Zebra S600 Specifications

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Zebra S600 Specifications | Manualzz
S400 & S600
Maintenance Manual
Proprietary Statement
This manual contains proprietary information of Zebra Technologies. It is intended solely for the information
and use of parties operating and maintaining the equipment described herein. Such proprietary information
may not be used, reproduced, or disclosed to any other parties for any other purpose without the
expressed written permission of Zebra Technologies.
Product Improvements
Continuous improvement of products is a policy of Zebra Technologies. All specifications and designs are
subject to change without notice.
FCC Compliance Statement
Note: This equipment has been tested and found to comply with the limits for a Class A Digital Device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with
the product manuals, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
In order to ensure compliance, this printer must be used with a Shielded Power Cord and Shielded
Communication Cables.
“The user is cautioned that any changes or modifications not expressly approved by Zebra Technologies
could void the user’s authority to operate the equipment.”
Canadian DOC Compliance Statement
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus
as set out in the radio interference regulations of the Canadian Department of Communications.
Liability Disclaimer
Zebra Technologies takes steps to assure that its published Engineering specifications and manuals are
correct; however, errors do occur. Zebra Technologies reserves the right to correct any such errors and
disclaims liability resulting therefrom.
No Liability for Consequential Damage
In no event shall Zebra Technologies or anyone else involved in the creation, production or delivery of the
accompanying product (including hardware and software) be liable for any damages whatsoever (including,
without limitation, 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 has been advised of the possibility of such damages. Because some states do not
allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may
not apply to you.
Copyrights
The copyrights in this manual and the label printer described therein are owned by Zebra Technologies.
All rights are reserved. Unauthorized reproduction of this manual or the software in the label printer may
result in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C.506). Copyright violators may
be subject to civil liability.
Zebra®, Barcode Anything®, Bar-One®, Element Energy Equalizer®, Integration w/o Modification®, Orion®, Stretch®, Stripe®,
The World’s #1 Name in Bar Code®, Track-One®, Ultracode®, When It’s on the Line®, Z-Band®, Zebra-Mate®, Z-Series™,
Z-Ultimate®, ZebraNet®, ZPL II®, and ZPL® are registered trademarks of Zebra Technologies.
All other trademarks and registered trademarks are property of their respective owners.
Copyright © 2002 Zebra Technologies. All rights reserved.
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All Zebra products are sold with warranties. Refer to the User’s Guide for warranty information
specific to each product. Here is some general information:
35,17(5352'8&76
Printers. All printers (excluding printheads) are warranted against defect in material or workmanship for twelve (12) months
from the purchase date.
Proof of purchase or shipment date is required to validate the warranty period. The warranty becomes void if the equipment
is modified, improperly installed or used, damaged by accident or neglect, or if any parts are improperly installed or
replaced by the user.
NOTE: Products returned must be packaged in the original or comparable packing and shipping container. In the event
equipment is not so packaged, or if shipping damage is evident, it will not be accepted for service under warranty. Surface
transportation charges for return to customers in the continental United States is paid by Zebra. Otherwise, Zebra pays
CPT (carriage paid to) nearest airport; customer pays customs, duties, taxes, and freight from airport to destination. If
Zebra determines that the product returned for warranty service or replacement is not defective as herein defined, the
customer will pay all handling and transportation costs.
Printheads. Since printhead wear is part of normal operation, the original printhead is covered by a limited warranty as indicated below. Warranty period begins on purchase date.
Printhead
Warranty Period
Barcode label printer printheads
6 months
Card printer printheads
12 months
To qualify for this warranty, the printhead must be returned to the factory or to an authorized service center. Customers are
not required to purchase Zebra supplies (media and/or ribbons) for warranty qualification. However, if it is determined that the
use of other manufacturer supplies has caused any defect in the printhead for which a warranty claim is made, the user is
responsible for Zebra’s labor and material charges required to repair the defect. The warranty becomes void if the printhead
is physically worn or damaged; also if it is determined that failure to follow the preventive maintenance schedule listed in
the User’s Guide has caused defect in the thermal printhead for which a warranty claim is made.
Software. Software is warranted to be free of defects in material and workmanship for 30 days from the date of purchase. In
the event of notification within the warranty period of defects, Zebra will replace the defective diskette or documentation.
Batteries. Mobile printer batteries are warranted to be free of defects in material and workmanship for 90 days from date of
purchase. In the event of notification within the warranty period, Zebra will replace the defective battery provided there had
not been damage resulting from user abuse.
Parts. All parts, maintenance kits, options kits, and accessories are warranted to be free of defects in material and
workmanship for 90 days (except where otherwise denoted) from date of purchase. This warranty becomes void if the item is
modified, improperly installed or used, or damaged by accident or neglect.
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Supplies are warranted to be free from defect in material and workmanship for a period of six (6) months for media and
twelve (12) months for ribbon from the date of shipment by Zebra. This is provided the user has complied with storage
guidelines, handling, and usage of the supplies in Zebra printers.
Zebra’s sole obligation under these warranties is to furnish parts and labor for the repair or possible replacement of products found to be defective in material or workmanship during the warranty period. Zebra may in its discretion issue a credit
for any such defective products in such amount as it deems reasonable.
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The warranties provided above are the only warranties applicable. No other warranties, expressed or
implied, are given. Zebra does not make any IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE in connection with its sale of products or services. While
Zebra’s desire is to be responsive to specific needs and questions, Zebra does not assume
responsibility for any specific application to which any products are applied including, but not limited
to, compatibility with other equipment. All statements, technical information or recommendations
relating to Zebra products are based upon tests believed to be reliable yet do not constitute a
guaranty or warranty.
Zebra’s maximum liability for warranty claims is limited to the invoice price of the product claimed
defective. Zebra does not assume responsibility for delays or replacement or repair of products.
Zebra shall not under any circumstances whatsoever be liable to any party for loss of profits, lost
data, diminution of good will, or any other special or consequential damages whatsoever with respect
to any claim made under agreement with Zebra. Specifically for software, Zebra is not liable for any
incidental or consequential damages caused by abuse or misapplication of the software or by its use
in violation of the U.S. copyright law or international treaty.
No salesperson, representative, or agent of Zebra is authorized to make any guaranty, warranty, or
representation that contradicts the foregoing. Any waiver, alteration, addition or modification to the
foregoing warranties must be in writing and signed by an executive officer of Zebra to be valid.
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Description ..............................................................................................................1-1
Printer Operating Modes ......................................................................................... 1-1
Specifications .......................................................................................................... 1-2
Agency Approvals ............................................................................................ 1-2
Bar Codes ........................................................................................................ 1-2
Electrical Requirements ................................................................................... 1-2
Environmental Ranges for Operation and Storage .......................................... 1-2
Fonts ................................................................................................................1-3
Standard Printer Fonts ................................................................................ 1-3
Bitmapped Fonts ......................................................................................... 1-3
Scalable Fonts ............................................................................................. 1-3
International Characters .............................................................................. 1-3
Optional Fonts ............................................................................................. 1-3
Media Considerations ....................................................................................... 1-4
Media Handling ................................................................................................ 1-4
Memory ............................................................................................................ 1-5
Microprocessor ................................................................................................. 1-5
Options ............................................................................................................. 1-5
Physical Dimensions ........................................................................................ 1-5
Printing Considerations .................................................................................... 1-6
Printing Method ................................................................................................ 1-6
Print Speeds .....................................................................................................1-6
Ribbon Considerations ..................................................................................... 1-7
Zebra Programming Language (ZPL II) ...........................................................1-7
Communication Interfaces ................................................................................ 1-8
Communication Specifications ................................................................................ 1-9
Serial Data Communication Interface Overview ............................................... 1-9
Standard Serial Communication Connector ..................................................... 1-9
RS-232 Interconnection .................................................................................. 1-10
Serial Communication Signal Levels .............................................................. 1-12
RS-232 Transmit and Receive Data .......................................................... 1-12
Centronics Parallel Data Port ......................................................................... 1-12
Parallel Port Interconnections ........................................................................ 1-12
Parallel Data Signal Levels ............................................................................ 1-12
Electronics System Block Diagram ....................................................................... 1-14
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Operator Indicators ................................................................................................. 2-1
Power Status Indicator (green) ......................................................................... 2-1
Printhead Status Indicator (yellow) ................................................................... 2-1
Paper/Ribbon Status Indicator (yellow) ............................................................ 2-1
Pause Status Indicator (yellow) ........................................................................ 2-1
Data Status Indicator (green) ........................................................................... 2-1
Darken Status Indicator (yellow) ......................................................................2-2
Position Status Indicator (yellow) ..................................................................... 2-2
Calibrate Status Indicator (yellow) ....................................................................2-2
Operator Controls .................................................................................................... 2-3
Pause Key ........................................................................................................ 2-3
Feed (s) Key .....................................................................................................2-3
Cancel (t) Key ................................................................................................... 2-3
Mode Key ......................................................................................................... 2-3
Power ON/OFF Switch ..................................................................................... 2-3
Accessing the Printer .............................................................................................. 2-5
Media Loading ......................................................................................................... 2-6
Tear-Off Mode Media Loading ......................................................................... 2-6
Cutter Mode Media Loading ............................................................................. 2-6
Peel-Off Mode Media Loading .......................................................................... 2-9
Removing the Liner ........................................................................................2-10
Adjusting the Media Sensor ........................................................................... 2-10
Media Sensor Adjustment for Non-Continuous Media .............................. 2-10
Media Sensor Adjustment for Continuous Media ...................................... 2-11
Ribbon Loading ..................................................................................................... 2-12
Adjusting the Ribbon Supply Spindle ............................................................. 2-12
Normal Position ......................................................................................... 2-12
Low-Tension Position ................................................................................ 2-12
Loading the Ribbon ........................................................................................2-13
Removing Used Ribbon ................................................................................. 2-13
Data Cable Installation .......................................................................................... 2-14
Power-On Self Test ............................................................................................... 2-14
Additional Printer Self Tests ........................................................................... 2-14
Printer Self Test/Reset Default Quick Reference Chart ................................. 2-15
Cancel Key Self Test ...................................................................................... 2-16
Pause Key Self Test ....................................................................................... 2-17
Feed Key Self Test ......................................................................................... 2-18
Mode Key Self Test ........................................................................................2-19
Feed and Pause Key Factory Default Reset .................................................. 2-19
Feed, Pause and Mode Key Reset (Communication Parameter Default) ...... 2-19
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Calibration ............................................................................................................. 2-21
Auto Calibration .............................................................................................. 2-21
Manual Calibration ......................................................................................... 2-22
Ribbon Parameter Calibration ........................................................................ 2-23
Configuration Mode ............................................................................................... 2-23
Print Darkness ................................................................................................ 2-23
Printing and Examining a Configuration Label ............................................... 2-24
Testing Print Darkness (Feed Key Self Test Method) .................................... 2-24
Testing Print Darkness (Pause Key Self Test Method) .................................. 2-25
To Set Darkness Setting Manually ............................................................ 2-25
To Start the Pause Key Self Test .............................................................. 2-25
Adjusting the Printer Darkness ....................................................................... 2-26
Tear-Off Position Adjustment ......................................................................... 2-27
Top of Label Position Adjustment ................................................................... 2-28
Routine Adjustments ............................................................................................. 2-29
Printhead Pressure Adjustment ...................................................................... 2-29
Liner Rewind Power Roller Adjustment .......................................................... 2-30
Adjusting the Rewind Power Roller ........................................................... 2-30
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Troubleshooting Charts ........................................................................................... 3-1
List of Tables ........................................................................................................... 3-1
LED Quick Reference Chart ............................................................................. 3-2
Troubleshooting Chart (Problems with LED Indications) .................................. 3-3
Troubleshooting Chart (Wrinkled Ribbon) ........................................................ 3-8
Troubleshooting Chart (Jammed or Stuck Labels) ........................................... 3-8
Troubleshooting Chart (Settings or Parameter-Related) .................................. 3-9
Printer Status Sensors ............................................................................................ 3-9
Troubleshooting Chart (Cutter-Related) ...........................................................3-9
Factory Assistance ................................................................................................ 3-11
ZIP Support ........................................................................................................... 3-11
Technical Support ................................................................................................. 3-11
Repair Service Department ................................................................................... 3-11
Returning Equipment ............................................................................................ 3-11
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Maintenance Concepts ........................................................................................... 4-1
Equipment Safety Tips ............................................................................................ 4-2
Equipment Safety Tips (Continued) ........................................................................ 4-3
Personal Safety Tips ............................................................................................... 4-4
Preventive Maintenance Schedule .......................................................................... 4-5
Cleaning – General ..........................................................................................4-5
Cleaning – Printhead and Platen Roller ...........................................................4-7
Printhead and Platen Roller Cleaning Procedure ............................................. 4-8
Cleaning the Cutter Module .............................................................................. 4-9
Remove the cutter module from the printer. ................................................4-9
Disassembling the Cutter Module ............................................................. 4-11
Cleaning the Cutter Module ....................................................................... 4-12
Reassemble the Cutter Module ................................................................. 4-12
Reinstall the Cutter Module ....................................................................... 4-14
Test the Cutter Operation .......................................................................... 4-14
Lubrication ............................................................................................................. 4-15
Diagnostics ............................................................................................................4-15
Printer Self Test/Reset Default Quick Reference Chart ................................. 4-15
Pause and Cancel Key Self Test ....................................................................4-16
Feed and Cancel Key Self Test ...................................................................... 4-16
Extended Printer Diagnostics ................................................................................ 4-22
Pause Key Loopback Test .............................................................................4-22
Feed Key Rollback Test ................................................................................. 4-23
Mechanical Adjustments ....................................................................................... 4-23
Printhead Position Adjustment ....................................................................... 4-23
Take-Label Sensor Adjustment ...................................................................... 4-26
Strip-Plate Adjustment .................................................................................... 4-27
Liner Rewind Spindle Adjustment ..................................................................4-28
Electrical Adjustments ........................................................................................... 4-29
Printhead Voltage Adjustment ........................................................................ 4-29
Cutter Voltage Adjustment .............................................................................4-32
Corrective Maintenance ........................................................................................4-34
Tools Required ............................................................................................... 4-34
Removing the Main Door ................................................................................ 4-34
Removing the Front Door ...............................................................................4-34
Removing the Rear Cover .............................................................................. 4-34
Tear-Off Plate Removal .................................................................................. 4-36
Control Panel Assembly Removal ..................................................................4-36
Control Panel Circuit Board Replacement ...................................................... 4-37
Main Logic Board Removal ............................................................................ 4-38
Main Logic Board Installation ......................................................................... 4-38
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Downloading Firmware ......................................................................................... 4-39
Print Mechanism Assembly Removal ............................................................. 4-40
Printhead Assembly Removal and Installation ............................................... 4-41
Ribbon Supply Spindle Disassembly .............................................................. 4-44
Ribbon Supply Spindle Installation ................................................................. 4-45
Media Sensor Assembly Removal ................................................................. 4-49
Media Sensor Assembly Installation .............................................................. 4-49
Main Drive Belt Removal, Replacement, and Adjustment .............................. 4-51
Printers without the Peel-Off Option .......................................................... 4-51
Printers Equipped With the Peel-Off Option ..............................................4-51
Platen Roller Replacement .............................................................................4-53
Ribbon Take-Up Motor Replacement ............................................................. 4-55
Stepper Motor Replacement .......................................................................... 4-56
Power Supply Board Removal ....................................................................... 4-57
Power Supply Board Installation ....................................................................4-58
AC Power Fuse Replacement ........................................................................ 4-61
Options .................................................................................................................. 4-62
Memory Upgrade Kit Installation Instructions ................................................. 4-62
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Description ..............................................................................................................5-1
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Figure 1-1. Safety Organizations .................................................................................. 1-2
Figure 1-2. Communication Cable Connections ........................................................... 1-9
Figure 1-3. RS-232 Connections................................................................................. 1-10
Figure 1-4. RS-232 Signal/ASCII Code Data .............................................................. 1-12
Figure 1-5. Electronic Block Diagram.......................................................................... 1-14
Figure 2-1. Front Panel ................................................................................................. 2-2
Figure 2-2. Power-On/Off Switch and Data Cable Connections ................................... 2-4
Figure 2-3. Printer Access............................................................................................. 2-5
Figure 2-4. Roll Media Loading ..................................................................................... 2-7
Figure 2-5. Fanfold Media Loading ............................................................................... 2-7
Figure 2-6. Cutter Mode Media Loading ....................................................................... 2-8
Figure 2-7. Peel-Off Mode Media Loading .................................................................... 2-8
Figure 2-8. Media Sensor Adjustment......................................................................... 2-11
Figure 2-9. Dual-Tension Ribbon Supply Spindle Adjustment .................................... 2-12
Figure 2-10. Ribbon Loading Diagram ........................................................................ 2-13
Figure 2-11. Cancel Key Self Test Printout (Configuration Label) .............................. 2-16
Figure 2-12. Pause Key Self Test Printout.................................................................. 2-17
Figure 2-13. Feed Key Self Test Printout.................................................................... 2-18
Figure 2-14. Mode Key Self Test Printout ................................................................... 2-19
Figure 2-15. Tear-Off Position Adjustment.................................................................. 2-27
Figure 2-16. Adjusting the Print of the Top of Label.................................................... 2-28
Figure 2-17. Printhead Pressure Adjustment .............................................................. 2-29
Figure 2-18. Liner Rewind Power Roller ..................................................................... 2-31
Figure 4-1. Main Door and Front Door .......................................................................... 4-8
Figure 4-2. Printhead Cleaning ..................................................................................... 4-9
Figure 4-3. Cutter Catch Tray Location....................................................................... 4-10
Figure 4-4. Cutter Connector and Mounting Screw..................................................... 4-10
Figure 4-5. Cutter Module Removal ............................................................................ 4-11
Figure 4-6. Cutter Module Disassembly...................................................................... 4-12
Figure 4-7. Cutter Module Reassembly ...................................................................... 4-13
Figure 4-8. Side View of Cutter Module Reassembly ................................................. 4-13
Figure 4-9. Reassembled Cutter Module .................................................................... 4-14
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Figure 4-10. Cutter Module Reinstallation................................................................... 4-15
Figure 4-11. Pause and Cancel Key Label ................................................................. 4-18
Figure 4-12. Test, Formats 1 and 8............................................................................. 4-19
Figure 4-13. Test, Formats 2 and 9............................................................................. 4-19
Figure 4-14. Test, Formats 3 and 10........................................................................... 4-20
Figure 4-15. Test, Formats 4 and 11........................................................................... 4-20
Figure 4-16. Test, Formats 5 and 12........................................................................... 4-21
Figure 4-17. Test, Formats 6 and 13........................................................................... 4-21
Figure 4-18. Test, Formats 7 and 14........................................................................... 4-22
Figure 4-19. Printhead Pressure Screws .................................................................... 4-23
Figure 4-20. Printhead Position Adjustment (Top View) ............................................. 4-25
Figure 4-21. Take-Label Sensor Location................................................................... 4-26
Figure 4-22. Strip Plate Adjustment ............................................................................ 4-27
Figure 4-23. Liner Rewind Spindle Adjustment........................................................... 4-28
Figure 4-24. Printhead Voltage Adjustment Potentiometer Location .......................... 4-31
Figure 4-25. Properly Adjusted Cutter Sensor ............................................................ 4-33
Figure 4-26. Home Position Potentiometer ................................................................. 4-33
Figure 4-27. Opening Main and Front Doors .............................................................. 4-35
Figure 4-28. Door and Cover Disassembly ................................................................. 4-35
Figure 4-29. Tear-Off Plate ......................................................................................... 4-36
Figure 4-30. Control Panel Assembly ......................................................................... 4-37
Figure 4-31. Main Logic Board.................................................................................... 4-39
Figure 4-32. Printhead Cable Ferrite assembly .......................................................... 4-40
Figure 4-33. Braided Ground Strap Location .............................................................. 4-42
Figure 4-34. Print Mechanism Assembly Mounting Screw Location ........................... 4-42
Figure 4-35. Printhead Assembly Removal/Installation .............................................. 4-43
Figure 4-36. Dual-Tension Ribbon Supply Disassembly............................................. 4-44
Figure 4-37. Ribbon Supply Spindle Subassembly Installation................................... 4-45
Figure 4-38. Spindle Assembly Installation ................................................................. 4-46
Figure 4-39. Spindle Assembly Installation ................................................................. 4-48
Figure 4-40. Spindle Assembly & Outer Spindle (Expanded) ..................................... 4-48
Figure 4-41. Spindle Assembly & Outer Spindle (Retracted)...................................... 4-48
Figure 4-42. Media Sensor Assembly ......................................................................... 4-50
Figure 4-43. Main Drive Belt Replacement and Adjustment ....................................... 4-50
Figure 4-44. Peel-Off Drive Belt Adjustment ............................................................... 4-52
Figure 4-45. Platen Roller Replacement ..................................................................... 4-54
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Figure 4-46. Replacing the Platen Roller .................................................................... 4-54
Figure 4-47. Ribbon Take-Up Motor ........................................................................... 4-55
Figure 4-48. Stepper Motor (Media Side).................................................................... 4-56
Figure 4-49. Stepper Motor (Electronics Side)............................................................ 4-57
Figure 4-50. Power Supply Assembly Removal.......................................................... 4-59
Figure 4-51. Power Supply Assembly Exploded View ................................................ 4-60
Figure 4-52. Fuse Holder Location.............................................................................. 4-61
Figure 4-53. Main Logic Board Conntector and Mounting Screw Location................. 4-62
Figure 4-54. Memory Board ........................................................................................ 4-63
Figure 4-55. Memory Board Mounting Screws............................................................ 4-64
Figure 4-56. Sample Before and After Configuration Labels
(8 MB Memory Board Installed) .................................................................................. 4-66
Figure 5-1. Cover Assemblies....................................................................................... 5-3
Figure 5-2. Logic Board and Control Panel................................................................... 5-5
Figure 5-3. Media Supply, Ribbon Supply, and Ribbon Take-Up ................................. 5-7
Figure 5-4. Toggle and Print Mechanism ...................................................................... 5-9
Figure 5-5. Print Mechanism and Printhead Assembly ............................................... 5-11
Figure 5-6. Tear/Cutter Media Sensor, Ribbon Guides, and Media Guide ................. 5-13
Figure 5-7. Peel-Off Option (Front View) .................................................................... 5-15
Figure 5-8. Tear/Cutter Drive System ......................................................................... 5-17
Figure 5-9. Peel Option and Peel Drive System ......................................................... 5-19
Figure 5-10. Platen and Power Supply ....................................................................... 5-21
Figure 5-11. Cutter Option .......................................................................................... 5-23
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Table 1-1.
