Zebra TLP 2824 Plus™ Desktop Thermal Printer User Guide
ii ©2009 ZIH Corp. The copyrights in this manual and the software and/or firmware in the label printer described therein are owned by ZIH Corp. Unauthorized reproduction of this manual or the software and/or firmware 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. All trademarks and registered trademarks are property of their respective owners. All rights reserved.
iii FCC Compliance Statement This device complies with Part 15 rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for Class B Digital Devices, pursuant to Part 15 of the FCC Rules.
iv Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ________________________________________________________
About This Document This section provides you with contact information, document structure and organization, and additional reference documents. Contents Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi About This Document Who Should Use This Document Who Should Use This Document This User Guide is intended for use by any person who needs to operate or to troubleshoot problems with the printer. How This Document Is Organized The User Guide is set up as follows: 980643-001 Rev. A Section Description Introduction on page 1 This section describes what you get in your shipping box and provides an overview of printer features.
About This Document Contacts Contacts Technical Support via the Internet is available 24 hours per day, 365 days per year. Web Site: www.zebra.com E-mail Back Technical Library: emb@zebra.com Subject line: Emaillist Self Service Knowledge Base: www.zebra.com/knowledgebase Online Case Registration: www.zebra.
viii About This Document Document Conventions Document Conventions The following conventions are used throughout this document to convey certain information. Alternate Color (online only) Cross-references contain hot links to other sections in this guide. If you are viewing this guide online in .pdf format, you can click the cross-reference (blue text) to jump directly to its location. Command Line Examples Command line examples appear in Courier New font.
Contents About This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Who Should Use This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi How This Document Is Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
x Modes of Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Determining Thermal Media Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xi 6 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Status Light Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Light Error Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Calibration . .
xii Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ _______________________________________________________
1 Introduction This section describes what you get in your shipping box and provides an overview of printer features. This includes procedures that describe how to open and close the printer and report any problems. Contents TLP 2824 Plus™ Thermal Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What’s in the Box? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpack and Inspect the Printer . . . . .
2 Introduction TLP 2824 Plus™ Thermal Printers TLP 2824 Plus™ Thermal Printers The Zebra TLP 2824 Plus™ model is the best in class desktop thermal printer with the widest range of features. The TLP 2824 Plus™ printer provides thermal transfer and direct thermal printing at speeds up to 4 ips (inches per second) at a 203 dpi (dots per inch) print density, supports both ZPL and EPL Zebra printer programming languages and a variety of interface and feature options.
Introduction What’s in the Box? What’s in the Box? Save the carton and all packing materials in case you need to ship or store the printer later. After unpacking, make sure you have all parts. Follow the procedures for inspecting the printer to familiarize yourself with printer parts so you can follow the instructions in this book.
4 Introduction What’s in the Box? Your Printer Status Light Ring Release Latches Feed Button Power Switch Release Latches Reset Button Access Pinhole DC Power Receptacle Interface Connectors Opening the printer To access the media compartment, you must open the printer. Pull the release latches towards you and lift the cover. Check the media compartment for loose or damaged components.
Introduction What’s in the Box? Printer Features Printhead Supply Spindles Ribbon Motion Sensor Take Up Spindles Printhead Roll Holders Web (GAP) Sensor Media Guides Black-Line Sensor Media Guide Adjustment Dispenser Option Platen Roller Head-Up Sensor (inside) Dispenser Door (open) Sensor 3/31/09 Pinch Roller Peel Bar TLP 2824 Plus™ User Guide 980643-001 Rev.
6 Introduction What’s in the Box? Media Cutter (Option) 980643-001 Rev.
Introduction What’s in the Box? Operator Controls Power Switch Press the rear of the switch to turn ON or front of the switch to turn OFF the printer. Caution • The printer power should be turned off before connecting or disconnecting the communications and power cables. Power Switch OFF Power Switch Power Switch ON Reset Button (hidden) Use a opened paper clip as a probe to press the hidden reset button below the power switch.
8 Introduction What’s in the Box? Feed Button • Tap the Feed button once to force the printer to feed one blank label. • Press the Feed button to take the printer out of a “pause” condition. The printer is put into “pause” by either a programming command or an error condition. See What the Status Light is Telling You on page 74 in the Troubleshooting chapter. • Use the Feed button for printer setup and status (see Feed Button Modes on page 84 in the Troubleshooting chapter).
Introduction What’s in the Box? Closing the printer 1. To lower the top cover, first press the top cover’s latching stand towards the center of the printer. Gently swing the top cover down onto the printer’s base. 2 1 2. Press down on both sides until the cover snaps closed, typically with an audible sound. 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
10 Introduction What’s in the Box? Printer Storage and Prolonged Inactivity • If you are not placing the printer into immediate operation, repackage it using the original packing materials. • Storage Temperature Range: –40° to 60°C (–40°F to 140°F) • Storage Humidity Range: 5% to 95% non-condensing • When storing the printer or if the printer is going to be inactive for more than a day, please place a label on the platen (drive) roller before closing the printer.
