
Table 1 Types o f Media (Continued)
Media Type How It Looks Description
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Load Media
Figure 25identifies the media-handling components of a right-hand print engine. A left-hand
unit contains a mirror image of these components. Figure 26 on page 45shows the print
engine with media loaded.
Figure 25 Components for Media Loading (Right-Hand)
1 Printhead latch 7 Pinch roller release button
2 Printhead assembly 8 Pinch roller assembly
3 Peel bar 9 Peel roller assembly4 Media liner roller 10 Peel roller latch
5 Printhead locking pin 11 Lower guide post
6 Media guide 12 Upper guide post
1
2
5689 7
3
4
12
11
10
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Figure 26 Loaded Media
To load media, complete these steps:
1. Load media on the media supply reel of the applicator (refer to the applicators user
guide).
2. Open the media door.
3. See Figure 27. Press the release button on the pinch roller assembly, and allow the
assembly to pivot up.
Figure 27 Opening the Pinch Roller
4. See Figure 28. Slide the outer media guide all the way out.
Left-Hand Right-Hand
1 Pinch roller assembly
2 Pinch roller release button
2
1
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Figure 28 Sliding the Outer Media Guide
5. See Figure 29. Open the printhead assembly by unlatching the printhead latch from the
locking pin.
Figure 29 Opening the Printhead Assembly
6. See Figure 30. Thread the media under the upper guide post, below the pinch roller
assembly, and under the printhead assembly.
7. See Figure 30. Extend approximately 30 in. (75 cm.) of media past the peel bar. Remove
and discard the labels from this exposed media.
1 Outer media guide
Caution The printhead may be hot and could cause severe burns. Allow the
printhead to cool.
1 Printhead latch
2 Locking pin
1
1
2
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Figure 30 Threading the Media
8. See Figure 31. Position the media so that it is aligned with and just touching the inner
media guide.
9. See Figure 31. Position the outer media guide so that it just touches the outer edge of the
media.
Figure 31 Adjusting the Outer Media Guide
1 Upper guide post
2 Pinch roller assembly
3 Printhead assembly
4 Label
5 Liner
1 Inner media guide
2 Outer media guide
3 Media
1 2
3
4
5
1
2
3
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10. See Figure 27 on page 45. Press down on the pinch roller assembly until it locks closed.
11. See Figure 29 on page 46. Close the printhead assembly by rotating the printhead latch
until it latches onto the locking pin.
12. See Figure 32. Raise the peel roller latch so that the peel roller assembly pivots down.
Figure 32 Releasing the Peel Roller Assembly
13. See Figure 33. Thread the media liner around the peel bar, under the media liner roller,
and through the peel roller assembly.
Figure 33 Threading the Liner
1 Peel roller latch
2 Peel roller assembly
Note If the applicator has an air tube, route the media liner between the air tube and the
peel bar. Do not thread the media liner over the air tube.
1 Lower guide post
2 Peel bar
3 Media liner roller
4 Peel roller assembly
1
2
2 3 41
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14. See Figure 34. Rotate the peel roller assembly up until it locks into the closed position.
Figure 34 Closed Peel Roller Assembly
15. See Figure 33. Thread the media liner past the lower guide post and around the take-up
spindle of the applicator (refer to the applicators user guide).
16. Close the media door.
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Ribbon
Ribbon is a thin film that is coated on one side with wax or wax resin, whic