Font Matrix for 8 dot/mm (203 dpi) Printheads .......................................... 1-3
Table 1-2.
Media Specifications.................................................................................. 1-4
Table 1-3.
Memory Specifications .............................................................................. 1-5
Table 1-4.
Physical Dimensions .................................................................................1-5
Table 1-5.
Printing Specifications ...............................................................................1-6
Table 1-6.
Print Speeds .............................................................................................. 1-6
Table 1-7.
Ribbon Specifications ................................................................................ 1-7
Table 1-8.
DP-9P Pinouts ......................................................................................... 1-11
Table 1-9.
Centronics Connector Pinouts................................................................. 1-13
Table 2-1.
Self Test and Calibration Quick Reference Chart.................................... 2-15
Table 2-2.
Factory Default Values ............................................................................ 2-20
Table 3-1.
LED Quick Reference Chart ......................................................................3-2
Table 3-2.
Troubleshooting Chart (Problems with LED Indications)........................... 3-3
Table 3-3.
Troubleshooting Chart (Print or Print Quality Related Problems ...............3-6
Table 3-4.
Troubleshooting Chart (Wrinkled Ribbon) ................................................. 3-8
Table 3-5.
Troubleshooting Chart (Jammed or Stuck Labels) .................................... 3-8
Table 3-6.
Troubleshooting Chart (Settings or Parameter Related) ........................... 3-9
Table 3-7.
Troubleshooting Chart (Cutter Related) .................................................... 3-9
Table 3-8.
Explanation of Sensors............................................................................ 3-10
Table 4-1.
Recommended Cleaning Schedule ...........................................................4-6
Table 4-2.
Self Test and Calibration Reference Table..............................................4-17
Table 4-3.
Sequence of Formats .............................................................................. 4-18
Table 4-4.
Printhead Voltage Values (S400 Only).................................................... 4-30
Table 4-5.
Printhead Voltage Values (S600 Only).................................................... 4-30
Table 5-1.
Cover Assemblies...................................................................................... 5-2
Table 5-2.
Logic Board and Control Panel.................................................................. 5-4
Table 5-3.
Media Supply,m Ribbon Supply, and Ribbon Take-Up ............................. 5-6
Table 5-4.
Toggle and Print Mechanism..................................................................... 5-8
Table 5-5.
Print Mechanism and Printhead Assembly..............................................5-10
Table 5-6.
Tear/Cutter Media Sensor and Ribbon Guide ......................................... 5-12
Table 5-7.
Peel-Off Option (Front View) ................................................................... 5-14
Table 5-8.
Tear/Cutter Drive System ........................................................................ 5-16
Table 5-9.
Peel-Off Option Drive System ................................................................ 5-18
Table 5-10. Platen and Power Supply ........................................................................ 5-20
Table 5-11. Cutter Option ........................................................................................... 5-22
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The Zebra Stripe S400 and S600 Thermal Printers are versatile label and ticket printers
designed to print high-quality bar codes, various sizes and styles of alphanumeric characters,
and graphics in either the thermal transfer or direct thermal mode. The Zebra Stripe printers
have the flexibility to meet a wide variety of applications. Zebra Programming Language II
(ZPL II) allows the programmer to format the printed material. ZPL II is transparent to protocol
converters and allows the Zebra Stripe printers to be easily integrated with most systems and
host mainframes.
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Tear-Off Mode. When the media is in the rest (idle) position, the webbing between labels is
over the tear-off/peel-off plate. To print a label, the printer first backfeeds the media until the
start of the label is directly under the printhead, then prints the entire label. The operator then
tears off the label, and a new label can be printed.
Peel-Off Mode. When the media is in the rest (idle) position, the start of the label to be
printed is slightly in front of the printhead. To print a label, the printer first backfeeds the
media until the start of the label is directly under the printhead, then prints the entire label.
In this mode, once the label is printed, the media passes over the tear-off/peel-off plate at a
sharp angle. The liner is peeled away from the label and winds around the liner rewind
spindle. The media feeds forward until most of the label hangs loose from the liner. The
label-available sensor detects this label and pauses printing until the operator removes the
label, then the next label prints.
The liner rewind spindle holds one half of the liner from a standard size media roll. The
rewind spindle full sensor detects when the spindle is full, then pauses.
Cutter Mode. When the media is in the rest (idle) position, the start of the label to be printed
is directly under the printhead. The printer prints the entire label and automatically cuts the
label after it is printed. The cutter catch tray catches the completed labels.
The cutter automatically cycles through one cutting motion when the printer’s power is turned
On (l). When printing labels, cutter activation is determined by a command sent to the printer
by the host computer from either ZPL II or from a different software driver.
External Rewind Mode. Some applications call for the media to be rewound onto a core as
the labels are printed. The Stripe printer does not have an internal media rewind capability.
The liner rewind spindle is not designed to rewind label stock. An external rewinder is
required for this application. An external rewinder is not available from Zebra Technologies.
When the media is in the rest (idle) position, the start of the label to be printed is directly
under the printhead. After the label is printed, the media feeds forward until the start of the
next label is under the printhead. The media never backfeeds in this mode. When the printer
completes a batch of labels, printing stops. The speed and tension of the rewind operation is
strictly a function of the external rewind unit.
44895L Rev. 3 3/12/04
S400/S600 Maintenance Manual
Page 1-1
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Figure 1-1. Safety Organizations
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The following bar codes are available:
•
Check digit calculation where applicable
•
Codabar (Supports ratios of 2:1 and 3:1)
•
Codablock
•
Code 11
•
Code 39 (Supports ratios of 2:1 and 3:1)
•
Code 49
•
Code 93
•
Code 128 (Supports serialization in all
subsets B and C and UCC Case C
Codes)
•
Interleaved 2 of 5 (Supports ratios of
2:1 and 3:1 and supports Modulus 10
Check Digit)
•
LOGMARS
•
MaxiCode
•
MSI
•
PDF 417
•
Plessey
•
POSTNET
•
QR
•
Datamatrix
•
Standard 2 of 5
•
EAN-8, EAN-13, EAN EXTENSIONS
•
UPC-A, UPC-E, UPC EXTENSIONS
•
Industrial 2 of 5
•
Micro PDF417
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Auto select 110 VAC ± 20% or 230 VAC ±15%, 48–62 Hz
3 Amps @ 110 VAC, 1.5 Amps @ 230 VAC
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Operating Temperature: +40° F to +105° F (5° C to 40° C)
Storage: – 40° F to +140° F (–40° C to +60° C)
Relative Humidity (Operating): 20% to 85% non-condensing
Relative Humidity (Storage): 5% to 85% non-condensing
Page 1-2
S400/S600 Maintenance Manual
44895L Rev. 3 3/12/04
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Standard Printer Fonts
Table 1-1. Font Matrix for 8 dot/mm (203 dpi) Printheads
Font
Matrix
Baseline
Dots
Type*
InterCharacter
Gap
Character Size
Inches
Millimeters
Cell
Width
Font Matrix
1
6
U-L-D
0.044
0.030
33.87
1.13
0.75
1.33
2
9
U
0.054
0.044
22.58
1.38
1.13
0.89
2
12
U-L-D
0.089
0.059
16.93
2.25
1.50
0.67
23
5
20
OCR-B
0.138
0.098
10.16
3.50
2.50
0.40
21
3
16
U-L-D
0.128
0.079
12.70
3.25
2.00
0.50
40
48
8
48
U-L-D
0.295
0.236
4.23
7.50
6.00
0.17
13
21
6
19
OCR-A
0.103
0.094
10.69
2.63
2.38
0.42
0.31
Height
Width
A
9
5
7
B
11
7
11
C, D
18
10
14
E
28
15
F
26
13
G
60
H
21
Height
Width
Char/
Inch
Height
Width
Char/
mm
GS
24
24
24
2
26
SYMBOL
0.118
0.128
7.82
3.00
3.25
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
*U = Uppercase, L = Lowercase, D = Descenders
Bitmapped Fonts
Zebra standard A, B, D, E, F, G, E, H, and GS.
Standard magnification up to 10 times vertical and horizontal independent.
Scalable Fonts
One smooth font, CG Triumvirate™ Bold Condensed, has the ability to expand using the
standard Zebra expansion routines, expanding on a dot-by-dot basis, height and width
independent, while maintaining smooth edges, to a maximum of 1500 × 1500 dots.
International Characters
IBM Code Page 850 — International Character Sets available in fonts A, B, D, E, F, G, and ∅
through software control.
Optional Fonts
Factory/Field-Installed Scalable: Futura, CG Triumvirate, CG Palacio, Univers,
GC Triumvirate Condensed, Century Schoolbook, Cyrillic, East European, Turkish, Greek.
Factory/Field Installed Bitmapped: Futura Bold, CG Triumvirate Bold, CG Palacio Bold,
CG Times Bold, Univers Bold, CG Triumvirate Bold Condensed.
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Table 1-2. Media Specifications
S400
S600
Minimum media width
0.75" (19 mm)
Maximum media width
4.5" (114 mm)
Maximum media width (cutter installed)
4.0" (102 mm)
Minimum media length (Tear-Off)
0.63" (16 mm)
Minimum media length (Peel-Off)
1.0" (25 mm)
Minimum media length (Cutter)
1.5" (38 mm)
Maximum media length
36" (914 mm)
Total thickness (includes liner)
0.0023" to 0.012" (0.058 mm to 0.305 mm)
Core size
3.0" (76 mm)
Maximum roll diameter
8" (203 mm)
Minimum Inter-label gap
0.08" (2 mm)
Maximum Inter-label gap
0.16 (4 mm)
Ticket/tag notch size (W × L)
0.08" × 0.48 (2 mm × 12 mm)
39" (990 mm)
0.118" (3 mm) preferred
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Tear-Off Mode: Labels produced in strips.
Peel-Off Mode*: Labels dispensed and peeled from the liner.
Cutter Mode*: Labels are printed and individually cut.
Rewind Mode*: Labels are externally rewound (requires optional media rewinder — not
available from Zebra Technologies).
* These options are not found on all printers.
Page 1-4
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Table 1-3. Memory Specifications
S400
S600
Flash ROM (firmware)
1 MB
1 MB
Standard DRAM
1 MB
2 MB
Available Standard Flash Memory
0
1 MB
Memory Upgrades (Options)
4 MB & 8 MB Flash
Modules
4 MB & 8 MB Flash
Modules
0LFURSURFHVVRU
32 Bit RISC
2SWLRQV
1 MB Flash expansion (S400 only)*
4 MB Flash expansion
8 MB Flash expansion
Peel-Off mode with liner-only rewind feature*
Cutter with label catch tray*
Scalable and bitmap smooth fonts available for text
Ethernet
* Factory-installed (contact your authorized Zebra distributor for information).
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Table 1-4. Physical Dimensions
S400 & S600
Height
13"
330 mm
Width
8.25"
210 mm
Depth
17"
432 mm
Weight (without options)
17 lbs
7.71 kg
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Page 1-5
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Table 1-5. Printing Specifications
S400
S600
Resolution
203 dots per inch (8 dots per mm)
Dot Size
0.005" (0.127 mm)
Minimum print width
0.75" (19 mm)
Maximum print width
4.09" (104 mm)
Minimum print length
0.005" (0.127 mm) (1 dot row)
Maximum print length
36" (914 mm)
Bar code modulus (“X”) dimension
5.0 mil to 55.0 mil
39" (990 mm)
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Direct Thermal Printing (requires direct thermal media). A substrate, typically paper, is
coated with a chemical that changes to a dark color upon exposure to heat over a period
of time to form an image.
Thermal Transfer Printing. The printhead is in contact with a ribbon that releases ink
above a certain threshold temperature.
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Table 1-6. Print Speeds
S400
Programmable
constant printing
speeds.
Page 1-6
S600
2.4" (61 mm)
2.4" (61 mm)
5" (127 mm)
3" (76 mm)
3" (76 mm)
6" (152 mm)
4" (102 mm)
4" (102 mm)
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Table 1-7. Ribbon Specifications
S400 & S600
Ribbon Width
Standard Length
Core Size
Minimum
1.57" (40 mm)
Maximum
4.5" (114 mm)
2:1 media to ribbon roll ratio
984’ (300 m)
3:1 media to ribbon roll ratio
1400’ (427 m)
Inner diameter
1.0" (25 mm)
Outer diameter
3.2" (81 mm)
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ASCII data commands provide the following features:
•
•
Downloadable graphics, scalable and
bitmap fonts and formats (with data
compression)
Bit image data transfer and printing,
including mixing of text and graphics
•
Format inversion
•
Mirror image printing
•
Four-position field rotation (0, 90, 180,
270 degrees)
•
Slew command
•
Programmable quantity with print
pause
44895L Rev. 3 3/12/04
•
Communicates in printable ASCII
characters
•
Controlled via mainframe, mini,
PC, or other data-entry device
•
Serialized fields in-spec OCR-A
and OCR-B
•
UPC/EAN at nominal 100%
magnification (6 dot/mm printhead
only)
•
(RAM and Memory Card)
S400/S600 Maintenance Manual
Page 1-7
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•
•
Page 1-8
Serial Port
◊
RS-232
◊
DB-9
◊
Baud Rate (110, 300, 600, 1200, 2400, 4800, 9600, 14400, 19200, 28800,
38400, 57600)
◊
Parity (disabled, even, odd)
◊
Stop Bits (7 or 8 data bits)
◊
Handshake (XON/XOFF or DTR/DSR)
◊
Error Detection (on or off)
◊
A null modem (crossover cable must be used to connect to a host 9-pin
connector (see Figure 1-2).
◊
A null modem cable must be used to connect to a host 25-pin connector (see
Figure 1-2).
Parallel Port
◊
36-pin Centronics
◊
Bi-directional port
◊
Parallel operation can be enabled or disabled in the firmware.
◊
8-bit Parallel Data Interface supporting IEEE 1284 bi-directional “nibble
mode.”
Ethernet
◊
Thinnet and 10BaseT connectivity are available through an external
connection to the parallel port.
◊
IPX, LAT, NetBIOS/Net BEUI, TCP/IP protocols are supported with a data
burst rate of 150 KB. HP bitronics mode is supported to provide bi-directional
high speed. SNMP - compatible and supports MIB I, MIB II, and Parallel MIB
as well as MPSPON: (Novell NetWare) PC console configuration utility IPX.
S400/S600 Maintenance Manual
44895L Rev. 3 3/12/04
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The S400 and S600 printers have a single Data Terminal Equipment (DTE) port that supports
RS-232 serial data communications. The RS-232 interface has a 9-pin DB-9S connector
located at the rear of the printer.
For all RS-232 data and control input and output signals, the S400 and S600 printers follow
both the Electronic Industries Association’s (EIA) RS-232 and the Consultative Committee for
International Telephony and Telegraphy (CCITT) V.24 specifications.
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Refer to Figure 1-2. The DTE Port is a DB-9P connector located at the rear of the printer. It
provides connection to a host via RS-232 signaling. The pinouts and signal descriptions for
the DTE port are found in Table 1-8.
Serial
Cable
or
Communication
Interface
Parallel
Cable
AC Power
Cable
AC Power
On/Off Switch
Figure 1-2. Communication Cable Connections
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The printer is configured as Data Terminal Equipment (DTE). Figure 1-3 illustrates the
connections required to interconnect the printer with the 9-pin or 25-pin serial port
connector on a PC.
25-Pin D-Sub to 9-Pin D-Sub Null Modem Cable
DB-25P
Connector
to PC
2
3
4
5
6
7
8
20
TXD
RXD
RTS
CTS
DSR
GND
DCD
DTR
DB-9S
Connector
to Printer
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
1
2
3
4
5
6
7
8
9-Pin D-Sub to 9-Pin D-Sub Null Modem Cable
DB-9S
Connector
to PC
1
2
3
4
5
6
7
8
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
DB-9P
Connector
to Printer
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
1
2
3
4
5
6
7
8
Figure 1-3. RS-232 Connections
Page 1-10
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Table 1-8. DB-9P Pinouts
Pin
Description
1
Not used.
2
RXD (RS-232 Receive Data): This is the serial data input to the printer from the host.
3
TXD (RS-232 Transmit Data): This lead is the serial data output from the printer. It is on
this lead that printer status or XON-XOFF information is relayed to the host.
4
DTR (RS-232 Data Terminal Ready): This lead is a control output from the printer to the
host. When the DTR control line from the printer is active (positive voltage), the host can
send data to the printer. When DTR is inactive (negative voltage), the host cannot send
data to the printer. This condition occurs when the printer is configured for DTR/DSR
hardware handshaking and the communication buffer is within 256 characters of its
capacity.
5
Signal ground for RS-232: Not tied to frame ground. This lead serves as the voltage
reference between the interfaced devices.
6
DSR (RS-232 Data Set Ready): This is a control input to the printer from the host. The
printer monitors this lead to determine whether the host is ready to receive data/status
from the printer.
7
RTS (RS-232 Request to Send): This is a control output from the printer to the host. RTS
is active (positive voltage) when the printer is On (l). An active RTS indicates that the
printer is ready to receive data.
8
Not used.
9
+5V Fused Output, 1 Amp Max.
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RS-232 Transmit and Receive Data
RS-232 data signals are defined as either MARK or SPACE while control signals are
either On (active—positive voltage) or Off (inactive—negative voltage). Although the
permitted voltage levels can range from 3 VDC to 25 VDC, both positive and negative, the
levels for the S400 and S600 printers are shown in Figure 1-4.
Start
Bit
Parity
Bit
Data Bits
+ Space
1
– Mark
2
3
4
5
6
7
(Idle)
(Idle)
Logic 1
Stop
Bit
Logic 0
Figure 1-4. RS-232 Signal/ASCII Code Data
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The S400 and S600 printers have a standard 36-pin Centronics parallel connector
(instead of a serial port) available at the rear of the printer, for connection to a parallel
data source. This data communication method sends the bits of data that make up each
character all at one time over several wires in the cable, one bit per wire.
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Table 1-9 on page 1-13 shows the pin configuration and function of a standard PC-toprinter Centronics parallel cable.
3DUDOOHO'DWD6LJQDO/HYHOV
Parallel data signals are defined as either HIGH or LOW, while control signals are either
active or inactive, meaning that some control signals are active HIGH while others are
active LOW. The voltage levels that represent these conditions are:
Page 1-12
Data Signal
Voltage Level
HIGH
+5 VDC
LOW
0 VDC
S400/S600 Maintenance Manual
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Table 1-9. Centronics Connector Pinouts
36-Pin
Connector
Description
1
STROBE — The high to low transition of this input signal latches the data at the
eight DATA inputs into the printer.
2–9
DATA BITS 0 through 7 — Parallel data inputs to the printer. TTL input level HIGH
(+5 V) corresponds to a Logic 1; level LOW (0 V) to a Logic 0.
10
ACKNOWLEDGE — This printer output is an active LOW pulse indicating that
the printer has received the previous character and is ready to accept another
data character.
11
BUSY — This printer output is active HIGH whenever it cannot accept data.
12
ERROR — This output signal is active HIGH whenever the printer is out of paper
or ribbon.
13
SELECT — The function of this output signal is determined by a printer
configuration. In the default condition, SELECT is active HIGH whenever the
parallel port is on and enabled.
14
AUTOFEED — Not used
15, 33, and
34
Not used
16, 19–30
SIGNAL GROUNDS — The logic grounds and returns for all input and output
signals.
17
Chassis ground (for cable shield connection)
18
+5V fused output, 1 amp max.
31
INITIALIZE (Reset) — Not used
32
FAULT — This printer output is active LOW whenever any of the following error
conditions are present: Head Open, Head Too Hot, Paper Out, Ribbon Out, or
Rewind Full (if optional rewind is used).
35
+5V resistive.
36
SEL IN — Connected but not used.
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Printhead
Assembly
(S600)
Printhead
Assembly
(S400)
Ribbon
Take-Up
Motor
Label Available
Sensor
(Peel Option)
Media/Ribbon
Sensor
J4
J9
J3
J11
J5
Serial Port
J1
J12
Control
Panel
J14
Head-Open
Sensor
Main Logic Board
Parallel Port
J6
J2
J10
J7
Cutter
(option)
Stepper
Motor J1
J8
J13
J2
Power
Supply
Board
Memory
Expansion
(option)
Full Roll
Switch
(Peel Option)
Power
Source
Figure 1-5. Electronic Block Diagram
Page 1-14
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44895L Rev. 3 3/12/04
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This section contains information and adjustments for becoming acquainted with,
adjusting, testing, and operating the printer. This information is also found in the User’s
Guide.
2SHUDWRU,QGLFDWRUV
Refer to Figure 2-1.
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Refer to Figure 2-2. Controlled by the power on/off (l/O) switch located on the left side
near the AC power cord.
On
Primary power is applied to the printer.
Off
Printer has been turned off or is not receiving power.
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On
Off
Flashing
A printhead over-temperature condition exists. Printing stops until the
printhead cools, then printing resumes automatically.
A printhead under-temperature condition exists. Printing continues.
Normal condition.
The printhead is open.
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On
Off
Flashing
Media is out.
Normal condition. Media and ribbon (if used) are properly loaded.
Direct Thermal Mode — Ribbon is in printer.
Thermal Transfer Mode — Ribbon is out.
Peel-Off Mode — Liner rewind spindle full.
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On
Off
Printer has stopped all printing operations.
Normal condition.
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On
Off
Single Flash
Flashing
Slow Flashing
44895L Rev. 3 3/12/04
Data processing or printing is taking place, but no data is being
received.
No data is being received or processed.
CANCEL was pressed and a format was successfully deleted from
the print queue.
Data is being received.
The printer sent a “stop transmitting” command to the host computer.
S400/S600 Maintenance Manual
Page 2-1
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On
Off
Printer is in Configuration Mode. See “Adjusting the Printer
Darkness” on page 2-26 and “Top of Label Position
Adjustment” on page 2-28 for more information.
Normal condition.
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On
Off
Printer is in Configuration Mode. See “Tear-Off Position
Adjustment” on page 2-27 for more information.
Normal condition.
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On
Off
Printer is in Configuration Mode. See “Top of Label Position
Adjustment” on page 2-28 for more information.
Normal condition.
POWER
PRINTHEAD
PAPER/RIBBON
PAUSE
FEED
DATA
CANCEL
DARKEN
POSITION
CALIBRATE
MODE
Figure 2-1. Front Panel
Page 2-2
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44895L Rev. 3 3/12/04
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Allows the operator to interrupt the printing of a batch of labels.
If Pause is pressed during printing, printing stops after completing the label being printed.
If the printer is not printing, no printing can occur.
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Forces the printer to feed one blank label.
•
If FEED is pressed during printing, a blank label feeds after the current batch of
labels is completed.