2 Getting Started This section describes how to set up your printer for the first time and use the most common operating procedures for loading media. Contents Attaching Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading Transfer Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Getting Started Attaching Power Attaching Power Important • Set up your printer so that you can handle the power cord easily if needed. To make certain the printer cannot carry electrical current, you must separate the power cord from the power supply receptacle or AC electrical outlet. Caution • Never operate the printer and power supply in an area where they can get wet. Serious personal injury could result! 1. Make sure the printer’s power switch is in the OFF position (0). 2.
Getting Started Loading Roll Media Loading Roll Media When you load media, you must place the roll onto the media hangers. You must use the correct media for the type of printing you require. Preparing Media Whether your roll media is inside or outside wound, you load it into the printer the same way. • Remove the outside length of media. During shipment, handling, or storage, the roll may become dirty or dusty.
14 Getting Started Loading Roll Media Placing the Roll in the Media Compartment 1. Open the printer. Remember that you need to pull the release latch levers toward the front of the printer. 2. Check the core of the media roll and adjust the roll holder’s slide adjustment, if necessary. 1 inch (25.4 mm) diameter 1.5 inch (38.1 mm) diameter 980643-001 Rev.
Getting Started Loading Roll Media 3. Open the media guides wider than the media width. Turn the media guide’s thumb wheel towards the rear of the printer to open the guides wider. 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
16 Getting Started Loading Roll Media 4. Open the media roll holders. Pull the media guides open with your free hand and place the media roll on the roll holders and release the guides. Orient the media roll so that its printing surface will face up as it passes over the platen (drive) roller. 980643-001 Rev.
Getting Started Loading Roll Media 5. Pull the media so that it extends out of the front of the printer. Verify the roll turns freely. The roll must not sit in the bottom of the media compartment. Verify that media’s printing surface is facing up. 6. Push the media under both of the media guides. Under Media Guides 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
18 Getting Started Loading Roll Media 7. Adjust the media guides so that the both sides of the media are just touching the inside of the guides. Turn the media guide’s thumb wheel towards the front of the printer to made the guides tighter (narrower). 8. Close the printer. To lower the top cover, first press the top cover’s latching stand towards the center of the printer. Gently swing the top cover down onto the printer’s base.
Getting Started Loading Transfer Ribbon Loading Transfer Ribbon Transfer ribbons come in several varieties and in some cases colors to match your application needs. Zebra brand transfer ribbons are specifically designed for your printer and Zebra brand media. Using non-Zebra brand or media or ribbon not approved for use in your Zebra printer may damage your printer or printhead. • The media and ribbon types should be matched to provide you with optimal print results.
20 Getting Started Loading Transfer Ribbon 2. First slide the ribbon roll onto the right hand supply spindle. Push the right spindle in and swing the left side of the ribbon roll onto the left side ribbon spindle. Rotate the ribbon roll on the left spindle till it locks the ribbon roll’s core notches onto the spindle. 2 1 4 3 Rotate the roll until the not ches al ign and l ock int o the l ef t side of the s upply hub. 980643-001 Rev.
Getting Started Loading Transfer Ribbon 3. Place an empty ribbon core on printer’s take-up spindles. Rotate the ribbon core until the notches align and lock into the left side of the take-up hub. You can find your first ribbon take-up core in the packing box. Subsequently, use the empty supply core to take up the next roll of ribbon. 4. Pull the transfer ribbon’s leader around from below the ribbon frame. Attach it with the adhesive strip on the leader to the empty ribbon core on the supply spindle.
22 Getting Started Loading Transfer Ribbon 5. Rotate the thumb wheel on the left side of the ribbon frame by the supply spindle until the ribbon is pulled tight across the printhead. DO NOT TOUCH Ribbon Out Sensor Thumb Wheel 6. Verify that the media is loaded and ready to print and then close the printer cover. 7. Press the Feed button to have the printer feed a minimum of 10 cm (4 inches) of media to remove slack and ribbon wrinkle, and to align the ribbon on the spindles. 8.
Getting Started Printing a Test (Printer Configuration) Label Printing a Test (Printer Configuration) Label Before you connect the printer to your computer, make sure that the printer is in proper working order. You can do this by printing a configuration label. 1. Make sure the media is properly loaded and the top cover of the printer is closed. Then, turn the printer power on if you have not already done so.