•
If the printer is not printing, a blank label feeds immediately.
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When in Pause Mode, this key cancels print jobs.
•
If there are no print jobs in queue, pressing CANCEL cancels the next print job to
be sent to the printer.
•
If there is one print job in the queue, pressing CANCEL once cancels the current
print job.
•
If there is more than one print job in the queue, pressing and holding CANCEL for
several seconds cancels all print jobs in memory.
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MODE puts the printer in Configuration Mode (for more information see “Configuration
Mode” on page 2-23) and activates the automatic media calibration procedure.
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Refer to Figure 2-2. On the left side of the printer, near the AC power cord, is the power
On/Off switch. Turn the power Off (O) before connecting or disconnecting any cables.
Turning the switch On (l) activates the printer and it performs a Power-On Self Test as it
begins operation. Turning the printer power On (l) while holding down certain front panel
keys launches additional printer self tests immediately following the Power-On Self Test.
These tests are described later in this section.
External influences such as lightning storms or unwanted noise on the power or data
cables may cause erratic printer behavior. Turning the AC power Off (O) and back On (l)
may reestablish proper printer operation.
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Serial
Cable
or
Communication
Interface
Parallel
Cable
AC Power
Cable
AC Power
On/Off Switch
Figure 2-2. Power-On/Off Switch and Data Cable Connections
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To access the printer for loading and unloading media and ribbon, and for operator
adjustments, do the following:
1.
Refer to Figure 2-3. Lift the main door and swing it up and to the left until it rests on
top of the right side cover.
2.
Grasp the tab on top of the front door and carefully pull down until it rests on the
desktop.
Main Door
Tab
1
2
Front Door
Figure 2-3. Printer Access
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Note • Media widths and thickness vary between applications. To maintain print quality
from one application to another, refer to “Configuration Mode” on page 2-23.
7HDU2II0RGH0HGLD/RDGLQJ
1.
Turn the head-open lever counterclockwise to the OPEN position and raise the
printhead.
2.
Slide the media guide and the media supply guide as far out from the printer frame
as possible.
3.
Roll Media — place the media roll on the media supply hanger and thread the
media through the printhead assembly as shown in Figure 2-4.
4.
Fanfold Media — feed fanfold media through either the bottom or rear access slot
of the printer as shown in Figure 2-5.
5.
Adjust the media supply guide and media guide against the outer edge of the
media.
Note • These guides must not cause pressure or excessive drag on the media.
6.
Close the head-open lever.
7.
Perform the media sensor position adjustment.
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1.
Turn the head-open lever counterclockwise to the OPEN position and raise the
printhead.
2.
Slide the media guide and the media supply guide as far out from the printer frame
as possible.
3.
Place the media roll on the media supply hanger and thread the media through the
printhead assembly as shown in Figure 2-6.
Note • The end of the media must be positioned on top of the platen roller.
4.
Adjust the media supply guide and media guide against the outer edge of the
media.
Note • These guides must not cause pressure or excessive drag on the media.
Page 2-6
5.
With the end of the media positioned directly on top of the platen roller, close the
head-open lever. The printer automatically feeds out and cuts one label when power
is turned On (l).
6.
Perform the media sensor position adjustment.
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Ribbon Release
Button
Head-Open
Lever
Ribbon
Supply
Media
Supply
OPEN
CLOSED
Media Sensor Assembly
Media Supply Hanger
Media Supply
Guide
Media Guide
Figure 2-4. Roll Media Loading
Head-Open
Lever
Ribbon Release
Button
Ribbon
Supply
Media
Supply
OPEN
CLOSED
Rear-Loaded
Fanfold Media
Media Sensor Assembly
Bottom-Loaded
Fanfold Media
Media Guide
Media Supply
Guide
Media Supply
Hanger
Figure 2-5. Fanfold Media Loading
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Ribbon Release
Button
Head-Open
Lever
Ribbon
Supply
Media
Supply
End of media
on top of platen roller
OPEN
Cutter
Module
Media Supply Hanger
Platen
Roller
Media Sensor Assembly
Media Guide
Media Supply Guide
Figure 2-6. Cutter Mode Media Loading
Ribbon Release
Button
Head-Open Lever
Printhead Assembly
Ribbon Supply
Media Supply
OPEN
Label
Media Supply
Guide
Media Supply
Hanger
Liner Only
Platen Guide Rod
Rewind
Power Roller
Upper
Guide Rod
Media Sensor Assembly
Hold Down Hook
Liner Rewind Spindle
Lower Guide Rod
Media Guide
Figure 2-7. Peel-Off Mode Media Loading
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1.
Turn the head-open lever counterclockwise to the OPEN position and raise the
printhead.
2.
Slide the media guide and the media supply guide as far out from the printer frame
as possible.
3.
Remove the hold down hook.
4.
Place the media roll on the media supply hanger and thread the media through the
printhead assembly as shown in Figure 2-7.
5.
From the front of the printer, pull the media through the printhead assembly until
approximately 24 in. (61 cm) of media extends out from the printer. Remove the
labels from the liner.
6.
Thread the liner behind the lower label available sensor through the slot under the
rewind power roller and below the lower guide rod to the liner rewind spindle.
7.
Wind the liner counterclockwise three or four times around the liner rewind spindle.
Ensure the edge of the liner material is against the round plate at the far end of the
spindle.
8.
Place the hold down hook over the liner and insert both ends into the small slots in
the round plate at the far end of the spindle. Rotate the liner rewind spindle
counterclockwise to remove any slack in the liner.
9.
Adjust the media supply guide inward until it is just touching the outer side of the
media supply roll. Lock the guide in place with the locking screw.
10.
Adjust the outer edge guides on the lower guide rod and the platen guide rod until
they just touch the outer edge of the media and liner without causing the material to
buckle.
11.
Adjust the media guide until it just touches the outer edge of the media and liner
without causing the material to buckle.
12.
Close the head-open lever.
13.
Refer to “Adjusting the Media Sensor” on page 2-10 and perform the media sensor
position adjustment.
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When the amount of liner wound on the liner rewind spindle reaches full capacity, the liner
rewind spindle full sensor activates, the Paper/Ribbon LED flashes, and printing pauses.
Use the following steps to remove the liner.
Note • You do not need to turn the printer Off (O) for this procedure.
1.
Unwind about 24 in (61 cm). of liner from the liner rewind spindle and cut it off at the
spindle.
2.
Pull out the hold down hook and slide the liner off of the spindle and discard.
3.
Feed the new starting edge of the liner through the mechanism and attach it to the
liner rewind spindle as described in “Peel-Off Mode Media Loading” on page 2-9.
4.
While holding the media in position against the tear-off/peel-off plate, open and
close the printhead without disturbing the media position. The printer is now ready
to print more labels.
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Refer to Figure 2-8. When the printer is turned On (l), it performs a self test and
configures its operating characteristics. Some of these characteristics are determined by
the position of the media sensor.
The media sensor assembly consists of two sections. The media passes between a
stationary light source and a movable light sensor. The light source is positioned below
the media, while the light sensor is above the media.
Media Sensor Adjustment for Non-Continuous Media
This type of media has some type of physical characteristic (web, notch, perforation, etc.)
that indicates the start or end of each label.
Page 2-10
1.
Turn the head-open lever counterclockwise to the OPEN position and raise the
printhead.
2.
Look through the front of the print mechanism and locate the media sensor
adjustment lever.
3.
Reposition the sensor until the top of the adjustment lever is in line with the notch in
the media.
4.
Close the head-open lever.
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Media Sensor Adjustment for Continuous Media
Continuous media does not contain label start or end indicators. You must tell the printer,
through the software, the length of each label. If you are using ZPL or ZPL II, include a
Label Length (^LL) instruction in each label format you send to the printer. Refer to your
ZPL II Programming Guide or instructions provided with your software driver.
Note • When using continuous media, position the Media Sensor anywhere over the
media so an “Out-of-Media” condition can still be sensed.
Media Sensor
Adjustment Lever
Media Guide
Figure 2-8. Media Sensor Adjustment
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Note • Do not load ribbon if the printer is to be used in direct thermal mode.
Caution:
Do not use ribbon that is narrower than the media. Premature printhead failure may
result due to excessive abrasion caused by thermal transfer media.
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The S400/S600 comes with a dual-tension ribbon supply spindle to provide the
appropriate amount of tension on the ribbon.
Normal Position
Refer to Figure 2-9. In the normal position, the dual-tension ribbon supply spindle
provides the desired amount of ribbon back-tension for different ribbon widths. To place
the spindle in the normal position, firmly pull the spindle end-cap until it clicks into place.
Low-Tension Position
The low-tension position is used in limited applications with ribbons wider than 2.4 in.
(61 mm) to provide lower back-tension. The low-tension position is recommended only
when normal tension hampers ribbon movement. To place the spindle in the low-tension
position, firmly push the spindle end-cap until it clicks into place.
Spindle End-Cap
Extended (normal)
Blades Aligned
Align blades if ribbon width is greater than 2.4 in. (61 mm).
Spindle End-Cap
Retracted (low-tension)
Figure 2-9. Dual-Tension Ribbon Supply Spindle Adjustment
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Notes • For the direct thermal print method, ribbon is not used and should not be
loaded in the printer when performing media calibration.
Use ribbon that is wider than the media. The smooth liner of the ribbon protects the
printhead from wear and premature failure due to excessive abrasion.
Refer to Figure 2-10.
1.
Adjust the ribbon supply spindle position for normal or low tension refer to
“Adjusting the Ribbon Supply Spindle” on page 2-12.
Note • Step 2 can be skipped if the ribbon width is 2.4 in. (61 mm) or less.
2.
Align the blades on the two sections of the spindle as shown in Figure 2-9.
3.
Place the ribbon roll on the ribbon supply spindle so the ribbon unwinds toward the
front of the printer from under the roll. Ensure the core is pushed against the stop
and the ribbon is aligned squarely with the core.
4.
Open the printhead assembly by turning the head-open lever counterclockwise to
the OPEN position.
5.
Thread the ribbon as shown in Figure 2-10. Do not to crease or wrinkle the ribbon.
Wind the ribbon onto the ribbon take-up spindle for several turns in a clockwise
direction.
6.
Close the printhead assembly by turning the head-open lever clockwise to the
CLOSED position.
Upper Ribbon
Guide Arm
Head-Open
Lever
Ribbon Release
Button
Ribbon
Supply
OPEN
CLOSED
Figure 2-10. Ribbon Loading Diagram
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Refer to Figure 2-10.
1.
Cut the ribbon between the upper ribbon guide roller and the ribbon take-up spindle.
2.
Press the ribbon release button and slide the ribbon off of the ribbon take-up
spindle.
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3.
Turn the printer Off (O).
4.
Determine whether you are using a parallel data cable or serial data cable.
5.
Follow your computer manufacturer’s instructions for installing data cables to the
computer. You may need to turn off the computer before making any cable
connections.
6.
Refer to Figure 2-2 on page 2-4. Connect the printer data cable from the computer
to the proper port on the rear of the printer.
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A Power-On Self Test is performed automatically each time the printer is turned on. This
test checks for proper initialization of various electronic circuits and establishes starting
parameters as those stored in the printer’s memory. During this test sequence, the front
panel LEDs turn on and off to ensure proper operation. Once completed, only the Power
LED remains on. If other LEDs are on, refer to “Troubleshooting” on page 3-1.
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These tests produce sample labels and provide specific information that helps the
operator determine the operating conditions for the printer.
Each self test is enabled by pressing and holding in a specific key while turning the power
switch On (l). Press the key until the front panel LEDs turn on. When the Power-On Self
Test is complete, the selected printer self test automatically starts.
Notes • When performing self tests (except for the Mode Key Self Test), disconnect
the printer data cable from the printer.
Use full-width media when performing self tests. Labels less than full width lose printing
on the right side. Printing may run on to the next label when using short labels.
When canceling a self test before its completion, turn the printer power switch Off (O)
and back On (l).
When performing the self tests in Peel-Off Mode, remove the labels as they become
available.
When the cutter option is installed and enabled, labels printed during the self test are
automatically cut as they are printed.
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Table 2-1 lists the self tests and default resets that can be accessed by pressing and
holding a front panel key or keys and turning power on. The “X” in the four columns on the
right indicates which key or keys are pressed.
The indicates that the self test is one that can be performed by the operator or
maintenance personnel. These tests produce sample labels and provide specific
information that helps the operator or maintenance personnel determine operating
conditions for the printer. Self tests without the are for repair and maintenance of the
printer and should be performed only by maintenance personnel.
Detailed information on the operator self tests immediately follows this chart. Detailed
information on maintenance personnel-only self tests are found in “Preventive and
Corrective Maintenance” on page 4-1 along with extended diagnostics.
Note • The printer data cable must be removed from the printer (except for the Mode
Key Self Test) prior to running the self tests.
Table 2-1. Self Test and Calibration Quick Reference Chart
Operator
Description
Pause Feed
3
Cancel Key Self Test — Produces a printer
configuration label printout
3
Pause Key Self Test — Produces test
printouts for adjustments (15 or 50 labels
@ 2 or 6 ips)
3
Feed Key Self Test — Produces test
printouts to determine the best darkness
setting
3
Mode Key Self Test — Produces a
Communications Diagnostic Mode printout
3
Factory Default Reset — Resets printer
configuration to factory default values
X
X
3
Communication Parameter Default Reset
— Resets printer communication
parameters to 9600 baud, 8 bit work length,
no parity, and 1 stop bit
X
X
3
Manual Calibration — Determines media
type, label length, media and ribbon sensor
settings, and printing method
X
X
Pause and Cancel Key Self Test —
Serialized test printouts that verify proper
printer operation (500 maximum)
X
Ribbon Parameter Calibration — Sets
ribbon parameters to factory default values.
Cancel
Mode
X
X
X
X
X
X
X
X
X
X
Note • This test is performed only when sensor assemblies are replaced or when a
manual calibration fails. A Manual Calibration must be performed after the Ribbon
Parameter Calibration.
Feed and Cancel Key Self Test —
Preprograms label test formats for major
overhauls
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Refer to Figure 2-11. This self test prints a listing of the printer’s configuration parameters
stored in configuration (EEPROM) memory.
Configuration can be changed temporarily (for specific label formats or ribbon and label
stock) or permanently (by saving the new parameters in memory). Saving new
parameters occurs whenever a printer configuration procedure is performed.
To start the Cancel Key Self Test, press CANCEL while turning the power on. The printer
first runs through a Power-On Self Test, then prints the configuration label.
Figure 2-11. Cancel Key Self Test Printout (Configuration Label)
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Refer to Figure 2-12.
This self test can be used to provide the test labels for making adjustments to the printer’s
mechanical assemblies and Configuration Mode adjustments.
To start the Pause Key Self Test, press and hold PAUSE while turning the power On (l).
This self test consists of four individual test features:
•
The initial self test prints 15 labels at 2 in. (50.8 mm) per second (ips) (speed A),
then automatically pauses the printer. Each time PAUSE is pressed, an additional
15 labels print, up to a maximum of 9999 labels.
•
While the printer is paused, pressing CANCEL once alters the self test. Now each
time PAUSE is pressed, 15 labels print at 6 ips (152.4 mm) (speed D), up to a
maximum of 9999 labels.
•
While the printer is paused, pressing CANCEL a second time alters the self test
again. Now each time PAUSE is pressed, 50 labels print at 2 ips (50.8 mm), up to
a maximum of 9999 labels.
•
While the printer is paused, pressing CANCEL a third time alters the self test
again. Now each time PAUSE is pressed, 50 labels print at 6 ips (152.4 mm), up to
a maximum of 9999 labels.
Figure 2-12. Pause Key Self Test Printout
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The results of this self test determine the best darkness setting for a specific media and
ribbon combination.
Refer to Figure 2-13.
The Feed Key Self Test prints a series of labels at various plus or minus darkness
settings relative to the current darkness setting. The operator inspects these printouts
and determines which printout has the best darkness setting. The value next to Relative
Darkness on the printout is added to (+) or subtracted from (–) the current darkness
value.
The following procedure sets the darkness of the printing on the label. To start the Feed
Key Self Test, press and hold FEED while turning the power On (l).
Note • To maximize the life of the printhead, use the lowest setting that provides the
necessary print quality.
1.
Press MODE. The pause and darken LEDs turn on.
2.
If the Feed Key Self Test produces a positive value, press FEED (V) the number of
times indicated on the printout.
Example • If the best label has Relative Darkness: 3, press FEED three times.
3.
If the value on the Feed Key Self Test printout is a negative value, press CANCEL
(W) the number of times indicated on the printout.
Example • If the best label has Relative Darkness: –2, press CANCEL twice.
4.
Press MODE three times. The mode LEDs flash to indicate the settings have been
saved to memory.
5.
Press PAUSE to exit Pause Mode and turn off the pause LED.
Positive value:
Press FEED (s)
3 times during
darkness adjustment.
Negative value:
Press CANCEL (t)
2 times during
darkness adjustment.
Figure 2-13. Feed Key Self Test Printout
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Note • The printer data cable must be connected to the host computer during this self
test.
Refer to Figure 2-14. This self test places the printer in a Communications Diagnostics
Mode, in which the printer prints the ASCII characters and their corresponding
hexadecimal values for any data received from the host computer.
To start the Mode Key Self Test, press and hold MODE while turning the power On (l).
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If it is ever necessary to return the printer configuration to factory default values, press
FEED and PAUSE at the same time while turning the power On (l). The default values
remain active until the power is turned off. To save the default values in memory, press
MODE four times. The darken, position, and calibrate LEDs cycle on and then off,
indicating the values have been saved. Refer to Table 2-2 for a list of factory default
values.
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To reset the communication parameters only, press and hold FEED, PAUSE, and MODE
while turning the power On (l). The communication parameters are reset to 9600 baud,
8 bit work length, no parity, and 1 stop bit.
To make these settings permanent, press MODE four times. The darken, position, and
calibrate LEDs flash, indicating the changes have been saved. To return to Printing Mode,
turn the power off then on.
Figure 2-14. Mode Key Self Test Printout
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Table 2-2. Factory Default Values
Parameter
Page 2-20
Default Value
Backfeed
Default
Baud
9600
Calibration
Auto
Darkness
10
Data Bits
8 bits/character
Error Detection
On
Handshake
XON/XOFF
Head Close
Calibration
Label Top
00
Left Position
000
Media Type
Non-Continuous Web Sensing
Parallel Port
Enabled
Parity
None
Print Method
Thermal Transfer
Print Mode
Tear-Off
Print Width
104 mm
ZPL Control Prefix
7E
ZPL Delimiter Char
2C
ZPL Format Prefix
5E
ZPL Mode
ZPL II
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Auto calibration occurs when the printer is turned On (l) or when the printhead is opened
and closed (with the printer turned on). During the procedure, the printer automatically
determines the media type, label length, media and ribbon sensor settings, and printing
method (direct thermal or thermal transfer). The procedure is set at the factory but may be
changed via ZPL II command.
Note • If the printer fails to auto calibrate when you are using preprinted labels or
preprinted liner, or if the printer does not auto calibrate at all, refer to
“Manual Calibration” on page 2-22.
1.
Load the media and ribbon.
2.
Turn the printer On (l).
3.
Several blank labels feed, completing the auto calibration procedure.
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Important • Perform manual calibration when using preprinted media, when in
Manual Calibration Mode, or if auto calibrate does not work.
During this procedure, the printer determines the media type, label length, media and
ribbon sensor settings, and printing method. Media type is determined by sensing either
continuous or non-continuous media as blank labels move through the printer. If noncontinuous media is sensed, label length is also calibrated. If ribbon is sensed, the
thermal transfer print method is configured. If ribbon is not sensed, the direct thermal print
method is configured.
The results of the calibration are stored in the printer’s memory and are retained even if
power is removed. These parameters remain in effect until the next calibration is
performed.
Notes • Perform this procedure only once to put the printer into manual calibration.
After that, press MODE three times and FEED once when changing media (a label
prints showing the sensor profile).
If the printer is in Peel-Off Mode, the operator must catch the labels as they peel away
from the liner.
1.
Turn printer power Off (O).
2.
Place the head-open lever in the OPEN position.
3.
Remove the ribbon.
4.
Remove approximately six labels from the media roll, enough so only the liner is
threaded under the media sensor.
5.
Reload the media.
6.
Press and hold PAUSE, FEED, and CANCEL.
7.
Turn the power switch On (l).
8.
After the calibrate LED goes out, release PAUSE, FEED, and CANCEL.
9.
When the printhead LED flashes, reload the ribbon.
10.
Ensure the media sensor is properly positioned.
11.
Close the printhead.
12.
A media and ribbon sensor profile prints.
Note • To return to auto calibration, press and hold PAUSE, CANCEL, and MODE
when you turn the printer on.
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Note • Perform this procedure only if the manual calibration fails or if sensor
assemblies are replaced. A manual calibration must be performed after the ribbon
parameter calibration.
To set the ribbon parameter to factory default values:
1.
Turn the printer Off (O).
2.
Open the printhead and remove the ribbon.
3.
Press and hold FEED, CANCEL, and MODE while turning the power On (l).
4.
After the printhead LED has flashed, load the ribbon.
5.
Close the printhead.
6.
Press MODE 4 times to save parameters.
Note • A label automatically prints, showing the ribbon sensor profile.
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Configuration Mode allows you to fine-tune the internal printer configuration settings for
your application. In this mode, you can change the following parameters:
•
Printer darkness.
•
Rest position of the media with respect to the web or inter-label gap.
•
Position of printing relative to the top of the label.
•
Media and ribbon sensor values.
•
Label length.
•
Printing method.
•
Media type (continuous or non-continuous).
Create a printout of the printer configuration by performing the Cancel Key Self Test.
To set the printer configuration to factory defaults, refer to “Feed and Pause Key Factory
Default Reset” on page 2-19.
The ZPL II Programming Guide contains information on instructions that may be sent to
the printer to disable the Mode key and set specific label format values for each of these
parameters. If you are not using ZPL II, refer to the instructions provided with your
software to determine whether it allows you to change these parameters.
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Differences in types of media, ribbon, and the wear on thermal printhead elements may
make it necessary to adjust the print darkness setting to achieve proper printing.
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First, it is a good idea to print out a configuration label to check the existing darkness
setting. Also, once the ideal parameters for a particular media and ribbon combination
have been determined, you can print a configuration label and save it for future reference.
To get a configuration label, you can print a Cancel Key Self Test.
Refer to Figure 2-11 on page 2-16. To start the Cancel Key Self Test, press and hold
CANCEL while turning the printer On (l). The printer runs through a Power-On Self Test,
then prints the configuration label.