24 Getting Started Connecting the Printer to the Computer Connecting the Printer to the Computer The Zebra 2824 Plus printers support a variety of interface options and configurations. These include: Universal Serial Bus (USB) interface, RS232 Serial, Parallel (IEEE 1284.4) and 10/100 Ethernet. Caution • Keep the power switch in the OFF position when attaching the interface cable.
Getting Started Connecting the Printer to the Computer USB Interface Requirements Universal Serial Bus (version 2.0 compliant) provides a fast interface that is compatible with your existing PC hardware. USB’s “plug and play” design makes installation easy. Multiple printers can share a single USB port/hub. When using a USB cable (not supplied with your printer), verify that the cable or cable packaging bears the “Certified USB™” mark (see below) to guarantee USB 2.0 compliance. .
26 Getting Started Connecting the Printer to the Computer Serial Communications The required cable must have a nine-pin “D” type (DB-9P) male connector on one end, which is plugged into the mating (DB-9S) serial port located on the back of the printer. The other end of this signal interface cable connects to a serial port at the host computer.
Getting Started Connecting the Printer to the Computer EPL Y Command Use the serial port setup (Y) command to change the communications settings on the printer. 1. With the host computer set at the same communications settings as the printer, send the Y command to change the printer to the desired settings. Note: the Y command does not support setting the data flow control, use the Xon/Xoff setting. 2. Change the host computer settings to match the new printer settings.
28 Getting Started Connecting the Printer to the Computer Parallel Port The required cable must have a twenty-five pin “D” type (DB-25P) male connector and a “Centronics” on the printer connector (IEEE 1284 A-C parallel interface specification). Tighten the cable connector’s screw locks to secure the cable to the printer and computer. Note • The printer design does not allow for the use non-molded cables such as hand-made cables with clam shell connector covers. Parallel Cable 980643-001 Rev.
Getting Started Connecting the Printer to the Computer Ethernet The printer requires UTP RJ45 Ethernet cable rated CAT-5 or better. For more information on configuring your printer to run on a compatible Ethernet based network, see the ZebraNet® 10/100 Internal Print Server manual. The printer must be configured to run on your LAN (local area network). The print server on board your printer can be accessed through the printer’s web pages.
30 Getting Started Connecting the Printer to the Computer Installing Printer Drivers and Communicating with the Printer Zebra provides the Zebra Setup Utilities (ZSU); a suite of Zebra printer drivers, utilities, and communications and installation tools for use with most Windows PC operating systems. Zebra Setup Utilities and Zebra Windows printer drivers are available on the user’s CD and the Zebra web site (www.zebra.com) for latest versions.
3 Print Operations This section provides media and print handling, font and language support, and the setup of less common printer configurations. Contents Determining Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 Print Operations Determining Printer Configuration Determining Printer Configuration The 2824 Plus printer uses a ZPL printer configuration status label to report the printer’s configuration status for both EPL and ZPL operations.The ZPL style label provides a more intuitive and functionally descriptive naming conventions than the EPL style printer status label. Operational status (darkness, speed, media type, etc.), installed printer options (network, interface settings, cutter, etc.
Print Operations Modes of Printing Modes of Printing You can operate this printer in many different modes and media configurations: • Direct thermal printing (which uses heat sensitive media to print). • Thermal transfer printing (which uses ribbon to heat transfer print to the media). • Standard Tear-Off mode allows you to tear off each label (or batch print a strip of labels) after it is printed.
34 Print Operations Print Media Types Table 1 • Types of Media Roll and Fanfold Media Media Type Non-Continuous Roll Media How It Looks Description Roll media is wound on a core that can be 1 in. to 1.5 in. (25 to 38.1 mm) in diameter. Labels have adhesive backing that sticks them to a liner, and they are separated by gaps, holes, notches, or black marks. Tags are separated by perforations.
Print Operations Replacing Supplies Determining Thermal Media Types Thermal transfer media requires ribbon for printing while direct thermal media does not. To determine if ribbon must be used with a particular media, perform a media scratch test. To perform a media scratch test, complete these steps: 1. Scratch the print surface of the media with a finger nail or pen cap. Press firmly and quickly while dragging it across the media surface.
36 Print Operations Adjusting the Print Width Replacing a Partially Used Transfer Ribbon To remove used transfer ribbon, perform the following steps. 1. Cut the ribbon from the take-up roll. 2. Remove the take-up roll and discard used ribbon. 3. Remove the supply roll and tape the end of any fresh ribbon to prevent it from unwrapping. When reinstalling a partially used supply roll, tape the cut end onto the empty take-up roll.
Print Operations Media Sensing Media Sensing The 2824 Plus printer has automatic media sensing capability. The printer is designed to continuously check and adjust media length sensing for minor variations. Once the printer is printing or feeding media, the printer continually checks and adjusts the media sensing to accommodate for minor changes in media parameters from label to label on a roll and from roll to roll of media.