The first item on the configuration label is the darkness setting. It is displayed as a
number between 0 and 30. The sample shown in Figure 2-11 on page 2-16 lists as
darkness setting of 20. The factory default for this value is 10.
If you already know the darkness setting for a particular combination of media and ribbon,
you may skip to “Adjusting the Printer Darkness” on page 2-26.
Note • Use full width media when performing the self tests. Labels less than full width
lose printing on the right side. Printing may run on to the next label when using short
labels.
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Refer to Figure 2-11 on page 2-16.
The Feed Key Self Test prints a series of labels at various plus or minus darkness
settings relative to the current darkness setting and at various print speeds. Inspect these
printouts to determine which printout has the best darkness setting. The value next to
Relative Darkness: on the printout is added to (+) or subtracted from (–) the current
darkness value. If the label with the best appearance has a value of “ØØ,” no adjustments
are necessary.
To start the Feed Key Self Test, press and hold FEED while turning the power On (l). The
printer runs through a Power-On Self Test, then starts printing the Feed Key Self Test
labels. Examine the labels and proceed to “Adjusting the Printer Darkness” on page 2-26.
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Another method of testing print darkness, with a test label that contains a large amount of
printing, is performed with the Pause Key Self Test. First, you must determine how you
want to proceed with the adjustments.
1.
You can run the Pause Key Self Test without knowing your current darkness setting.
You can run the test, examine the labels, and then perform the procedure “Adjusting
the Printer Darkness” on page 2-26 using your best guess as to how far to increase
or decrease the setting to the optimal setting.
2.
You can set the darkness to the factory default value or anything you wish, then run
the Pause Key Self Test, and then perform the procedure “Adjusting the Printer
Darkness” on page 2-26.
To Set Darkness Setting Manually
1.
Press MODE. The pause and darken LEDs come on.
2.
Press and release CANCEL (W) to decrease the setting, each time waiting for the
darken LED to flash once before pressing again. Continue to press CANCEL (W)
until the LED does not flash. This means you are at setting “0.”
3.
Press and release FEED (V) to increase the setting, each time waiting for the LED
to flash once before pressing again. Continue to press FEED (V) until you count up
to 10 (factory default) or to your desired setting.
4.
Press MODE three times. The mode LEDs will flash to indicate that the settings
have been saved permanently to memory.
5.
Press PAUSE to resume printing. You are now ready to start the Pause Key Self
Test.
To Start the Pause Key Self Test
Press and hold PAUSE while turning the printer On (l). This self test consists of four
individual test features:
•
The initial self test prints 15 labels at 2 in. (50.8 mm) per second (ips) (speed A),
then automatically pauses the printer. Each time PAUSE is pressed, an additional
15 labels print, up to a maximum of 9999 labels.
•
While the printer is paused, pressing CANCEL once alters the self test. Now each
time PAUSE is pressed,15 labels print at 6 (152.4 mm) ips (speed D) up to a
maximum of 9999 labels.
•
While the printer is paused, pressing CANCEL a second time alters the self test
again. Now each time PAUSE is pressed, 50 labels print at 2 (50.8 mm) ips, up to
a maximum of 9999 labels.
•
While the printer is paused, pressing CANCEL a third time alters the self test
again. Now each time PAUSE is pressed, 50 labels print at 6 (152.4) ips up to a
maximum of 9999 labels.
•
To conserve labels, check the sample labels in tests 1 or 2 of the Pause Key Self
Test. If you are not satisfied with the print darkness quality, proceed to “Adjusting
the Printer Darkness” on page 2-26 and adjust accordingly.
Run test 1 or 2 of the Pause Key Self Test and repeat the procedures if the desired print
darkness is still not achieved.
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Caution:
Set Print Darkness to the lowest setting possible for desired print quality. Darkness set
too high may cause ink smearing, ribbon wrinkle, or ribbon burning.
The following procedure sets the darkness of the printing on the label.
Note • It is not necessary to turn the printer power off to adjust this parameter.
1.
Press MODE. The pause and darken LEDs turn on.
2.
Press FEED (V) to increase or CANCEL (W) to decrease the darkness setting.
Refer to Figure 2-11 on page 2-16.
Example 1 • The configuration label lists a darkness setting 20. You know your media
and ribbon combination should be 15. Press CANCEL (W) five times.
Refer to Figure 2-13.
Example 2 • After running the Feed Key Self Test, you have determined that the label
that looks the best has a relative darkness of 03. Press FEED (V) three times.
Example 3 • After manually resetting the darkness to the factory default of 10, you run
the Pause Key Self Test and determine the labels are too light. Make your best
estimate and press FEED (V) the necessary number of times.
Page 2-26
3.
Press MODE three times. The mode LEDs flash to indicate the settings have been
saved permanently to memory.
4.
Press PAUSE to exit Pause Mode and turn off the pause LED.
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Refer to Figure 2-15.
This procedure sets the end-of-label position relative to the tear-off plate or cutter. The
media stopping position is adjustable in increments of four dot rows at a time. The
possible adjustment range is ± 80 dot rows or a distance of 0.392 in. (10 mm) up or down
from the center. Adjust if the label is not being torn or cut at the correct position.
1.
Press MODE twice. The pause and position LEDs turn on.
2.
To adjust the label position, press FEED (V) to move the label forward (out of the
printer) or CANCEL (W) to move the label back (into the printer).
3.
Press MODE twice. The mode LEDs flash to indicate that the settings have been
saved to memory.
4.
Press PAUSE to exit Pause Mode and turn off the pause LED.
Nominal factory-set
tear line location,
usually 00.
Label Motion
Figure 2-15. Tear-Off Position Adjustment
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This procedure positions the printing on the label relative to the top edge of the label.
Adjust if the printing is too close or too far away from the top or bottom edge of the label.
1.
Press MODE twice briefly and then press and hold it for approximately five seconds
(until the pause, darken, and calibrate LEDs turn on).
2.
Press FEED (V) to move the printing closer to the top edge or CANCEL (W) to
move away from the top edge. Each press of either of these keys equals eight dot
rows, or approximately 0.0394 in.
3.
Press MODE twice. The mode LEDs will flash to indicate that the settings have
been saved to memory.
4.
Press PAUSE to exit the Pause Mode and turn off the pause LED.
Example • In Figure 2-16, the configuration label printed on the right was printed first.
It was decided to move the print closer to the top edge (in the “–” direction)
approximately 15/32 in. (11 mm).
Notice that the label top line (of the configuration label on the right) has a value of
+012.
Divided 15/32 in. (11 mm) by 0.0394 in. (.925 mm) = 11.89 (round to 12). Press
CANCEL (W) 12 times (completing the adjustment procedures) will give us the
configuration label shown on the left when you print a new configuration label.)
The printed configuration label on the left has a LABEL TOP line value of –084 and the
printing is closer to the top of the label (approximately 15/32 in. (11 mm) from its original
position).
Position of
Print
Label direction out or printer
Figure 2-16. Adjusting the Print of the Top of Label
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If the printing is too light on one side of the label, or if a different thickness of media is
used, the printhead pressure may need to be adjusted to provide the best print quality.
Refer to Figure 2-17 and perform the following procedure:
1.
Begin by performing a Pause Key Self Test.
2.
After printing a few labels, press PAUSE and check the print quality.
3.
If necessary, increase or decrease the toggle pressure using the knurled adjustment
nuts at the top of the toggle shafts.
Example 1 • If printing is acceptable on the left side, but too light on the right,
increase the toggle pressure by turning the right toggle pressure knob clockwise.
Example 2 • If printing is acceptable on the right side, but too dark on the left,
decrease the toggle pressure by turning the left toggle pressure knob
counterclockwise.
4.
Press PAUSE to continue printing and check for proper print quality.
5.
Repeat steps 2 through 4 as needed.
Notes • Using the lowest pressure that produces the desired print quality can extend
printhead life. Do not increase overall head pressure to increase darkness unless the
continued increase of the darkness setting does not provide satisfactory results.
When using narrow media, adjust the toggle pressure knob that is away from the side
frame to zero or the minimum required for acceptable print. This reduces the wear on
those areas of the printhead and the platen where ribbon and media are not present.
Head-Open
Lever
Toggle
Pressure
Knobs
Figure 2-17. Printhead Pressure Adjustment
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Note • The rewind power roller is present only on printers with the Peel-Off Option.
This roller is pre-set during manufacture for proper operation with most applications.
Adjust this roller only when necessary.
In Peel-Off Mode, proper media tracking is critical. The rewind power roller automatically
turns along with the movement of media to ensure continuous rewind of the liner. When
adjusting this roller, the operating position may vary due to the type, width, and thickness
of the liner.
Before performing this adjustment, review the procedures in
“Media Loading” on page 2-6. Ensure minimal sideways movement during the printing
process by positioning the left edge of the liner even with the edge guide mark on the
tear-off/peel-off plate. Position the outer media guides against the outside edge of the
media, but no so tight as to bind the material.
When the rewind power roller is properly adjusted, the liner should have even tension
across its entire width and be wrapped snugly around all guides and rollers. If the tension
is not even, the liner may slide (walk) to the left or the right as printing occurs. This can
cause print registration problems on the labels.
Note • Balancing the tension increases the reliability of the printer to provide properly
printed labels by preventing the liner from walking.
Adjusting the Rewind Power Roller
1.
Refer to Figure 2-18. Locate the power roller adjustment screw.
2.
Use a screwdriver to turn the power roller adjustment screw counterclockwise to
increase the tension on the right side of the rewind power roller. Turn the power
roller adjustment screw clockwise to decrease the tension on the right side of the
rewind power roller.
Note • The adjustment changes the position of the right end of the rewind power roller
only. The left end remains stationary.
3.
Use the Feed Key Self Test to print several labels to ensure tracking is maintained
and tension on both edges of the liner remains consistent. Remember to remove
each label as it is automatically peeled away from the liner.
Example 1 • Figure 2-18 illustrates an improperly adjusted rewind power roller. On
the left side, the liner is not contacting the rewind power roller. This is because the liner
has more tension on the right edge than on the left.
By turning the power roller adjustment screw clockwise, the tension in the right side
decreases. Adjust screw until the tension is equal on the left and right sides of the
rewind power roller and the liner tracking is maintained.
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Edge
Guide
Mark
Power
Roller
Adjustment
Up
Liner
Down
Rewind
Power
Roller
Figure 2-18. Liner Rewind Power Roller
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Consult the following charts when troubleshooting the printer.
/LVWRI7DEOHV
Table 3-1. LED Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table 3-2. Troubleshooting Chart (Problems with LED Indications) . . . . . . . . . . . . . . . 3-3
Table 3-3. Troubleshooting Chart (Print or Print Quality Related Problems) . . . . . . . . . 3-6
Table 3-4. Troubleshooting Chart (Wrinkled Ribbon) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Table 3-5. Troubleshooting Chart (Jammed or Stuck Labels) . . . . . . . . . . . . . . . . . . . . 3-8
Table 3-6. Troubleshooting Chart (Settings or Parameter Related) . . . . . . . . . . . . . . . 3-9
Table 3-7. Troubleshooting Chart (Cutter Related) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Table 3-8. Explanation of Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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Table 3-1 is a quick reference troubleshooting chart based on the status of the LEDs after
the Power-On Self Test has been completed (or attempts to complete) or during printer
operation. Using the legend at the bottom of the table, match the LED condition of the
printer to the chart. The rightmost column refers to possible solutions found in
“Troubleshooting Chart (Problems with LED Indications)” on page 3-3.
Table 3-1. LED Quick Reference Chart
Power
Printhead
Paper/
Ribbon
Pause
Data
Darken
Position
Calibrate
Refer to
Table 3-2
Item #
1
=
=
=
=
=
=
=
=
2
=
3
=
=
=
=
=
=
=
4
=
=
=
=
=
=
5
=
=
=
=
=
6
=
=
=
=
7
=
=
=
8
=
=
=
9
=
)
=
10
=
F
=
11
=
=
=
12
=
=
13
=
=
14
=
F
15
=
SF
16
=
F
17
=
SLF
18
=
AF
AF
19
= LED Off
Z= LED On
Page 3-2
AF = Alternate Flashing
F = Flashing
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SF = Single Flash
SLF = Slow Flashing
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Table 3-2 lists a number of problems or conditions that may be encountered with the
printer. These condition or problems generally have LED indications as listed in Table 3-1,
“LED Quick Reference Chart” on page 3-2.
Table 3-2. Troubleshooting Chart (Problems with LED Indications)
#
1
2
3
Symptom
No LEDs turn on.
All LEDs turn on and stay
on and printer locks up
while running Power-On
Self Test.
Power LED on and all
other LEDs off. No printer
operation possible.
Diagnosis
Action
No AC power applied to
the printer.
Ensure AC power cable is
connected to a working voltage
source.
Faulty AC power fuse.
Replace fuse.
No voltage from the power
supply.
Replace power supply.
An improper configuration
was set.
Reload factory defaults and then
set correct parameters.
Main logic board faulty or
loose interconnecting
cables.
Ensure cables are properly
connected. Replace main logic
board.
Printer misconfigured for
peel-off mode or peel-off
option not installed
If peel-off option is installed,
check take-label sensor.
If peel-off option is not installed,
check printer configuration and
ensure peel-off mode is not
selected.
Main logic board faulty or
loose interconnecting
cables
Ensure cables are properly
connected. Replace main logic
board.
4
Calibrate LED turns off
after 5 seconds but all
other LEDs stay on.
Boot block error.
Download new boot block and
firmware. Replace main logic
board.
5
Calibrate and position
LEDs off but all other
LEDs on.
Dynamic RAM failed.
Replace main logic board.
6
Calibrate, position, and
darken LEDs off but all
other LEDs on.
Firmware decompression
error.
Download and install firmware.
7
Calibrate, position,
darken, and data LEDs off
but all other LEDs on.
Firmware error.
Download and install firmware.
8
Calibrate, position,
darken, data, and pause
LEDs off but all other
LEDs on.
Firmware error.
Download and install firmware.
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Table 3-2. Troubleshooting Chart (Problems with LED Indications) (Cont.)
#
9
10
11
12
Symptom
Diagnosis
Printer stops, pause and
paper/ribbon LEDs both
on.
Printer stops, pause LED
on and paper/ribbon LED
flashing.
Printer stops, pause LED
on and printhead LED
flashes.
Printer stops, pause LED
and printhead LED on.
Media incorrectly loaded
or not loaded.
Load media correctly, then turn
printer off and on.
Cutter error.
Clear jam, then open and close
printhead.
Calibration error.
Recalibrate printer.
Misadjusted media
sensor.
Check position and sensitivity
media sensor.
Ribbon incorrectly loaded
or not loaded.
Reload ribbon correctly, then turn
printer off and on.
Liner rewind spindle is full. Remove liner from spindle.
Ribbon not calibrated.
Recalibrate the ribbon.
Malfunctioning ribbon
sensor.
Replace ribbon sensor.
Printhead not fully closed.
Close printhead completely.
Printhead-open sensor
not detecting flag or flag
not in proper position.
Check head-open sensor and
flag for proper operation.
Printhead element
overheated.
Printer resumes printing when
printhead element cools.
Power supply
over-temperature.
Printer resumes printing when
power supply cools.
PAUSE was accidentally
or intentionally pushed.
Press PAUSE to resume
operation.
Not enough memory to:
1. Download graphics.
13
Page 3-4
Printer stops and pause
LED on.
Action
2.
Create bitmap (not
enough memory for
length of label).
3.
Build format (label
too complex).
You may do the following:
1. Check for proper
Communication
Configuration.
2.
With PAUSE on, use the
~HM ZPL II command to
display the amount of free
memory.
3.
With PAUSE on, press
CANCEL to skip that label
format and continue to the
next one.
4.
Cycle power off and on to
clear printer memory and
start again.
14
Printhead LED on but
printing continues.
Printhead is
under-temperature.
Check print quality.
Printhead heats up by printing or
moving printer to a warmer area.
15
Pause LED flashing.
Waiting for user to remove
peeled label.
Remove Label.
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Table 3-2. Troubleshooting Chart (Problems with LED Indications) (Cont.)
#
Symptom
Diagnosis
Action
16
Data LED single flash.
CANCEL key pressed and
a format deleted.
No action required.
17
Data LED flashing.
Printer receiving data.
Printing resumes when data is
received.
18
Data LED flashing slow.
Printer sent a “stop
transmitting” to the host
computer.
No action required.
19
Pause and Data LED
alternately flashing, but all
other LEDs on.
Firmware error.
Download and install firmware.
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Table 3-3. Troubleshooting Chart (Problems with LED Indications)
Symptom
Dots missing in printed
area of label.
Diagnosis
Dirty printhead.
Clean printhead.
Print quality problems.
Check print quality.
Printhead element going
bad.
Replace printhead.
Possible media sensor
problem.
Loss of printing
registration on labels.
Adjust media sensor.
Replace media sensor.
Printer set for noncontinuous media, but
Set printer for correct media.
continuous media loaded.
Loss of printing
registration on labels (for
Peel-Off Mode).
Improperly adjusted
media edge guides or
power roller.
Check edge guides and power roller.
Adjust as necessary.
Vertical drift in top-of-form
registration.
Incorrect media loading
or media sensor
adjustments.
Reload media or adjust sensors as
necessary.
Dirty printhead or ribbon
rollers.
Clean printhead and ribbon rollers.
Defective printhead
elements.
Replace printhead.
Light vertical lines
approximately 0.006"
(0.15 mm) wide running
through all labels
Light printing or no
printing on left or right
side of label.
Printhead pressure needs
Perform printhead balance adjustments.
balancing.
Short printed lines at 45°
to label edge on left or
right side of label.
Too much printhead
pressure.
Reduce toggle pressure.
Media or ribbon
improperly loaded.
Reload media or ribbon.
Incorrect media sensor
position or sensitivity.
Adjust media sensor.
Wrinkled ribbon.
See “Troubleshooting Chart
(Wrinkled Ribbon)” on page 3-8.
Media pulled when motor
not moving.
Open and close printhead so it
calibrates to find label length.
Incorrect media sensor
position or sensitivity.
Adjust media sensor.
Auto-calibrate failed.
Perform manual calibration.
Too much back tension
on ribbon.
Adjust dual-tension ribbon supply
spindle to provide low tension by
pushing in spindle end-cap.
Truncated print, no print,
or FEED operates
incorrectly while using
non-continuous media.
Fine gray lines on blank
labels at angles.
Misregistration and
misprint of one to three
labels.
When using ribbon wider
than 2.4" (61 mm), image
gets lighter or smears
near end of roll of ribbon.
Ribbon appears to slow
down or stop.
Page 3-6
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Table 3-3. Troubleshooting Chart (Problems with LED Indications) (Cont.)
Symptom
Poor print quality.
Misregistration/skips
labels.
Printing across web or in
wrong position.
Long tracks of missing
print on several labels.
44895L Rev. 3 3/15/04
Diagnosis
Action
Darkness too low.
Increase print darkness.
Incorrect media and
ribbon combination.
Replace media or ribbon.
Printhead adjustments
incorrect.
Perform required adjustments.
Misadjusted media
sensors.
Perform media sensor adjustments. Also
try recalibrating.
Improper ZPL format.
Correct ZPL format.
Loss of registration,
indicating media sensor
problem.
Adjust media sensor position.
Adjust media sensor sensitivity.
Printer set for continuous
media, but nonSet printer for correct type of media.
continuous media loaded.
Peel-Off Mode:
Improperly adjusted
media edge guides or
power roller.
Reposition and adjust as necessary.
Wrinkled ribbon.
See “Troubleshooting Chart
(Wrinkled Ribbon)” on page 3-8.
Print element damaged.
Replace printhead.
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Table 3-4. Troubleshooting Chart (Wrinkled Ribbon)
Symptom
Diagnosis
Action
Ribbon fed through printer
Load ribbon correctly.
incorrectly.
Wrinkled ribbon.
Incorrect darkness setting.
Set darkness to lowest setting possible
for good print quality.
Incorrect printhead
pressure or balance.
Set pressure to minimum needed.
Media not feeding
properly. Media walking
side to side.
Make sure media is running parallel to
main frame with balance adjustment.
Incorrect dual-tension
spindle setting.
Pull spindle end cap out when using wide
media to obtain normal (higher) tension.
Strip plate needs
adjusting.
Perform adjustments.
Ribbon supply spindle
tension needs adjusting.
Perform adjustments.
Printhead needs
realigning with platen
roller.
Perform adjustments.
Ribbon take-up spindle
tension needs adjusting.
Perform adjustments.
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Table 3-5. Troubleshooting Chart (Jammed or Stuck Labels)
Symptom
Diagnosis
Action
In Peel-Off Mode, skewed
or stuck labels.
Label adhesive material
causing media movement
problems.
Perform maintenance and clean printer.
Media and liner not
Reload media. Adjust
properly aligned in printer. power roller.
Upper media plate needs
cleaning.
Page 3-8
Label jam in rear area of printhead.
Remove jam and clean
upper media plate.
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Table 3-6. Troubleshooting Chart (Settings or Parameter-Related)
Symptom
Changes in parameter
settings did not take
effect.
Diagnosis
Parameters set or saved
incorrectly.
Action
Reload factory defaults, calibrate printer,
then cycle power off and on.
If problem continues, may
be a problem with main
Replace main logic board.
logic board.
Communications
parameters incorrect.
Print a configuration label to verify host
computer and printer settings match. If
they do, perform Mode Key Self Test to
check for format or overrun errors.
ZPL sent to printer, but not
recognized. Data LED
Prefix and delimiter
remains off.
Set characters to match ZPL format.
characters set in printer do
If problem continues, check ZPL format
not match ones used in
for changed ^CC, ^CT and ^CD.
ZPL.
Printer does not
successfully auto
calibrate.
Printhead open.
Close printhead.
Preprinted media being
used.
Perform manual calibration.
Media out.
Load media and check media sensor.
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The printer contains several status sensors that indicate conditions by either stopping
printing or turning on an LED.
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Table 3-7. Troubleshooting Chart (Cutter-Related)
Symptom
Diagnosis
In Cutter Mode, skewed or
Dirty cutter.
stuck labels.
The cutter is not cutting
labels cleanly.
Action
Clean cutter module.
Dirty cutter.
Clean cutter.
Dull cutter blades.
Replace cutter module.
Jamming up with labels or Dirty cutter.
labels being cut more than
Label length too short.
once.
Clean cutter.
Increase label length.
Cutter option not
available.
Cutter option installed at the factory.
Noncutter units not retrofittable.
Cutter option not installed
or enabled.
Check cutter configuration.
Labels not being cut at all.
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Table 3-8. Printer Status Sensors
Sensor
Printhead Sensor
What It Monitors
Checks open/closed status of printhead
lever.
How It Works
If printhead is open, printhead
LED flashes.
Checks for proper media loading.
Media Sensor
If printer runs out of media,
If non-continuous media is used, sets label paper/ribbon LED turns on.
length for individual labels.
Ribbon Sensor
Monitors presence of ribbon.
Label-Available
Sensor (Peel-Off
option only)
Once a label prints, it passes
between the two parts of this
In Peel-Off Mode, checks to see whether a
sensor and causes printer to
label is available.
pause. When label is removed,
printing resumes.
If printer runs out of ribbon,
paper/ribbon LED flashes.
Liner Rewind
Spindle Full Sensor Senses when liner rewind spindle is full of When spindle is full, paper/
(Peel-Off option
used liner.
ribbon LED flashes.
only)
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Should you encounter any problem that cannot be corrected with the aid of this manual,
and you have Internet access, check out ZIP Support. If you cannot solve your problem
via ZIP Support or do not have Internet access, contact your Distributor or
Zebra Technologies Technical Support Department to minimize or avoid printer
downtime.
=,36XSSRUW
•
Can identify, diagnose, and resolve your questions in one brief, easy, online
session.
•
ZIP Support is updated regularly by Zebra product experts, guaranteeing the most
comprehensive, timely product information available.
•
High-speed, accurate, intuitive database uses text and graphics.
•
Available any time, all time zones, 24 hours a day, 365 days a year.
Access ZIP Support at http://support.zebra.com.
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Zebra Technologies, USA
Zebra Technologies Europe Limited, UK
Phone: +1 847.793.2259
Phone: +44 (0) 1494 536644
Fax:
Fax:
+1 847.913.2578
+44 (0) 1494 450103
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For in-factory service and repair:
Zebra Technologies, USA
Zebra Technologies Europe Limited, UK
Phone: +1 847.913.2259
Phone: +44 (0) 1494 472872
Fax:
+1 847.913.2578
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A Return Materials Authorization (RMA) number is required for all equipment being
returned. Contact Zebra Technologies Technical Support Department to obtain an RMA
number. Equipment returned for service without prior authorization may be refused.
Whenever possible, the original shipping container should be used. Should it become
necessary to ship your printer, carefully pack the printer in a suitable container to avoid
damage during transit. A note describing the failure must be enclosed with the unit.
Replacement shipping containers can be ordered by contacting Zebra Technologies
Technical Support Department.
If other containers are used, packaging material similar to the original factory packaging
should be used. Remove all media from the printer. Enclose the unit in a protective,
dustproof bag and ensure that the unit floats in an outer carton of shock-absorbing
material.
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Maintenance for the Zebra Stripe S400 and S600 thermal transfer demand printers can
be divided into two basic categories:
•
Preventive Maintenance procedures and operator care instructions. These
procedures may be performed by the operator as well as the service technician
and should be performed on a regular basis. Preventive maintenance consists of
a visual inspection and general cleaning of the interior and exterior of the printer,
as well as cleaning the printhead and the associated media and ribbon paths.
•
Corrective Maintenance provides the service technician detailed steps for
resolving faults by adjusting or replacing components or modules.
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After reviewing each procedure, place a check in the box.
o
The AC power plug and IEC 320 connectors on all Zebra Printers must bear
the certification mark of at least one international safety organization listed
below.
+
R
Page 4-2
o
Unless indicated otherwise, turn the power Off (O) before performing any
maintenance procedures to the printer.
o
To prevent damage to the spindles, do not lubricate the S400™ and S600™
printer spindle assemblies.
o
To prolong printhead life, when reinstalling the printhead, secure the
grounding strap to the printhead mounting screw.
o
Zebra printers comply with international regulations governing radiated
emissions when using fully shielded data cables. Data cables must be fully
shielded and fitted with metal or metalized connector shells. Required
shielded data cables and connectors prevent radiation and reception of
electrical noise. Use of unshielded data cables may increase radiated
emissions above the regulated limits.
S400/S600 Maintenance Manual
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To ensure optimum printhead life, observe proper electrostatic safety
precautions (for example; ESD, Electrostatic Service Device, wrist straps)
when removing, handling, and replacing the printhead.
o
Zebra recommends using solvent containing 90% isopropyl alcohol and 10%
distilled water for cleaning:
•
Printheads
•
Platen Rollers
•
Peel-Off Roller
•
Media Path
•
Peel/Tear Bar
•
Spindles
o
Ribbons used in the printers must be as wide as or wider than the media. If the
ribbon is narrower than the media, areas of the printhead will be unprotected
and subject to premature wear.
o
To ensure the printer has proper ventilation and cooling, do not place any
padding or cushioning material under the unit because this restricts air flow.
o
Install Zebra printers on a solid, level surface of sufficient size and strength to
accommodate the physical dimensions and weight of the unit. The area
enclosure in which the printer will operate must meet the environmental
conditions specified in the maintenance manual or User’s Guide. Electrical
power must be available and in close proximity to the printer.
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Page 4-4
o
Do not wear any jewelry (rings, watches, etc.) and loose clothing when
servicing the printers.
o
Beware of “Pinch Points” on the printers. Be especially careful of:
•
Opening and closing covers
•
Printhead
•
Rewind Spindle
•
Platen Roller
o
Wear protective eye wear when removing E-Rings, C-Clips, and springs.
o
For personal and equipment safety, use a three-prong plug with a ground
(earth) connection.
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Caution:
Use only the cleaning agents described in the following procedures. Damage can occur
if the incorrect cleaning agents are used on this printer.
Exterior – Clean the exterior surfaces of the printer as required by using a lint free cloth.
Do not use solvents or harsh cleaning agents. If the unit is excessively dirty, a mild
detergent solution or desktop cleaner may be used sparingly.
Interior – As required, remove any dirt/lint accumulated in the interior of the printer by
using a softbristle brush, dry compressed air, or vacuum cleaner. It is a good practice to
inspect these areas with each media change.
Media and Ribbon Paths – Clean with a solution of 90% isopropyl alcohol and 10%
distilled water. No other cleaning fluids or sprays should be used.
Table 4-1 lists a recommended cleaning schedule showing the area, method, and interval
for cleaning the printer. Actual schedule should be adjusted based on volume of labels
printed and environmental conditions where the printer is located.
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Table 4-1. Recommended Cleaning Schedule
AREA
METHOD
Printhead
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Platen Roller
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Media Sensor
Air blow.
Media Path
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Ribbon Path
Air blow.
Rewind Power Roller (Peel-Off)
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Upper Guide Rod (Peel-Off)
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Platen Guide Rod (Peel-Off)
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Lower Guide Rod (Peel-Off)
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
INTERVAL
After every roll of media
or 500 feet (150 m) of
fanfold media) when in
direct thermal mode.
After every roll of ribbon
when printing in thermal
transfer mode.
Cutter Assembly – If using
continuous pressure-sensitive
media.
Citrus-based adhesive remover.
After every roll of media
or more often
depending on
application and media.
Cutter Assembly – If using tag
stock or liner only.
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water. Air blow.
After every 2 or 3 rolls
of media.
Tear-Off/Peel-Off Plate
Clean with a solution of 90% isopropyl alcohol
and 10% distilled water.
Once a month.
Exterior
Mild detergent or desktop cleaner
As needed.
Interior
Air blow/brush/vacuum.
As needed.
Label Available Sensor
Air blow.
6 months/500 rolls
Belts
Visual inspection for wear
6 months/500 rolls
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Inconsistent print quality such as voids in the bar codes or graphics may indicate a dirty
printhead. For optimum performance, the printhead should be cleaned regularly with a
swab soaked in 90% isopropyl alcohol and 10% distilled water. This cleaning procedure is
the best thing you can do to maintain consistent, high quality printing.
Zebra recommends performing the cleaning procedure when installing a new roll of
ribbon, when installing a new roll of direct thermal media, or after having printed 500 feet
(150 m) of continuous or fanfold media.
It is not necessary to turn the power off prior to cleaning. If the power is turned off, all label
formats, images, and parameter settings stored in RAM will be lost. Permanent parameter
settings stored in Flash memory will be retained. When power is turned back on, it may
be necessary to reload some information items into the printer’s memory.
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1.
Refer to Figure 4-1. Open the main door and front door.
2.
Open the printhead by turning the locking lever counterclockwise.
3.
Remove the media and ribbon if present.
4.
Refer to Figure 4-2 on page 4-9. Use a cleaning swab to wipe the print elements
from end to end. Allow a few seconds for the solution to evaporate.
5.
Rotate the platen roller and clean thoroughly with a cleaning swab.
6.
Brush or vacuum any accumulated paper, lint, and dust away from all of the rollers
and the media and ribbon sensors.
7.
Reload the ribbon and/or media. Close and latch the printhead. Close the main and
front doors, and restore power (if previously turned off).
8.
Run the Pause Key Self Test to check print quality.
Main Door
Tab
1
2
Front Door
Figure 4-1. Main Door and Front Door
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Figure 4-2. Printhead Cleaning
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The cutter module is an option available on the S400/S600 that requires periodic cleaning
to remove paper dust and gummed label residue. The following procedure should be
performed, as scheduled in Table 4-1, by the operator. However, depending on the
application and media type, it may be necessary to clean the cutter more or less often.
Note • In figures shown, media, and ribbon have been removed for clarity. It is not
necessary to remove the media or ribbon prior to performing the maintenance
procedures described.
Caution:
Do not exchange cutter modules between different printers. The cutter module
adjustment are optimized during installation to work with a particular printer, and may not
perform correctly if placed on a different printer.
Remove the cutter module from the printer.
1.
Turn the printer’s AC power Off (O).
2.
Refer to Figure 4-3 on page 4-10. Remove the cutter catch tray by lifting it up and
away from the front of the cutter module.
3.
Refer to Figure 4-1 on page 4-8. Raise the main door and lower the front door.
4.
Refer to Figure 4-4 on page 4-10. Gently pull straight down on the cutter cable
connector to remove it from the cutter module.
5.
Turn the cutter mounting screw in a counterclockwise direction until it is loose.
6.
Hold the cutter module as shown in Figure 4-5 on page 4-11. Apply gentle upward
pressure to the left and right ends while raising the cutter module up and away from
the mounting posts. If necessary, rock the cutter module side to side to loosen it.
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Cutter
Module
Label
Catch
Tray
Figure 4-3. Cutter Catch Tray Location
Mounting
Screw
Cutter
Cable
Connector
Figure 4-4. Cutter Connector and Mounting Screw
Page 4-10
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Mounting
Posts
Cutter
Module
Mounting
Slots
Figure 4-5. Cutter Module Removal
Disassembling the Cutter Module
1.
Lay the cutter module on a table or other surface. Hold the cutter module as shown
in Figure 4-6 on page 4-12. Put your thumbs on the two wire spring loops and your
index fingers on the top of the rear cutter blade guard.
2.
To remove the rear cutter blade guard, first press down simultaneously on the two
wire spring loops. While still pressing down on the wire spring loops, press the rear
cutter guard back toward you and over the top of the loops. You are trying to tuck
the wire spring loops under the cutter blade guard.
3.
Continue pressing the rear cutter guard toward you and allow the back edge of the
guard to pop up as it comes free from its holders. You may now remove the rear
cutter guard by lifting it off of the module.
Note • The wire springs may flip up out of position during this process. They will be
repositioned during reassembly.
4.
Observe the ends of the rear cutter blade guard and note the small metal pins
protruding toward the inside. During the reassembly procedure, these pins will be
mounted into the corresponding mounting slots in the cutter side panels.
5.
To provide complete access to the area to be cleaned, raise the upper cutter blade
guard as shown in Figure 4-6 on page 4-12.
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Wire Spring Loop
Upper Cutter
Blade Guard
Rear Cutter
Blade Guard
Wire
Spring
Loop
Figure 4-6. Cutter Module Disassembly
Cleaning the Cutter Module
1.
Remove any label material that has adhered to the cutter parts and use a small
brush to remove any paper dust from the cutter module.
2.
If pressure-sensitive media has been used, use a lint-free cloth soaked in an
adhesive remover to clean all gum and label residue from the cutting blades and
guards.
3.
If tag stock was used, use 90% isopropyl alcohol and 10% distilled water to remove
any dirt.
Reassemble the Cutter Module
1.
Refer to Figure 4-7 on page 4-13. Position the two wire springs down against the
lower cutter blade.
2.
Place the rear cutter blade guard over the wire springs, perpendicular to its final
position. Place your thumbs on the top (flat) part of the guard.
Note • Ensure that the ends of the rear cutter blade guard are positioned on the
outside of the cutter side panels.
3.
Refer to Figure 4-8 on page 4-13. Press the rear cutter blade guard down and
forward, rotating the guard as you proceed, to lock the mounting pins into position in
the cutter side panel mounting slots. Slide the guard forward until the two wire
spring loops pop up on the backside of the guard.
Note • Ensure that the wire springs remain positioned under the rear cutter blade
guard when assembly is completed.
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Lower the upper cutter bade guard back to its normal position. When reassembled,
the back of the cutter module looks like Figure 4-9 on page 4-14.
Upper Cutter
Blade Guard
Wire Spring
Wire
Spring
Figure 4-7. Cutter Module Reassembly
Metal
Pin
Pin
Slot
Rear Cutter
Blade Guard
Rear Cutter
Blade Guard
Wire
Spring
Cutter
Side Panel
Wire
Spring
Loop
Cutter
Side Panel
Figure 4-8. Side View of Cutter Module Reassembly
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Figure 4-9. Reassembled Cutter Module
Reinstall the Cutter Module
1.
Refer to Figure 4-10 on page 4-15. Position the cutter module above the cutter
mounting posts. Press down on the cutter module until the mounting slots engage
the mounting posts on the printer.
2.
Refer to Figure 4-4 on page 4-10. Tighten the mounting screws in a clockwise
direction to hold the cutter module in position.
3.
Position the cutter cable connector so the flat side of the connector faces away from
the printer. Insert the connector up into the mating connector on the cutter module.
4.
Replace the cutter catch tray on to the two mounting slots located on the front of the
cutter module.
Test the Cutter Operation
1.
If necessary, reload ribbon and media into the printer. Close the printer’s front door
and main door.
Note • When loading media, make sure the end of the label is positioned on top of the
platen roller, then close the printhead latch.
Page 4-14
2.
When the printer is turned on, the cutter module will cycle through one cutting
operation and be ready to print labels.
3.
Further tests may be performed by running a Pause Key Self Test.
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Mounting
Posts
Cutter
Module
Mounting
Slots
Figure 4-10. Cutter Module Reinstallation
/XEULFDWLRQ
Caution:
No lubricating agents of any kind should be used on the printer! Some commercially
available lubricants will damage the finish and mechanical parts.
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Table 4-2 lists the self tests and default resets that can be accessed by pressing and
holding a front panel key or keys and turning the power On (l). The “X” in the four columns
on the right indicates which key or keys are pressed.
The indicates whether the self test should be performed by the operator (user) and/or
maintenance personnel. These tests produce sample labels and provide specific
information that helps the operator/maintenance personnel determine the operating
conditions for the printer. self tests without the require special tools or knowledge and
are for repair and maintenance of the printer and only should be performed by
maintenance personnel.
Detailed information on the operator self tests are found in Section II Operations
Overview. Detailed information on maintenance personnel-only self tests immediately
follows.
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Note • The data cable must be removed from the printer (except for the Mode key test)
prior to running the self tests.
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Refer to Figure 4-11. This self test can be used to verify proper printer operation after
parts have been replaced or adjusted. When activated, the printer prints a maximum of
500 head test labels. Each label backfeeds prior to printing and feeds forward to the rest
position after printing. A serialized number prints on each label.
To start the Pause and Cancel Key Self Test, press and hold PAUSE and CANCEL while
turning the power on.
Press PAUSE or turn the power off to stop printing.
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This self test is normally performed during the manufacturing process or after a major
overhaul of the mechanical assemblies. This test prints seven preprogrammed formats at
6 ips and 2 ips. The printer automatically pauses after each format. Table 4-3 shows the
sequence of formats. Refer to Figures 4-12 through 4-18 for sample label formats.
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Table 4-2. Self Test and Calibration Reference Table
Operator
Pause
Key
Description
Cancel Key Self Test – Produces a printer
configuration label printout
Pause Key Self Test – Produces test
printouts for adjustments (15 or 50 labels @
2 or 6 ips)
Feed Key Self Test – Produces test
printouts to determine the best darkness
setting
Mode Key Self Test – Produces a
communications diagnostic mode printout
Feed
Key
Cancel
Key
Mode
Key
X
X
X
X
Factory Default Reset – Resets printer
configuration to factory default values
X
X
Communication Parameter Default Reset
– Resets printer communication parameters
to 9600 baud, 8 bit work length, no parity,
and
1 stop bit.
X
X
Manual Calibration – Printer determines
the media type, label length, media, and
ribbon sensor settings, and printing method.
X
X
Pause and Cancel Key Self Test –
Serialized test printouts verify proper printer
operation (500 maximum)
X
Ribbon Parameter Calibration – Sets
ribbon parameters to factory default values.
X
X
X
X
X
X
Note • This test is performed only when sensor assemblies are replaced or if a manual
calibration fails. A manual calibration procedure must be performed after the ribbon
parameter calibration.
Feed and Cancel Key Self Test –
Preprogrammed label test formats for major
overhauls
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X
Page 4-17
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Table 4-3. Sequence of Formats
Format
# of Labels
Speed
Test Function
Figure
1
20
6 ips (Speed D)
Left Ribbon Wrinkle Test
4-12
2
20
6 ips (Speed D)
Right Ribbon Wrinkle Test
4-13
3
20
6 ips (Speed D)
Bar Code Wrinkle Test (Code – 39)
4-14
4
10
6 ips (Speed D)
Usable Area Test
4-15
5
10
6 ips (Speed D)
Head Temperature Test
4-16
6
10
6 ips (Speed D)
Upper Smear Test
4-17
7
10
6 ips (Speed D)
Lower Smear Test
4-18
8
20
2 ips (Speed A)
Left Ribbon Wrinkle Test
4-12
9
20
2 ips (Speed A)
Right Ribbon Wrinkle Test
4-13
10
20
2 ips (Speed A)
Bar Code Wrinkle Test (Code – 39)
4-14
11
10
2 ips (Speed A)
Usable Area Test
4-15
12
10
2 ips (Speed A)
Head Temperature Test
4-16
13
10
2 ips (Speed A)
Upper Smear Test
4-17
14
10
2 ips (Speed A)
Lower Smear Test
4-18
Figure 4-11. Pause and Cancel Key Label
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Figure 4-12. Test, Formats 1 and 8
Figure 4-13. Test, Formats 2 and 9
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Figure 4-14. Test, Formats 3 and 10
Figure 4-15. Test, Formats 4 and 11
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Figure 4-16. Test, Formats 5 and 12
Figure 4-17. Test, Formats 6 and 13
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Figure 4-18. Test, Formats 7 and 14
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Additional diagnostic tests are available for printhead assembly adjustments. These
diagnostic tests are accessible only when the data cable is disconnected from the printer
and a loopback connector is attached in its place.
The serial loopback connector is a 9-pin “D” Type (DB9P – male) with pins 2 and 3, and
pins 4 and 6 tied together.
The parallel loopback connector is a standard 36-pin parallel connector mounted to a
small printed circuit board. This connector is available from Zebra Technologies as part #
44680.
For each of these diagnostic tests, the printer transmits the test label format out of the
data connector to the loopback connector. The loopback connector passes the test label
format to the printer as received data and the test label is printed.
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This test demonstrates the media movement capabilities of the printer and provides a test
label to view while making print quality adjustments.
With the loopback connector in place, press and hold PAUSE while turning the power On
(l). After the Power-On Self Test, 500 head test labels print. Each label backfeeds prior to
printing and feeds to the rest position after printing. A serialized number prints on each
label. Press PAUSE to stop and restart the printing operation. The labels should look like
the one in Figure 4-11 on page 4-18.
Page 4-22
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This test demonstrates the media movement capabilities of the printer and provides a test
label to view while making print quality adjustments.
With the loopback connector in place, press and hold FEED while turning the power On
(l). After the Power-On Self Test, the printer begins printing the same series of label
formats as shown in Table 4-3. then pauses at the end of each printed format. Press
PAUSE to begin printing the next format. Sample labels are shown in Figures 4-11
through 4-18.
PAUSE can be used to stop and restart the printing operation. When the printer is
paused, CANCEL can be used to move to the next label format.
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1.
Ensure the printer is loaded with full width media and ribbon, and has had a media
calibration performed with this combination of media and ribbon.
2.
Refer to Adjust the two printhead pressure screws for equal pressure.
Head-Open
Lever
Toggle
Pressure
Knobs
Figure 4-19. Printhead Pressure Screws
3.
Turn the printer Off (O).
4.
Remove the cutter module.
5.
Refer to Figure 4-20 on page 4-25. Loosen, but do not remove, the two printhead
position locking screws two full turns, then finger-tighten them.
6.
Perform a Pause Key Self Test by pressing and holding PAUSE while turning the
printer On (l).
7.
When the printer completes its Power-On Self Test, it will begin the Pause Key Self
Test. Once the Pause Key Self Test begins, let several labels print and then press
PAUSE.
8.
Examine the labels and make adjustments as required.
9.
Using a flat-blade screwdriver, adjust the position adjustment slots to change the
printhead position (forward and rearward), and adjust for parallelism.
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Note • The desired result produces the darkest printing evenly across the label and
lines printed on the test labels that are parallel to the top of the label.
10.
Press PAUSE, let several more labels print, and then press PAUSE again.
11.
Examine this set of labels and make any additional adjustments.
12.
Repeat steps 10 and 11 until consistent print quality and parallelism is achieved.
13.
Tighten the two printhead position locking screws.
14.
Press PAUSE, let several more labels print, then press PAUSE again.
15.
Examine this set of labels to make sure the print quality and parallelism are still
good. If the adjustment “slipped” when you tightened the printhead position locking
screws, loosen them, then repeat steps 9–13 until the print quality and parallelism
are good. Tighten the printhead position locking screws.
Notes • If after the above adjustments the print quality is even, but not dark
enough, perform "Adjusting the Printer Darkness" on page 2-26 until optimum
darkness is achieved. If optimum darkness still cannot be achieved, it may be
necessary to perform the "Printhead Pressure Adjustment" on page 2-29.
To extend the life of the printhead, use the lowest toggle pressure that produces
the desired print quality.
Page 4-24
16.
If labels are printing properly, press PAUSE to stop printing.
17.
Press MODE three times. The Mode LEDs flash and the settings are permanently
saved to memory.
18.
To exit the Pause Key Self Test, the printer must be turned Off (O).
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Braided
Ground
Strap
Braided
Ground
Strap
Printhead
Position
Locking
Screw
Printhead
Position
Locking
Screw
Printhead
Adjustment
Slot
Printhead
Adjustment
Slot
Strip Plate
Figure 4-20. Printhead Position Adjustment (Top View)
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The label sensor functions only when the printer is set to Peel-Off Mode. This mode
requires that the peel-off option be installed. This sensor is not installed on printers
without the peel-off option.
Figure 4-21 shows the location of the take-label sensor. When the sensing beam is
interrupted, printing and feeding are prevented. It may accept additional label formats if
the buffer is not full. When the label is removed, the next label prints automatically.
There is no sensitivity adjustment of the take-label sensor. Sensors are attached, and
aligned at the factory when the peel-off option is installed. If a problem is encountered,
check the alignment of the sensor components. They should point directly at one another.
Also verify that the format sent contains the peel-off mode command.
Take-Label
Sensors
Figure 4-21. Take-Label Sensor Location
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Refer to Figure 4-22. The ribbon strip plate position can be adjusted to provide proper
tracking, and separation of the ribbon from the media after printing. If the ribbon does not
track properly, or if ribbon wrinkle problems appear adjust the strip plate by following this
procedure.
1.
Begin printing labels by performing a Pause Key Self Test.
2.
Loosen the screws securing the strip plate to the front of the printhead assembly.
3.
Position the strip plate for proper ribbon tracking. Ensure the ribbon does not
wrinkle, and stays flat, and smooth when fed to the upper ribbon guide when FEED
is pressed.
Note • If the strip plate is too high, the result is a noisy operation and possible wrinkle,
especially on the backfeed. Smudging or print quality problems result if the strip plate is
positioned too low.
4.
Tighten the strip plate adjustment screws.
5.
Perform another Pause Key Self Test, checking for ribbon wrinkle and proper ribbon
tracking. Readjust the strip plate as necessary.
6.
If ribbon wrinkle and/or tracking problems persist, check the torque settings of the
ribbon take-up spindle as detailed in this section, and adjust the tension as required.
Strip
Plate
Tear-0ff
Plate
Figure 4-22. Strip Plate Adjustment
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Refer to Figure 4-23 and follow the procedures below to adjust the liner rewind spindle
tension.
1.
Turn the printer Off (O) and remove all media and ribbon.
2.
Tape the end of the 30" long Mylar tape (Zebra part # 01776) to the rewind spindle.
3.
Wrap the Mylar strip around the rewind spindle in a clockwise direction.
4.
Connect a 1000 gram spring scale to the Mylar strip.
5.
Pull the spring scale to create the tension measurement.
6.
The rotation of the rewind spindle, created by pulling on the spring scale, should be
smooth and similar to the pace of sweep of a clocks second hand. Ensure there is
no platen movement when measuring the rewind spindle tension.
7.
When the rewind spindle is moving smoothly with even pull, read the tension setting
on the spring scale. The correct tension should be 700 grams (+100/–50).
8.
If the tension is incorrect, use a pair of utility pliers and hold the locking nut
stationary while rotating the rewind spindle until there is easy access to the locking
screws.
9.
Use a wrench driver to loosen the locking nut screws.
10.
Using the utility pliers, turn the nut clockwise to increase tension, and
counterclockwise to decrease tension.
11.
After achieving the correct tension, tighten the locking screws.
12.
Reload the media and ribbon, and test the printer’s liner rewind function.
Mylar
Strip
600
800
700
1000
900
Rewind
Spindle
Spring
Scale
Locking
Nut
Figure 4-23. Liner Rewind Spindle Adjustment
Page 4-28
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Caution:
The printhead voltage adjustment is critical to the life of the printhead. Do not use this
adjustment to try to increase printing darkness.
When a printhead or power supply board is replaced, the printhead voltage must be
adjusted for the proper value. This adjustment provides the voltage applied to the print
elements during the printing process.
1.
Calculate the proper printhead voltage using the formula or values found in
Table 4-4 on page 4-30 for the S400 or Table 4-5 on page 4-30 for the S600.
Notes • The S400 printhead resistance value can be read from the fork bracket
label RXXXX (where XXXX is the value in ohms).
The S600 printhead resistance value can be read from the label on the
printhead (R=XXX ohms).
2.
Refer to Figure 4-28 on page 4-35. Remove the rear cover.
3.
Refer to Figure 4-31 on page 4-39. Attach a voltmeter between F2 and ground on
the main logic board.
4.
Turn the printer On (l), and let it complete the Power On Self Test.
5.
Refer to Figure 4-24 on page 4-31. Locate RV2 on the power supply board and
adjust until the voltmeter reads the value determined in step 1.
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Table 4-4. Printhead Voltage Values (S400 Only)
Printhead Voltage Formula: V
Ω
Resistance
Voltage VDC
= 0.78 + (0.49 × Resistance)
Resistance
Ω
Voltage VDC
935 to 945
22.2
1092 to 1110
24.0
946 to 963
22.4
1111 to 1129
24.2
964 to 981
22.6
1130 to 1148
24.4
982 to 999
22.8
1149 to 1168
24.6
1000 to 1017
23.0
1169 to 1187
24.8
1018 to 1035
23.2
1188 to 1207
25.0
1036 to 1053
23.4
1208 to 1227
25.2
1054 to 1072
23.6
1228 to 1247
25.4
1073 to 1091
23.8
1248 to 1265
25.6
Table 4-5. Printhead Voltage Values (S600 Only)
Printhead Voltage Formula: V
Resistance
Page 4-30
Ω
Voltage VDC
= 0.78 + (0.673 × Resistance)
Resistance
Ω
Voltage VDC
680 to 688
22.2
795 to 808
24.0
689 to 701
22.4
809 to 822
24.2
702 to 714
22.6
823 to 836
24.4
715 to 727
22.8
837 to 850
24.6
727 to740
23.0
851 to 864
24.8
741 to 754
23.2
865 to 879
25.0
755 to 767
23.4
880 to 893
25.2
768 to 781
23.6
894 to 908
25.4
782 to 794
23.8
909 to 920
25.6
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Ground
Wire
Power Supply Board
(Access RV2 through
cutout in base.)
RV2
Figure 4-24. Printhead Voltage Adjustment Potentiometer Location
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Caution:
Use caution around cutter blades. Keep fingers away from blades.
The voltage applied to the printhead is the same voltage applied to the cutter module. The
specific voltage applied to the cutter motor is controlled by the home position
potentiometer.
There are three cases in which you must adjust the cutter module’s home position
potentiometer:
•
Before placing a new cutter module into service.
•
If a new printhead is installed on the printer.
•
If a cutter module is installed on a printer other than the one it was previously
adjusted for.
1.
Turn the printer power Off (O). Load media and ribbon if not already installed.
2.
Attach the new cutter module to the cutter cable connector on the printer and lay it
on the table or on the inside of the printer’s open front door.
Note • Do not mount the cutter module at this time.
3.
Perform a Pause and Cancel Key test, press, and hold PAUSE and CANCEL while
turning the printer On (l).
Note • Do not allow the printed labels to pass through the cutter module. Let them
accumulate on the table or floor.
Page 4-32
4.
Refer to Figure 4-25 on page 4-33. While the labels are printing, observe where the
sensor disc on the cutter module stops after completing a cut cycle. It can be viewed
between the outer cover, and the side plate. The desired stopping position of the
censor disc is when the embossed line on the sensor disc is aligned with the edge
of the side plate.
5.
Refer to Figure 4-26 on page 4-33. Adjust the home position potentiometer with the
potentiometer adjustment tool (Zebra part # 01428) until the embossed line on the
sensor disc is in alignment with the side plate edge.
6.
Turn the power Off (O), and install the cutter module.
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Side Plate
Edge
Embossed
Line
Sensor
Disc
Outer
Cover
Home Position
Potentiometer
Figure 4-25. Properly Adjusted Cutter Sensor
Home Position Potentiometer
Figure 4-26. Home Position Potentiometer
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Page 4-33
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Open-End Wrench Set
Spring Scale, 2200 gram and 1000 gram
Metric Allen Wrench Set
0.010" Shim or Feeler Gauge
Small Flat-Blade Screwdrivers
0.020" Shim or Feeler Gauge
Phillips Screwdrivers
Anti-Static Mat
Digital Voltmeter
Anti-Static Wrist Strap
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1.
Refer to Figure 4-27 on page 4-35. Lift the main door to swing it up and to the left
until it rests on top of the right side cover.
2.
Using both hands, slide the main door toward the rear of the printer. Lift the end of
the main door nearest the front of the printer, pivoting it to the rear and off the main
frame.
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1.
Open the main door.
2.
Grasp the tab on top of the front door and carefully pull down until it rests on the
desktop.
3.
Refer to Figure 4-27 on page 4-35. Notice the front door’s hinges in three places on
the base of the printer.
4.
Grasp the front door near the left and right hinge.
5.
Pull the left side away from base while pivoting on the right side.
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Page 4-34
1.
Refer to Figure 4-28 on page 4-35. Remove the three cover screws attaching the
rear cover to the main frame.
2.
Lift the rear cover straight up approximately ½" (12.7 mm) then slide off toward the
rear.
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Main Door
Tab
1
2
Front Door
Figure 4-27. Opening Main and Front Doors
Rear Cover
Main Door
Front Door
Figure 4-28. Door and Cover Disassembly
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1.
Open the main door.
2.
Grasp the tab on top of the front door and carefully pull down until it rests on the
desktop.
3.
Refer to Figure 4-29. Remove the two screws securing the tear-off plate.
4.
Push up on the bottom of the tear-off plate, and pull the plate out.
5.
Reverse the procedure to replace the tear-off plate.
Tear-Off
Plate
5 mm Hex
Screws
Figure 4-29. Tear-Off Plate
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Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
Page 4-36
1.
Turn the power Off (O), and remove the AC power cord.
2.
Remove the front door.
3.
Remove the rear cover.
4.
Refer to Figure 4-30 on page 4-37. Remove the screw securing the control panel
assembly.
5.
Remove the screw that secures the ribbon cable strain relief to the main frame.
6.
Refer to Figure 4-31 on page 4-39. Detach the control panel ribbon cable from the
main logic board (J12).
7.
Grasp the control panel assembly by its sides and carefully lift it out of the base
guide slots.
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1.
Turn the printer Off (O), and remove the AC power cord.
2.
Remove the control panel assembly.
3.
Refer to Figure 4-30. Remove the control panel board from the control panel cover
by removing the two mounting screws.
4.
Carefully align the replacement board over the mounting holes on the control panel
cover and reinstall the two mounting screws.
5.
Remount the control panel assembly in the base guide slots and secure into the
main frame by reinstalling the mounting screw.
6.
Refer to Figure 4-31 on page 4-39. Reattach the control panel ribbon cable to the
main logic board (J12).
7.
Reinstall the ribbon cable strain relief to the main frame.
8.
Reinstall the rear cover, and front door.
Control Panel Cover
Control Panel
Ribbon Cable
Strain Relief
Figure 4-30. Control Panel Assembly
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Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
1.
Turn printer Off (O), and remove the AC power cord.
2.
Remove the printer data cable.
3.
Remove the rear cover.
4.
Refer to Figure 4-31 on page 4-39. Note the position of all ribbon cable connectors
and wire harness connectors. Remove all connectors to the main logic board.
5.
Remove the three screws securing the main logic board.
6.
Carefully grasping both sides of the main logic board, pull the board straight up from
the power supply connector and out of the unit. A gentle rocking motion may be
necessary to release it from the power supply board.
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Page 4-38
1.
Refer to Figure 4-31 on page 4-39. Align connector (J8) at the bottom of the main
logic board with the mating power supply board connector (J2).
2.
Press the main logic board straight down until connector J8 has seated completely
onto the power supply board.
3.
Reinstall the three mounting screws, making sure the mounting screw in the upper
right-hand side of the main logic board goes through the braided ground strap first.
4.
Reconnect all ribbon and wire harness cables.
5.
Replace the rear cover.
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Mounting Holes
Ground
Ground
J5
RV1
J4
J11
J9
J3
J12
F1
J1
J14
(Back of
Board)
J2
J13
Mounting Hole
J7
Ground
J6
J10
F2
F3
J8
Figure 4-31. Main Logic Board
J1
Serial Port
J10
Full Roll Switch Assembly
J2
Parallel Port
J11
Media/Ribbon Sensor Assembly
J3
Ribbon Take-Up Motor Assembly
J12
Control Panel Assembly
J4
Printhead Assembly (S600)
J13
Not Used
J5
Printhead Assembly (S400)
J14
Option Connector (on back of board)
J6
Not Used
RV1 Spindle Tension Adjustment
J7
Cutter Assembly
F1
5 MF 2A/250V
J8
Power Supply Assembly
F2
E 5A/125V
J9
Label Available Sensor Assembly
F3
E 250mA/125V
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To download the correct version of firmware go to: www.zebra.com/firmware and choose
the your printer model. Choose a version from the firmware matrix and follow the
directions.
Or call:
44895L Rev. 3 3/15/04
USA: 1-847.913.2259
Europe: 44 (0) 1494 536644.
S400/S600 Maintenance Manual
Page 4-39
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1.
Turn printer Off (O), and remove the AC power cord.
2.
Remove the printer data cable.
3.
Remove the media and ribbon.
4.
Remove the main door, front door, and rear cover.
5.
Remove the main logic board.
6.
Refer to Figure 4-31 on page 4-39, and locate the printhead cable (J4 or J5).
7.
Refer to Figure 4-32. Remove the ferrite assembly from around the printhead cable
by sliding the clips off of the ferrites.
8.
Rotate the head-open lever counterclockwise to remove the pressure on the
printhead.
9.
Refer to Figure 4-33 on page 4-42. Locate the braided ground straps, on the print
mechanism assembly, that lead to the main frame and to the riot bar on the
electronics side of the printer. Remove the screws securing the braided ground
strap to the main frame.
10.
Refer to Figure 4-34 on page 4-42. Remove the single screw with two washers on
the electronics side of the printer securing the print mechanism assembly to the
main frame and riot bar.
11.
Carefully slide the printhead cable through the cutout in the main frame and remove
the printhead assembly.
12.
Reverse the procedures to reinstall the print mechanism assembly.
13.
Test the unit and perform a printhead position adjustment if necessary.
Ribbon Cable
1
Clip
3
2
Clip
Ferrite
Figure 4-32. Printhead Cable Ferrite assembly
Page 4-40
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1.
Turn printer Off (O), and remove the AC power cord.
2.
Remove the printer data cable.
3.
Remove the main door, front door, and rear cover.
4.
Refer to Figure 4-22 on page 4-27. Remove the two screws securing
the strip plate.
5.
Rotate the head-open lever counterclockwise to remove the pressure on the
printhead.
6.
Refer to Figure 4-35 on page 4-43. Using an open-end wrench, remove the two nuts
securing the printhead assembly to the print mechanism assembly.
Note • Do not remove, loosen or adjust the two screws on top of the printhead
assembly. They are used only when a printhead alignment is necessary.
7.
Carefully remove the printhead cable from the printhead assembly.
8.
Install the replacement printhead assembly by reversing steps 4 through 7.
Notes • When installing the printhead cable to the printhead assembly, ensure
the insulation sleeve is pushed as far forward (toward the printhead assembly)
as possible.
Do not remove, loosen or adjust the two screws on top of the replacement
printhead assembly. They are used only when a printhead alignment is
necessary.
9.
10.
Reconnect the AC power cord.
Perform a voltage calibration as described in "Printhead Voltage Adjustment" on
page 4-29.
Caution:
The printhead voltage adjustment is critical to the life of the printhead. Do not use this
adjustment to try to increase the printing darkness.
11.
Print test labels to determine print quality. Adjust the strip plate as described in,
"Strip-Plate Adjustment" on page 4-27, only if experiencing ribbon wrinkle or if the
ribbon is not tracking properly. Adjust the printhead as described in. "Printhead
Position Adjustment" on page 4-23, only if necessary (replacement printheads are
pre-aligned at the factory).
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Braided
Ground
Straps
Print
Mechanism
Assembly
Figure 4-33. Braided Ground Strap Location
Cutout
Braided
Ground Strap
Print Mechanism
Assembly
Mounting
Screw
Printhead
Cable
Figure 4-34. Print Mechanism Assembly Mounting Screw Location
Page 4-42
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Nuts
Print Mechanism
Assembly
Printhead
Cable
Assembly
Printhead
Assembly
Figure 4-35. Printhead Assembly Removal/Installation
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Page 4-43
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Refer to Figure 4-36.
1.
Turn printer Off (O), and remove the AC power cord.
2.
Remove the printer data cable.
3.
Remove any media and ribbon.
4.
Ensure the dual-tension ribbon supply spindle outer spindle is in the retracted
(pushed in) position to gain access to the set screws.
5.
Rotate the outer spindle to locate and loosen the two set screws securing the cup
and spring assembly to the ribbon supply spindle shaft.
6.
Slide the cup and spring assembly and the outer spindle off the shaft.
7.
Remove the C-clip.
8.
Slide the spindle assembly off the shaft.
9.
Rotate the ribbon supply spindle subassembly to locate and loosen the two set
screws securing the cup and spring assembly to the ribbon supply spindle shaft.
10.
Slide the ribbon supply spindle subassembly off the shaft.
Cup and Spring
Assembly
Ribbon Supply
Spindle Subassemby
Spindle
Assembly
C-Clip
Outer
Spindle
Cup and
Spring Assembly
Set Screws
Figure 4-36. Dual-Tension Ribbon Supply Disassembly
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1.
Use an emery cloth to remove burrs and nicks on the ribbon supply spindle shaft.
2.
Refer to Figure 4-37. Slide the ribbon supply spindle subassembly on the ribbon
supply spindle shaft.
3.
Slide one of the cup and spring assemblies on the ribbon supply spindle shaft.
4.
Place a 0.010" (.254 mm) shim or feeler gauge between the C-clip and ribbon
supply spindle subassembly.
5.
While applying light pressure against the cup and spring assembly, tighten the two
set screws on the cup and spring assembly.
Note • Rotate the ribbon supply spindle subassembly to access the set screws.
0.010" (0.254 mm) shim or feeler
gauge placed between
C-clip and ribbon supply
spindle subassembly
Ribbon Supply
Spindle Subassemby
Cup and Spring
Assembly
Set Screws
Figure 4-37. Ribbon Supply Spindle Subassembly Installation
6.
Once the cup and spring assembly is tightened, remove the shim/feeler gauge. The
ribbon supply spindle subassembly should have some “play” on the shaft. When
rotated counterclockwise, the ribbon supply spindle subassembly spins freely until it
encounters the spring. Continuing to turn the ribbon supply spindle subassembly
counterclockwise produces a “snap,” and the ribbon supply spindle subassembly
moves freely.
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7.
When rotated clockwise, the ribbon supply spindle subassembly encounters the
spring and attempts to spin the ribbon supply spindle subassembly
counterclockwise.
8.
If the results in steps 6 and 7 are not achieved, repeat steps 2 through 7.
9.
Refer to Figure 4-38. Slide the spindle assembly onto the shaft.
0.010" (0.254 mm) shim or feeler
gauge placed between
C-clip and ribbon supply
spindle subassembly
Ribbon Supply
Spindle Subassemby
Cup and Spring
Assembly
Set Screws
Figure 4-38. Spindle Assembly Installation
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10.
Refer to Figure 4-39 on page 4-48. Reinstall the C-clip in the groove on the shaft.
11.
Place a 0.020" (0.508 mm) shim or feeler gauge between the spindle assembly and
the ribbon supply spindle subassembly.
12.
Slide the outer spindle on the shaft.
13.
Align the large notch on the outer spindle with the corresponding protrusion on the
spindle assembly. The protrusion on the spindle assembly is in line with the metal
core clip.
14.
Carefully slide the outer spindle on to the spindle assembly to the first notch.
15.
Refer to Figure 4-41 on page 4-48. If it is pushed on too far, simply pull the outer
spindle away from the spindle assembly until it looks like Figure 4-40 on page 4-48.
16.
Slide the cup and spring assembly on the shaft.
17.
While applying light pressure against the cup and spring assembly, and with the
0.020 shim or feeler gauge between the spindle assembly and the ribbon supply
spindle sub-assembly, tighten the two set screws on the cup and spring assembly.
Note • Rotate the outer spindle to access the set screws.
18.
Once the cup and spring assembly is tightened, remove the shim/feeler gauge. The
outer spindle and spindle assembly should have some “play” on the shaft. When
rotated counterclockwise, the outer spindle and spindle assembly spins freely until it
encounters the spring. Continuing to turn the outer spindle and spindle assembly
counterclockwise produces a “snap,” and the ribbon supply spindle subassembly
moves freely.
19.
Rotating in a clockwise direction, the outer spindle and spindle assembly encounter
the spring and attempt to spin the outer spindle and spindle assembly in the
counterclockwise direction.
20.
Push in the outer spindle until it is flush against the spindle assembly. The outer
spindle and spindle assembly should now spin freely clockwise and
counterclockwise with no restrictions.
21.
If the results in steps 17, 18, and 19 are not achieved, repeat steps 9 through 19.
22.
Replace the printer data cable and AC power cord.
23.
Reload media and ribbon, and test the printer operation.
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0.010" (0.254 mm) shim or feeler
gauge placed between
C-clip and ribbon supply
spindle subassembly
Ribbon Supply
Spindle Subassemby
Cup and Spring
Assembly
Set Screws
Figure 4-39. Spindle Assembly Installation
Figure 4-40. Spindle Assembly & Outer Spindle (Expanded)
Figure 4-41. Spindle Assembly & Outer Spindle (Retracted)
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Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
1.
Turn printer Off (O), and remove the AC power cord and the printer data cable.
2.
Remove media and ribbon.
3.
Remove the main door and rear cover.
4.
Refer to Figure 4-31 on page 4-39. Disconnect the wiring harness
from J11 on the main logic board.
5.
Refer to Figure 4-42 on page 4-50. Slide out the upper media guide
assembly.
6.
Locate the two mounting screws securing the media sensor assembly to the main
frame.
7.
Using a long-reach magnetic tip screwdriver, remove the two mounting screws.
8.
Remove the media sensor assembly.
0HGLD6HQVRU$VVHPEO\,QVWDOODWLRQ
1.
Remove the wiring harness from W1 on the media sensor board and connect it to
W1 on the replacement board.
2.
Install the media sensor assembly on to the main frame, ensuring the wiring
harness attached to W1 on the media sensor board is threaded through the cutout
in the main frame.
3.
Using a long-reach magnetic tip screwdriver, carefully reinstall the two mounting
screws.
4.
Refer to Figure 4-31 on page 4-39. Reconnect the wiring harness from the media
sensor board to J11 on the main logic board.
5.
Refer to Figure 4-42 on page 4-50. Reinstall the upper media guide assembly.
6.
Reinstall the media and ribbon.
7.
Reinstall the main door and rear cover.
8.
Reconnect the AC power cord and data cable.
9.
Turn the printer On (l), and recalibrate the media. Verify proper printer operation.
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Media Sensor
Assembly
Upper Media
Guide Assembly
Figure 4-42. Media Sensor Assembly
Shoulder
Bolt and
Idler Pulley
Platen
Roller
60
70
80
90
10
0
0
0
0
00
Spring
Scale
Stepper
Motor
1
HE
C
IN
S
2
3
Figure 4-43. Main Drive Belt Replacement and Adjustment
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Printers without the Peel-Off Option
Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
1.
Turn printer Off (O), and remove the AC power cord and the printer data cable.
2.
Remove media and ribbon.
3.
Remove the main door and rear cover.
4.
Remove the main logic board and media sensor assembly.
Note • Scribing a mark into the printer main frame indicating the position of the idler
pulley prior to performing the next step may help when adjusting the belt tension.
5.
Refer to Figure 4-43 on page 4-50. Loosen the shoulder bolt holding the idler pulley
in position until the pulley freely moves up and down.
6.
Remove the main drive belt and install the new one.
7.
Hook a 1000 gram spring scale to the belt as shown in Figure 4-43 on page 4-50,
and carefully pull up on the idler pulley to increase belt tension.
8.
When a scale reading of 500 grams ± 100 grams creates a deflection of ¼" (6.4
mm), tighten the shoulder bolt.
9.
Reinstall the media sensor assembly, main logic board, main door, and rear cover.
10.
Reload media and ribbon.
11.
Reconnect the AC power cord and data cable. Turn the printer On (l), and test for
proper operation.
Printers Equipped With the Peel-Off Option
Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
1.
Turn the printer Off (O), and remove the AC power cord and the printer data cable.
2.
Remove media and ribbon.
3.
Remove the main door and rear cover.
4.
Remove the main logic board and media sensor assembly.
Note • Scribing a mark into the main frame indicating the position of the idler pulley
prior to performing the next step may help when adjusting the belt tension.
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5.
Refer to Figure 4-44. For the particular belt being replaced, loosen the shoulder bolt
holding the idler pulley in position until the pulley freely moves up and down.
6.
Remove the main drive belt and/or rewind spindle drive belt and install the new one.
7.
Hook a 2200 gram spring scale to the new main drive or rewind spindle drive belt,
dependant on which one is being replaced/adjusted, and carefully pull up on the
idler pulley to increase belt tension.
8.
Main Drive Belt Adjustment. When a scale reading of 900 grams (± 225 grams)
creates a deflection of ¼" (6.4 mm), tighten the shoulder bolt.
9.
Rewind Spindle Drive Belt Adjustment. When a scale reading of 1800 grams (±
225 grams) creates a deflection of ¼" (6.4 mm), tighten the shoulder bolt.
10.
Reinstall the media sensor assembly, main logic board, main door, and rear cover.
11.
Reload media and ribbon.
12.
Reconnect the AC power cord and data cable. Turn the printer On (l), and test for
proper operation.
Rewind Spindle
Belt Tension
2300 gm ± 225 gm
Shoulder bolt and
idler pulley for
main drive belt
adjustment
14
Shoulder bolt and
idler pulley for
rewind spindle
belt adjustment
00
16
00
18
00
20
00
22
1400
1600
2000
GR
AM
S
GRAMS
2
1
1800
00
INCHES
2200
1/4"
3
Main Drive
Belt Tension
1800 gm ± 225 gm
Figure 4-44. Peel-Off Drive Belt Adjustment
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1.
Turn the printer Off (O), and remove the AC power cord and the data cable.
2.
Remove media and ribbon.
3.
Remove the main door, rear cover, and control panel assembly.
4.
Remove the main logic board and media sensor assembly.
Note • Scribing a mark into the main frame indicating the position of the idler pulley
prior to performing step 5 may help when adjusting the belt tension.
5.
Refer to Figure 4-45 on page 4-54. Loosen the shoulder bolt holding the idler pulley
in position until the pulley freely moves up and down.
6.
Remove the main drive belt.
7.
Remove the screw securing the platen roller ground chain assembly to the main
frame.
8.
Refer to Figure 4-29 on page 4-36. Remove the tear-off plate.
9.
Remove the platen roller by lifting up on the end with the platen pulley and pivoting
the platen bearings out of the slots.
10.
Remove the platen pulley from the platen roller.
11.
Install the platen bearings, nylon spacer washers, ground chain assembly, and the
platen pulley on the replacement platen roller as shown in Figure 4-45.
Note • Refer to Figure 4-46 on page 4-54. Ensure the platen bearings are oriented with
the off-center holes at the top when installed.
12.
Reinstall the platen roller by sliding the outside platen bearing into its cutout and
dropping the inside platen bearing into its slot.
13.
Reattach the ground chain assembly to the main frame.
14.
Reinstall the main drive belt.
15.
Adjust the main drive belt tension.
16.
Reinstall the main logic board and media sensor assembly.
17.
Reinstall the tear-off plate, control panel assembly, rear cover, and main door.
18.
Reload media and ribbon.
19.
Reconnect AC power cord and data cable. Turn the printer On (l), and test for
proper operation.
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Shoulder Bolt
and Idler Pulley
Platen
Pulley
Ground
Chain
Assembly
Main Drive
Belt
Figure 4-45. Platen Roller Replacement
Platen Bearings
Outboard/Inboard Guides
Platen Roller
Bearings pictured here
are installed this way for
the S400 only.
For the S600, rotate the
bearings 180 degrees
(turn upside down).
Figure 4-46. Replacing the Platen Roller
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1.
Turn the printer Off (O), and remove the AC power cord and the data cable.
2.
Remove media and ribbon.
3.
Remove the main door and rear cover.
4.
Remove the main logic board.
5.
Remove the main drive belt.
6.
Refer to Figure 4-47 on page 4-55. Loosen the two screws and slide the bevel gear
from the ribbon take-up spindle shaft.
7.
Remove the ground chain assembly from around the idler pulley.
8.
Remove the screw securing the ground chain assembly to the ribbon supply spindle
shaft.
9.
Remove the two screws securing the ribbon tension motor assembly and mounting
bracket to the main frame.
10.
Install the replacement ribbon tension motor assembly by reversing steps
6 through 9.
11.
Perform a main drive belt tension adjustment.
12.
Reinstall the main logic board, rear cover, and main door.
13.
Perform the ribbon take-up spindle tension adjustment.
14.
Reinstall the media and ribbon.
15.
Reconnect the AC power cord and data cable. Turn the printer On (l), and test for
proper operation.
Set Screws
Mounting Screws
Bevel Gear
Ground Chain Assembly
(to idler pulley)
Ground Chain Assembly
(to ribbon supply spindle shaft)
Ribbon Tension
Motor Assembly
Figure 4-47. Ribbon Take-Up Motor
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1.
Turn the printer Off (O), and remove the AC power cord and data cable.
2.
Remove media and ribbon.
3.
Remove the main door and rear cover.
4.
Remove the main logic board.
5.
Remove the main drive belt.
6.
Refer to Figure 4-48. Remove the screw, underneath the upper media guide
assembly, holding the stepper motor to the main frame.
7.
Refer to Figure 4-49 on page 4-57. Disconnect the stepper motor cable (J1) from
the power supply board.
8.
Carefully grasping the stepper motor, turn it counterclockwise and remove it from
the slots.
9.
Reverse steps 6 through 8 to install the replacement stepper motor.
10.
Replace the main drive belt and adjust the tension.
11.
Replace the main logic board.
12.
Replace the rear cover and main door.
13.
Reload media and ribbon.
14.
Reconnect the AC power cord and data cable. Turn the printer On (l), and test for
proper operation.
Printhead
Assembly
OPEN
Upper Media
Guide Assembly
Stepper Motor
Mounting Screw
Stepper Motor
Figure 4-48. Stepper Motor (Media Side)
Page 4-56
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Stepper Motor
Ground
Wire
Stepper Motor
Cable
Power Supply
Board (J1)
(access through
cutout in base)
Figure 4-49. Stepper Motor (Electronics Side)
Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
3RZHU6XSSO\%RDUG5HPRYDO
1.
Turn the printer Off (O), and remove the AC power cord and the data cable.
2.
Remove media and ribbon.
3.
Remove the main door and rear cover.
4.
Remove the main logic board.
5.
Refer to Figure 4-49. Disconnect the stepper motor cable from the power supply
board (J1).
6.
Disconnect the ground wire leading from the power supply board to the ground bar.
7.
Refer to Figure 4-50 on page 4-59. Remove the screw in the middle of the media
compartment that secures the main base to the power supply base together.
8.
Insert a flat-blade screwdriver tip into the slots shown in Figure 4-50 on page 4-59.
9.
Gently pull the screwdriver handle toward the front of the printer until the tabs pop
out of the cutout (tabs slide into the base).
10.
Carefully pry the front of the power supply base downward to remove the assembly.
11.
Refer to Figure 4-51 on page 4-60. Remove the two mounting screws that secure
the power supply board to the base.
12.
Pivot the board off the front snaps.
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Page 4-58
1.
Refer to Figure 4-51 on page 4-60. Press the power supply board onto the three
mounting snaps.
2.
Reinstall the two mounting screws.
3.
With the printer tilted up on the front cover, position the front hooks of the power
supply base into the holes.
4.
Route the ground wire through the opening in the base.
5.
Engage the rear snaps by pivoting the power supply base assembly to the printer
base.
6.
Insert the screw in the middle of the media compartment that secures the main base
to power supply base together.
7.
Refer to Figure 4-49 on page 4-57. Connect the ground wire to the riot (ground) bar.
8.
Replace the main logic board.
9.
Reconnect all ribbon cable and wire harness connectors to the main logic board.
10.
Reconnect the AC power cord and perform the voltage adjustment described in
"Printhead Voltage Adjustment" on page 4-29.
11.
Replace the rear cover and main door.
12.
Reload media and ribbon.
13.
Reconnect the data cable. Turn the printer On (l), and test for proper operation.
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1. Remove the screw in the
middle of the media
compartment that
secures the main
base and power
supply base.
6HFWLRQ
Screw
2. Remove the ground
wire from the ground
bar.
3. Insert flat-blade
screwdriver
tip into slot.
4. Gently pull the
screwdriver handle
Ground
toward the front of the
Wire
printer until tab pops out of
cutout (into the base).
Tab
Slot
5. Carefully pry the front of the
power supply base downward to
remove power supply.
Figure 4-50. Power Supply Assembly Removal
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Power Supply
Base Mounting
Screw
Power Supply
Board Mounting
Screws
Power Supply
Board
Power Supply
Base
Figure 4-51. Power Supply Assembly Exploded View
Page 4-60
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Caution:
The replacement fuse must have the ratings specified below. Serious damage may
occur if a higher-rated fuse is installed.
Refer to Figure 4-52. A user-replaceable AC power fuse is located just to the left of the
power switch. For 120 VAC operation, a F5A/250V fuse is used. For 220 VAC operation,
a F3A/250V is used.
Note • Do not rely on a visual inspection to determine whether a fuse is blown. Always
turn the printer off and remove the power cord. Then remove the fuse from the fuse
holder (or circuit board) and test with an ohmmeter. A good fuse gives a short (0 ohm)
indication.
1.
Turn the printer Off (O), and remove the AC power cord.
2.
Insert the tip of a flat-blade screwdriver into the slot found on the fuse holder cap.
Press in on the cap and turn counterclockwise. Remove the screwdriver.
3.
Grasp the fuse holder cap with your fingers and remove from the fuse holder.
4.
Remove the blown fuse from the fuse holder cap and insert the proper fuse.
5.
Replace the fuse holder cap by placing it into the fuse holder. Insert the tip of a flatblade screwdriver into the slot found on the fuse holder cap. Press in on the cap and
turn clockwise until the cap will no longer turn. Remove the screwdriver.
AC Power
Fuse
AC Power
Cable
To open, turn
counterclockwise.
AC Power
On/Off
Switch
To close,
turn clockwise.
Figure 4-52. Fuse Holder Location
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Caution:
Observe proper electrostatic safety precautions when removing, handling, and replacing
printed circuit boards.
1.
Turn the printer Off (O), and remove the AC power cord.
2.
Remove the data cable.
3.
Remove the rear cover.
Note • It is not necessary to remove the main door or the front door if installing only the
memory upgrade kit.
Mounting Holes
Ground
Ground
RV1
J5
J4
J11
J9
J3
J12
F1
J1
J14
(Back of
Board)
J2
J13
Mounting Hole
J7
Ground
J6
F2
J10
F3
J8
Figure 4-53. Main Logic Board Conntector and Mounting Screw Location
Page 4-62
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4.
Refer to Figure 4-53. Note the positions of all ribbon cable and wire harness
connectors. Remove all connectors to the main logic board.
5.
Remove the three screws securing the main logic board to the main frame.
6.
Carefully grasping both sides of the main logic board, pull the board straight up from
the power supply connector and out of the unit. A gentle rocking motion of the main
logic board may be necessary to release it from the power supply board.
7.
Inspect the back of the main logic board. Remove any contaminants with a cotton
swab and isopropyl alcohol (90% alcohol and 10% distilled water) on J14 (found at
the left edge of the board when looking at the back of the board).
8.
Lay the main logic board on the anti-static mat face up.
9.
Refer to Figure 4-54 on page 4-63. Remove the three mounting screws from the
memory board and put aside for use later.
Main Logic Board
Memory Board
Mounting
Screw
Mounting
Screws
Figure 4-54. Memory Board
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10.
Refer to Figure 4-55. With the memory board face up (100-pin connector to the left
and pins up), carefully slide the memory board underneath the main logic board.
11.
Align the three screw holes in the main logic board with the three holes in the
connector on the memory board.
Main Logic Board
Memory Board
Mounting
Screw
Mounting
Screws
Figure 4-55. Memory Board Mounting Screws
12.
Finger tighten the three screws through the main logic board and the memory
board.
13.
Align connector J8 at the bottom of the main logic board with the mating connector
on the power supply board.
Note • Do not over-torque screws.
14.
Starting with the center screw, tighten all screws.
15.
Press straight down on the main logic board until connector J8 has seated
completely onto the power supply board.
16.
Reinstall the three screws securing the main logic board to the main frame.
17.
Refer to Figure 4-53 on page 4-62. Reconnect all ribbon cable and wire harness
connectors.
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Important • Use full width media when performing the Cancel Key Self Test. Labels
less than full width lose printing on the right side. Printing may run on to the next label
when short labels.
18.
Reconnect the AC power cord.
19.
Reload media and ribbon.
20.
Perform a Cancel Key Self Test. To start the Cancel Key Self Test, press and hold
Cancel while turning the power On (l). The printer runs through a Power-On Self
Test and then prints the configuration label.
Note • Refer to Figure 4-56 on page 4-66. This self test prints a listing of the printer’s
current configuration parameters that are currently stored in configuration (EEPROM)
memory.
21.
Inspect the label to determine if the main logic board recognizes the amount of
memory that was installed. If the label indicates “NOT INITIALIZED,” turn the printer
off, and run the test again (this is normal for the first time power up with the optional
memory).
Note • If the installed memory is still not recognized, turn the printer off, remove the
power cord, and repeat steps 5 through 7. Remove the memory board and reclean the
gold pads on J14 of the main logic board. Repeat steps 9 through 21.
22.
Reinstall the rear cover, AC power cord, and data cable.
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Page 4-65
6HFWLRQ
3UHYHQWLYHDQG&RUUHFWLYH0DLQWHQDQFH
Figure 4-56. Sample Before and After Configuration Labels
(8 MB Memory Board Installed)
Page 4-66
S400/S600 Maintenance Manual
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
6HFWLRQ
6HFWLRQ
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
'HVFULSWLRQ
Use the mechanical assembly drawings when troubleshooting or replacing components and
use the associated parts list when ordering replacement parts. Item parts that do not have
associated part numbers are not available and need to be ordered using the next highest
assembly number.
All parts in bold face are purchasable. All parts in light face italic are not purchasable, but may
be available as part of a maintenance kit. Hardware parts in light face are not available as an
individual part, but may be purchased as part of a hardware kit.
Caution:
The printer electronics is susceptible to static discharge. Before proceeding, it is
recommended that the technician wear an antistatic strap connected to the printer chassis.
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Page 5-1
#
Part No.
1
Description
44114* Screw, M4.2 × 1.41 × 8
Qty
3
2
44185M
Front Door Retention Clip
1
3
44075-1
Rear Cover
1
44076-5
Front Door (S400)
1
44076-4
Front Door (S600)
1
44070-3
Main Door (Standard)
1
44070-4
Main Door (Quick Release)
1
4
5
6HFWLRQ
Page 5-2
Table 5-1. Cover Assemblies
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
* Available only as HW44114 in quantities of 50.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
6HFWLRQ
Figure 5-1. Cover Assemblies
1
3
2
4
5
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Page 5-3
#
Part No.
1
Description
44114* Screw, M4.2 × 1.41 × 8
2
Qty
3
44506M
(A) LED/Button Array Maintenance Kit
1
3
44071-400M
(B) Front Panel Cover Assembly
(includes one Front Door Retention Clip,
two M4.2 × 1.41 × 8 screws, and one
M4 × 10 screw)
1
4
45925M
Head-Open Sensor Flag
1
45195 Set Screw, 10–32 × 0.25
1
5
44123
Braided Ground Strap
1
7
44053
Screw, M3 × 0.6 × 10
2
44784M
(C) Main Logic Board (S400)
1
44782M
(C) Main Logic Board (S600)
1
8
9
22416 Hex Stand-Off, 4–40
10
11 44077
12
01155** Lock Washer, #4
Ground Bezel
44115*** Screw, M4 × 10
* Available only as HW44114 in quantities of 50.
** Available only as HW01155 in quantities of 100.
*** Available only as HW44115 in quantities of 10.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
2
2
1
1
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
6
6HFWLRQ
Page 5-4
Table 5-2. Logic Board and Control Panel
6HFWLRQ
8
7
12
2
1
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Figure 5-2. Logic Board and Control Panel
9
3
A
10
C
B
5
11
4
6
1
7
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
Page 5-5
Page 5-6
#
Part No.
Description
Qty
44052-400M
Ribbon Take-Up Spindle Assembly
(Tear-Off and Cutter Option)
1
44052-402M
Ribbon Take-Up Spindle Assembly
(Peel-Off Option)
1
1
2
30251* Washer, 0.836 × 0.390 × 0.048
1
44912-400M
(C) Dual Torque Ribbon Supply Spindle Kit
1
4
44069
Media Bracket
1
5
44066-1M
(B) Media Edge Guide & Thumb Screw
1
6
44068-1
Media Edge Guide
1
7
44067
Nylon Thumb Screw, M3.5 × 6 × 5
1
8
9
44176** Wire Clip
44466
10
Ground Cable
44053*** Screw, M3 × 0.6 × 10
11 44118
12
13
14 44046-2
Shaft Collar, 0.377 × 0.750
44100† Set Screw, M3 × 0.5 × 6
44084†† Washer, 0.70 × 0.38 × 0.03
Bevel Gear, 60T
1
1
1
1
4
4
1
Part No.
15
Description
44339††† Hex Stand-Off
16
44356‡ Washer, 0.198 × 0.75 × 0.085
17 44043M
18
(A) RTU Motor Assembly
44278‡‡ Chain Assembly 1-¾"
Qty
1
1
1
1
19 44198M
Ribbon Take-Up Motor Cable
1
20 44481
Ground Chain Assembly 1-3/8"
1
21
22
44114‡‡‡ Screw, M4.2 × 1.41 × 8
10432¶ Screw, M4 × 0.7
* Available only as HW30251 in quantities of 25.
** Available only as HW44176 in quantities of 25.
*** Available only as HW44053 in quantities of 10.
† Available only as HW44100 in quantities of 25.
†† Available only as HW44084 in quantities of 10.
††† Available only as HW44339 in quantities of 10.
‡ Available only as HW44356 in quantities of 25.
‡‡ Available only as HW44278 in quantities of 25.
‡‡‡ Available only as HW44114 in quantities of 50.
¶ Available only as HW10432 in quantities of 25.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
2
1
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
3
#
6HFWLRQ
Table 5-3. Media Supply, Ribbon Supply,
and Ribbon Take-Up
Table 5-3. Media Supply, Ribbon Supply,
and Ribbon Take-Up
2
8
11
C
9
12
2
12
13
}
10
3
5
7
S400/S600 Maintenance Manual
15
B
14
16
22
4
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
1
6
18
21
20
19
A
17
6HFWLRQ
Page 5-7
Figure 5-3. Media Supply, Ribbon Supply, and Ribbon Take-Up
Part No.
Description
1
44329-400M
(A) Toggle Assembly
2
44360
Spring Washer
3
77687 Braided Ground Strap
4
44054
5
Screw, M3.5 × 20
01448* Screw, 6–32 × 0.37
6
44484** Screw, M4.2 × 1.41 × 25
7
44923*** Braided Ground Strap
8
45925M
44860† Screw, 10-32 × 1.5 SHCS
10
11
12
13
14
15
44339†† Hex Stand-Off
44180M
(B) Print Mechanism Assembly (S400)
44204M
(B) Print Mechanism Assembly (S600)
30466††† Washer, 0.26 × 0.63 × 0.06
07257‡ Washer, 0.438 × 0.188 × 0.049
44386‡‡ Screw, M4 × 0.7 × 16
06262‡‡‡ Nut, 6–32
44895L Rev. 3 3/15/04
* Available only as HW01448 in quantities of 25.
** Available only as HW44484 in quantities of 10.
*** Available only as HW44923 in quantities of 5.
† Available only as HW44860 in quantities of 25.
†† Available only as HW44339 in quantities of 10.
††† Available only as HW30466 in quantities of 25.
‡ Available only as HW44860 in quantities of 25.
‡‡ Available only as HW44386 in quantities of 25.
‡‡‡ Available only as HW06262 in quantities of 25.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
9
Head Open Sensor Flag
Qty
6HFWLRQ
#
7RJJOHDQG3ULQW0HFKDQLVP$VVHPEO\
Page 5-8
Table 5-4. Toggle and Print Mechanism
2
1
9
1
A
A
10
12
3
11
B
14
5
4
12 13
S400/S600 Maintenance Manual
6
7
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
8
15
B
15
{
Page 5-9
Figure 5-4. Toggle and Print Mechanism
6HFWLRQ
11
Print mechanism and mounting
hardware only.
See Table 5-5 and Figure 5-5 for
printhead assembly and printhead cable.
#
1
Part No.
4
Qty
44999M
(A) Printhead Assembly (S400)
1
44998M
(A) Printhead Assembly (S600)
1
2
3
Description
10460* Nut, M3 × 2.4 × 5.5
2
44180M
(B) Print Mechanism Assembly (S400)
1
44204M
(B) Print Mechanism Assembly (S600)
1
44527
Printhead Cable Assembly (S400)
1
44920
Printhead Cable Assembly (S600)
1
44386** Screw, M4 × 0.7 × 16
1
6
07257*** Flat Washer, 0.438 × 0.188 × 0.049
1
30466† Washer, 0.26 × 0.63 × 0.06
* Available only as HW10460 in quantities of 25.
** Available only as HW44386 in quantities of 25.
*** Available only as HW07257 in quantities of 25.
† Available only as HW30466 in quantities of 25.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
1
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
5
7
6HFWLRQ
Page 5-10
Table 5-5. Print Mechanism and Printhead Assembly
6HFWLRQ
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Figure 5-5. Print Mechanism and Printhead Assembly
A
1
3
1
A
B
2
7
6
5
4
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
Page 5-11
Table 5-6. Tear/ Cutter Media Sensor and Ribbon Guide
#
#
Part No.
1
Description
44054* Screw, M3 × 20
Qty
1
2
44123
Braided Ground Strap
1
3
44190-400M
(B) Ribbon Guide Assembly
1
4
44189
Anti-Static Brush
1
5
6
7
5
Ground Cable
1
30466*** Washer, 0.26 × 0.63 × 0.06
8
07257† Washer, 0.438 × 0.188 × 0.036
30393-008†† Screw, 8-32 × 0.500
10 44968
1
1
1
Ribbon Out Reflective Bracket
1
44135-400M
(A) Media Sensor Assembly
(Standard)
1
44911M
(A) Media Sensor Assembly (Black Mark)
1
12 44747
Media/Ribbon Sensor Cable
1
13 44011
Media Guide
1
11
Description
Qty
44140-400M
(C) Upper Media Guide Plate Assembly
(Tear-Off and Cutter Option only)
1
44140-402M
(C) Upper Media Guide Plate Assembly
(Peel-Off Option only)
1
Stationary Guide
1
44110-1 Adjustable Guide
1
14
15 44109
16
17
18
30208‡ Flat Washer, 0.50 × 0191 × 0.03
40194‡‡ Curved Washer, 0.344 × 0.172 × 0.006
1
1
19 44016
Upper Media Guide
1
20 Q10034
Washer, 0.381 × 0.126 × 0.042
1
21 10403
Screw, M3 × 0.5 × 6
1
* Available only as HW44054 in quantities of 10.
** Available only as HW44114 in quantities of 50.
*** Available only as HW30466 in quantities of 25.
† Available only as HW07257 in quantities of 25.
†† Available only as HW30393-008 in quantities of 25.
††† Available only as HW44484 in quantities of 10.
‡ Available only as HW30208 in quantities of 25.
‡‡ Available only as HW40194 in quantities of 25.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
9
44114** Screw, M4.2 × 1.41 × 8
44466
Part No.
6HFWLRQ
Page 5-12
Table 5-6. Tear/ Cutter Media Sensor and Ribbon Guide
1
2
3
7
6
B
9
8
B
S400/S600 Maintenance Manual
4
3
10
5
11
14
A
21
20
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
This end of the ground
strap attaches to the
print mechanism assembly.
5
C
12
19
18
17
16
13
Page 5-13
Figure 5-6. Tear/Cutter Media Sensor, Ribbon Guides, and Media Guide
6HFWLRQ
15
#
Part No.
1
44463M
Description
(A) Platen Guide Rod Kit
Qty
1
2
30224* Crescent Ring
2
3
44147** Set Screw
2
44118
Shaft Collar, 0.377 × 0.750
1
5
44349M
(B) Upper Media Rod Kit
1
6
44398M
(C) Lower Guide Rod Kit
1
7
44346
Edge Guide
2
8
10473
Washer, M4
1
44114*** Screw, M4.2 × 1.41 × 8
3
9
10 44391
Anti-Static Brush
1
11 44218
Backing Rewind Hook
1
12 44284M
(D) Media Take-Up Spindle Assembly
1
13 44390
Washer, 0.500 × 0.377 × 0.020
3
07257† Flat Washer, 0.438 × 1.41 × 25
1
14
15 44383
16
17 44191
Ground Cable Assembly
44386†† Screw, M4 × 0.7 × 16
Ground Chain Assembly
* Available only as HW30224 in quantities of 50.
** Available only as HW44147 in quantities of 25.
*** Available only as HW44114 in quantities of 50.
† Available only as HW07257 in quantities of 25.
†† Available only as HW44386 in quantities of 25.
44895L Rev. 3 3/15/04
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
1
1
1
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
4
6HFWLRQ
Page 5-14
Table 5-7. Peel-Off Option (Front View)
6HFWLRQ
6
13
13
10
6
7
5
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
11
C
B
A
1
2
12
D
3
4
9
8
Figure 5-7. Peel-Off Option (Front View)
A
1
14
B
C
5
D
15
B
12
D
17
16
13
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
Page 5-15
#
Part No.
1
Description
Qty
44023-0M
Stepper Motor (Tear-Off and Cutter Option)
1
44023-2M
Stepper Motor (Peel-Off Option)
1
2
44216* Screw, M4.2 × 1.41 × 13
1
44177
Tear-Plate Ground Strap
1
4
44019
Idler Shaft
1
5
44025
Idler Pulley, 20T (Tear-Off and Cutter
Option only)
1
Washer 0.198 × 0.75 × 0.085
(Tear-Off and Cutter Option)
1
Nut, M5 × 0.8 × 2.6
1
44172-2*** Ground Chain Assembly 1-1/8"
1
6
44356**
S400/S600 Maintenance Manual
7
44055
8
9
10
11
12
45189-5
Main Drive Belt (S400/600 Peel-Off
Option)
1
45189-6
Main Drive Belt (S600 Tear-Off and Cutter
Option)
1
45189-8
Main Drive Belt 160T (S400 Tear-Off and
Cutter Option)
1
44017
Platen Pulley (S400)
1
44022
Platen Pulley, 50T (S600)
1
44485 Screw, M3 × 8
44100† Set Screw, M3 × 0.5 × 6
44895L Rev. 3 3/15/04
* Available only as HW44216 in quantities of 25.
** Available only as HW44356 in quantities of 25.
*** Available only as HW44172-2 in quantities of 10.
† Available only as HW44100 in quantities of 25.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
1
1
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
3
6HFWLRQ
Page 5-16
Table 5-8. Tear/Cutter Drive System
6HFWLRQ
11
12
4
10
5
6
8
9
Figure 5-8. Tear/Cutter Drive System
7
3
1
2
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
S400/S600 Maintenance Manual
Page 5-17
#
Part No.
Description
Qty
#
Part No.
Description
Qty
1
44359M
(B) Peel-Off Upper Idler Assembly
1
21 44376
Washer, 0.420 × 0.254 × 0.010
3
2
44363
Screw, M5 × 0.8 × 25
1
22 44274
Bearing Plate
1
1
23 30104
Ball Bearing, 0.50 × 0.250 × 0.125
2
3
30261* Flat Washer, 0.442 × 0.255 × 0.020
4
44496 Peel Pulley Assembly
1
24 02252
External Crescent Ring 0.250
2
5
44359 Idler Spacer
1
25 44172-1
Ground Chain Assembly 1-3/4"
1
30163
Flat Washer, 0.720 × 0.262 × 0.047
1
26 44275
Power Roller
1
7
44142
Square Nut
1
27 10461
Nut, M4 × 0.7
2
8
45189-7
Belt 118T
1
28 44293
Eccentric Spring
1
9
44358M
(C) Media Take-Up Idler Assembly
1
29 44292
Eccentric Power Roller
1
10 44489
Shoulder Screw, M5 × 0.8 × 8
2
30 44383
Ground Cable Assembly
11 44487
Idler pulley, 0.750
2
31 44191
Ground Chain Assembly
12 10476
Flat Washer, M5
2
32
7
33 44387
Screw, M3.5 × 0.6 × 6
3
1
34 10427
Screw, M4 × 0.70 × 10
2
1
35 44282
Tear-Off Plate
1
3
36 44023-2M
Stepper Motor (Peel-Off Option)
1
13
44114** Screw, M4.2 × 1.41 × 8
14
44488 Idler Bracket
15 44536M
16
(A) Take-Label Sensor Assembly
44216*** Screw, M4.2 × 1.41 × 13
17 44665M
Full Roll Switch Assembly
1
18 44275M
(E) Power Roller Assembly
1
19 45189-5
Peel-Off Main Drive Belt
1
20 44368
(D) Carrier Idler Assembly
1
44176† Wire Clip
* Available only as HW30261 in quantities of 25.
** Available only as HW44114 in quantities of 50.
*** Available only as HW44216 in quantities of 25.
† Available only as HW44176 in quantities of 25.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
1
3
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
6
6HFWLRQ
Page 5-18
Table 5-9. Peel-Off Option Drive System
Table 5-9. Peel-Off Option Drive System
A
7
1
6
2 3 4 5
B
36
16
B
S400/S600 Maintenance Manual
13 14 15
9
37
1
13
A
11
34
35
C
A
10 12
19
8
33
17
30
31
16
15
18
24
20
D
18
E
12
10 11
32
22
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
15
E
29
E
26
24
21
23
13
27 28
18
21
13
21
25
23
Page 5-19
6HFWLRQ
Figure 5-9. Peel Option and Peel Drive System
#
Part No.
1
Description
44114* Screw, M4.2 × 1.41 × 8
Qty
4
2
44282
Tear-Off Plate
1
3
44015
Platen Sleeve Bearing
2
4
44120
Outboard Guide
1
44182
Platen Roller (S400)
1
44214
Platen Roller (S600)
1
44121
Inboard Guide
1
44484** Screw, M4.2 × 1.41 × 25
1
5
6
7
9
44115*** Screw, M4 × 10
45770M
10 44004-400M
2
Power Supply Assembly 120/240 VAC
1
Base Cover
1
* Available only as HW44114 in quantities of 50.
** Available only as HW44484 in quantities of 10.
*** Available only as HW44115 in quantities of 10.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
44895L Rev. 3 3/15/04
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
8
6HFWLRQ
Page 5-20
Table 5-10. Platen and Power Supply
1
2
4
3
3
6
7
S400/S600 Maintenance Manual
Bearings (item #3)
pictured here are installed
this way for the S400 only.
For the S600, rotate
bearings 180 degrees
(turn upside down).
8
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
5
9
10
6HFWLRQ
Page 5-21
Figure 5-10. Platen and Power Supply
#
Part No.
Description
Qty
1
44710M
Cutter Maintenance Kit
1
2
44986
Catch Tray
1
3
10432M
Plate Mounting Maintenance Kit
1
4
10432* Screw, M4 × 0.7 × 12
5
10474** Split Washer, M4
6
07257*** Washer, 0.438 × 0.188 × 0.036
7
44437M
Cutter Mounting Maintenance Kit
3
2
3
1
44437 Mounting Bushing
2
9
44433 Spring Washer
2
10
44432 Locating Post
2
11 06223
Cable Clamp 0.188
1
12 44674
Cable 8 Cond DIN (Cutter Cable)
1
13 10461
Nut M4 × 0.7
1
15
16 30781
17
44434 Nut Plate
01159† External Lock Washer, #6
Ground Cable
44053†† Screw, M3 × 0.6 × 10
44895L Rev. 3 3/15/04
* Available only as HW10432 in quantities of 25.
* Available only as HW10474 in quantities of 25.
** Available only as HW07257 in quantities of 25.
* Available only as HW01159 in quantities of 100.
* Available only as HW44053 in quantities of 10.
Bold=Part available for purchase
Light italic=Part not available for purchase, listed and shown for reference only
1
1
1
1
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
S400/S600 Maintenance Manual
8
14
6HFWLRQ
Page 5-22
Table 5-11. Cutter Option
16 15
14
Note: The cutter option is not field-installable.
Parts displayed below are for repairing
the factory-installed option. These parts
cannot be installed on non-cutter option
printers.
13
S400/S600 Maintenance Manual
7
8
9
B
10
2
65
4
0DLQWHQDQFHDQG$VVHPEO\'UDZLQJV
44895L Rev. 3 3/15/04
17
C
3
11
A
6
4
Page 5-23
Figure 5-11. Cutter Option
1
6HFWLRQ
12
0DLQWHQDQFH
Page 5-24
6HFWLRQ
S400/S600 Maintenance Manual
44895L Rev. 3 3/15/04
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AC Power Fuse Replacement .............. 4-61
Accessing the Printer .............................. 2-5
Additional Printer Self Tests ................. 2-14
Auto Calibration .................................... 2-21
%
Bar Codes ............................................... 1-2
Bitmapped Fonts ..................................... 1-3
&
Calibration ............................................. 2-21
Auto Calibration .............................. 2-21
Manual Calibration .......................... 2-22
Ribbon Parameter ........................... 2-23
Status Indicator ................................. 2-2
Calibration Reference Table ................. 4-17
Cancel Key .....................................2-3, 2-16
Cleaning
Cutter Module ..........................4-9–4-15
Exterior .............................................. 4-5
Interior ............................................... 4-5
Media and Ribbon Path .................... 4-5
Printhead and Platen ........................ 4-7
Schedule ........................................... 4-6
Codes, Bar .............................................. 1-2
Communication
.......................................................... 1-8
Specifications .................................... 1-9
Configuration Label ............................... 2-24
Configuration Mode ............................... 2-23
Control Panel ........................................ 4-36
Circuit Board Replacement ............. 4-37
Removal .......................................... 4-36
Cutter Mode ............................................ 1-1
'
Darken Status Indicator .......................... 2-2
Data Cable Installation .......................... 2-14
Data Status Indicator .............................. 2-1
Diagnostics ............................................ 4-15
Calibration Reference Table ........... 4-17
44895L Rev. 3 3/15/04
Extended Diagnostics ..................... 4-22
Feed Key Rollback Test .................. 4-23
Head Temp Test Label .......... 4-20, 4-21
Left Wrinkle Label ........................... 4-19
Lower Smear Test Label ................. 4-22
Pause & Cancel Key Label ............. 4-18
Pause and Cancel Key Self Test .... 4-16
Pause Key Loopback Test .............. 4-22
Right Wrinkle Label ......................... 4-19
Self Test Reference Table .............. 4-17
Sequence of Formats ..................... 4-18
Speed A Label ................................ 4-20
Upper Smear Test Label ................. 4-21
Usable Area Speed A Label ........... 4-20
Downloading Firmware ......................... 4-39
(
Electrical Adjustments .......................... 4-29
Cutter Voltage ........................ 4-32–4-33
Printhead Voltage .................. 4-29–4-31
Electrical Requirements .......................... 1-2
Electronics System Block Diagram ...... 1-14
Environmental Ranges ........................... 1-2
Equipment Safety .................................... 4-2
External Rewind Mode ............................ 1-1
)
Factory Assistance ............................... 3-11
Factory Default Reset ........................... 2-19
Factory Default Values ......................... 2-20
Feed and Pause Key ............................ 2-19
Feed Key ........................................ 2-3, 2-18
Feed Key Rollback Test ........................ 4-23
Fonts ....................................................... 1-3
Bitmapped ......................................... 1-3
International Characters ................... 1-3
Matrix (203 dpi) ................................. 1-3
Optional ............................................. 1-3
Scalable ............................................ 1-3
Standard ............................................ 1-3
S400/S600 Maintenance Manual
Index-1
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Green Light
See Operator Indicators .................... 2-1
,
International Characters ......................... 1-3
/
Label
Head Temp Test ............................. 4-21
Left Wrinkle ..................................... 4-19
Lower Smear Test ........................... 4-22
Pause and Cancel Key ................... 4-18
Right Wrinkle ................................... 4-19
Speed A .......................................... 4-20
Upper Smear Test ........................... 4-21
Language, Zebra Programming .............. 1-7
LED Quick Reference Chart ................... 3-2
Liner Rewind Power Roller Adjustment 2-30
Loading
Ribbon Supply Spindle ................... 2-12
Lubrication ............................................. 4-15
0
Main Drive Belt
...............................................4-51–4-52
Main Logic Board .................................. 4-38
Downloading Firmware ................... 4-39
Installation ..............................4-38–4-39
Removal .......................................... 4-38
Manual Calibration ................................ 2-22
Mechanical Adjustments ....................... 4-23
Liner Rewind Spindle ...................... 4-28
Printhead Position ..................4-23–4-25
Strip-Plate ....................................... 4-27
Media Loading ........................................ 2-6
Cutter Mode ...................................... 2-6
Fanfold Media ................................... 2-6
Peel-Off Mode ................................... 2-9
Removing the Liner ......................... 2-10
Roll Media ......................................... 2-6
Tear-Off Mode ................................... 2-6
Index-2
Media Sensor ........................................ 2-10
Media Sensor Assembly ....................... 4-49
Installation .............................. 4-49–4-50
Removal .......................................... 4-49
Memory
Options .............................................. 1-5
Upgrade .......................................... 4-62
Memory Specifications ............................ 1-5
Mode
Cutter ................................................ 1-1
External Rewind ................................ 1-1
Peel-Off ............................................. 1-1
Printer Operating ............................... 1-1
Tear-Off ............................................. 1-1
Mode Key ....................................... 2-3, 2-19
Modes, Printer Operating ........................ 1-1
2
Operating Modes, Printer ........................ 1-1
Operations Overview .............................. 2-1
Operator Controls ................................... 2-3
Cancel Key ........................................ 2-3
Feed Key ........................................... 2-3
Mode Key .......................................... 2-3
On/Off Switch .................................... 2-3
Pause Key ......................................... 2-3
Operator Indicators ................................. 2-1
Calibrate Status ................................ 2-2
Darken Status ................................... 2-2
Data Status ....................................... 2-1
Green Light ....................................... 2-1
Paper/Ribbon Status ......................... 2-1
Pause Status ..................................... 2-1
Power Status ..................................... 2-1
Printhead Status ............................... 2-1
Yellow Light ....................................... 2-1
Operators Indicators
Position Status .................................. 2-2
Optional Fonts ......................................... 1-3
3
Paper/Ribbon Status Indicator ................ 2-1
S400/S600 Maintenance Manual
44895L Rev. 3 3/15/04
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Parallel Data .......................................... 1-12
Connector Pinouts .......................... 1-13
Signal Levels ................................... 1-12
Pause and Cancel Key Self Test .......... 4-16
Pause Key ......................................2-3, 2-17
Pause Key Loopback Test .................... 4-22
Pause Status Indicator ............................ 2-1
Peel-Off Mode ......................................... 1-1
Personal Safety ....................................... 4-4
Physical Dimensions ............................... 1-5
Platen Roller Replacement ..........4-53–4-54
Position Status Indicator ......................... 2-2
Power On/Off Switch .............................. 2-3
Power Status Indicator ............................ 2-1
Power Supply ........................................ 4-57
Board Installation ...................4-58–4-60
Board Removal ...................... 4-57–4-60
Power-On Self Test ............................... 2-14
Print Darkness ...................................... 2-23
Setting Manually ............................. 2-25
Testing ............................................ 2-24
Print Mechanism Assembly Removal ... 4-40
Print Speeds ............................................ 1-6
Printer Operating Modes ......................... 1-1
Printhead
Assembly Removal and Installation .......
4-41– .................................... 4-43
Pressure Adjustment ...................... 2-29
Status Indicator ................................. 2-1
Printing Considerations ........................... 1-6
Printing Method ....................................... 1-6
Programming Language, Zebra .............. 1-7
5
Ranges
Environmental ................................... 1-2
Operating .......................................... 1-2
Storage .............................................. 1-2
Removing
Front Door ....................................... 4-34
Liner ................................................ 2-10
Main Door ........................................ 4-34
Rear Cover ...................................... 4-34
44895L Rev. 3 3/15/04
Used Ribbon ................................... 2-13
Repair Service Department .................. 3-11
Requirements, Electrical ......................... 1-2
Returning Equipment ............................ 3-11
Ribbon ..................................................... 1-7
Parameter ....................................... 2-23
Supply Spindle Disassembly .......... 4-44
Supply Spindle Installation .... 4-45–4-48
Take-Up Motor Replacement ......... 4-55
Routine Adjustments ............................. 2-29
Printhead Pressure ......................... 2-29
Rewind Power Roller ...................... 2-30
6
Scalable Fonts ........................................ 1-3
Self Test ................................................ 2-14
Calibration Quick Reference ........... 2-15
Cancel Key ...................................... 2-16
Feed Key ......................................... 2-18
Mode Key ........................................ 2-19
Pause and Cancel .......................... 4-16
Pause Key ....................................... 2-17
Power-On ........................................ 2-14
Reference Table ............................. 4-17
Self Test Reference Table .................... 4-17
Serial Data Connector ............................ 1-9
DB-9 Pinouts ................................... 1-11
RS-232 Interconnection .................. 1-10
RS-232 Signal Levels ..................... 1-11
Specifications
Agency Approvals ............................. 1-2
Communication ................................. 1-9
Media Considerations ....................... 1-4
Media Handling ................................. 1-4
Memory ............................................. 1-5
Microprocessor ................................. 1-5
Physical Dimensions ......................... 1-5
Print Speeds ..................................... 1-6
Printing Considerations ..................... 1-6
Printing Method ................................. 1-6
Ribbon Considerations ..................... 1-7
Serial Data ........................................ 1-9
Status Indicators
S400/S600 Maintenance Manual
Index-3
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See Operator Indicators .................... 2-1
Status Lights
See Operator Indicators .................... 2-1
Stepper Motor Replacement ........ 4-56–4-57
7
Tear-Off
Mode ................................................. 1-1
Plate Removal ................................. 4-36
Position Adjustment ........................ 2-27
Technical Support ................................. 3-11
Top of Label Position Adjustment ......... 2-28
Troubleshooting ...................................... 3-1
Cutter-Related ................................... 3-9
Jammed or Stuck Labels .................. 3-8
LED Quick Reference Chart ............. 3-2
Printer Status Sensors .............3-9, 3-10
Problems with LED Indications ..3-3, 3-6
Settings or Parameter-Related ......... 3-9
Wrinkled Ribbon ................................ 3-8
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Yellow Light
See Operator Indicators .................... 2-1
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Zebra Programming Language ............... 1-7
ZIP Support ........................................... 3-11
ZPL II ....................................................... 1-7
Index-4
S400/S600 Maintenance Manual
44895L Rev. 3 3/15/04

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