38 Print Operations Ribbon Overview Ribbon Overview Ribbon is a thin film that is coated on one side with wax, resin, or wax resin, which is transferred to the media during the thermal transfer process. The media determines whether you need to use ribbon and how wide the ribbon must be. When ribbon is used, it must be as wide as or wider than the media being used. If the ribbon is narrower than the media, areas of the printhead are unprotected and subject to premature wear.
Print Operations Ribbon Overview Ribbon Scratch Test Perform the ribbon scratch test when labels are unavailable. To perform a ribbon scratch test, complete these steps: 1. Unroll a short length of ribbon. 2. Place the unrolled section of ribbon on a piece of paper with the outer surface of the ribbon in contact with the paper. 3. Scratch the inner surface of the unrolled ribbon with your fingernail. 4. Lift the ribbon from the paper. 5. Observe the results.
40 Print Operations Printing on Fan-Fold Media Printing on Fan-Fold Media Printing on fan-fold media requires you to adjust the media guide’s stop position. 1. Open the top cover. 2. Open the hangers to their widest position. 3. Snap the holder-open lock towards the front of the printer. 4. With a sample of your media, adjust the guides to the width of the media. The guides should just touch, but not restrict, the edges of the media. 5. Insert the media through the slot at the rear of the printer. 6.
Print Operations Printing with Externally Mounted Roll Media Printing with Externally Mounted Roll Media The 2824 Plus printer accommodates externally mounted roll media similar to the printer’s support of fan-fold media. The printer requires the media roll and stand combination to have a low initial inertia to pull the media off the roll. Zebra at this time does not offer an external media option for the 2824 Plus printer.
42 Print Operations Fonts and Your Printer Fonts and Your Printer The 2824 Plus printer supports your language and font requirements with a variety of internal fonts, on-board font scaling, international font sets and character code page support, Unicode support, and font download. The printer includes utilities and application software that support font download into the printer for both printer programming languages. The 2824 Plus printer’s font capabilities are programming language dependent.
Print Operations Fonts and Your Printer Localizing the Printer with Code Pages The 2824 Plus printer supports two sets of language, region and character sets for permanent fonts loaded into the printer for each printer programming language, ZPL and EPL. The printer supports localization with common international character map code pages. • For ZPL code page support, including Unicode, see the ^CI command in the ZPL programmer’s guide.
44 Print Operations Stand Alone Printing Stand Alone Printing Your printer can be configured to work without being attached to a computer. The printer has the ability to automatically run a single label form. One or more downloaded label forms can be accessed and run with a terminal or wedge device or a Zebra KDU (keyboard display unit) to call a label form. These methods allow the developer to incorporate data input devices, such as scanners or weight scales, to the printer via the serial port.
4 Printer Options This section covers the common printer options and accessories with brief descriptions and how to get you started using or configuring your printer option or accessory. Contents Label Dispenser Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutter Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZebraNet® 10/100 Internal (Wired) Print Server Option . . . .
46 Printer Options Label Dispenser Option Label Dispenser Option The factory installed label dispenser option allows you to print a label with backing (liner/web) being removed from the label as it prints, ready for application. When printing multiple labels, removing the dispensed (peeled) label notifies the printer to print and dispense the next label.
Printer Options Label Dispenser Option 2. Lift the liner over the top of the printer and open the dispenser door. 3. Insert the label liner between the dispenser door and the printer body. 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
48 Printer Options Label Dispenser Option 4. Close the dispenser door. 5. Press the Feed button to advance the media. 6. During the print job, the printer will peel off the backing and present a single label. Taking the label from the printer to allow the printer to print the next label. Note: If you did not activate the label taken sensor to detect the removal of the dispensed (peeled) label with software commands, the printer will stack and eject peeled labels. 980643-001 Rev.
Printer Options Cutter Option Cutter Option The printer has a factory installed media cutter option for full width cutting of label liner, tag or receipt media. The type of cutter option installed in your printer can be verified by printing a printer configuration status label. The cutter options are: • A medium duty cutter for cutting label liner and light tag media (LINER/TAG) Maximum Paper Weight (thickness): up to 180 g/m2 (0.0077 in.) Life*: 2 million cuts: 0.
50 Printer Options Cutter Option Loading Media with the Cutter Option 1. Open the printer. Remember that you need to pull the release latch levers toward the front of the printer. 2. Check the core of the media roll and adjust the roll holder’s slide adjustment, if necessary. 1 inch (25.4 mm) diameter 1.5 inch (38.1 mm) diameter 980643-001 Rev.
Printer Options Cutter Option 3. Open the media guides wider than the media width. Turn the media guide’s thumb wheel towards the rear of the printer to open the guides wider. 4. Open the media roll holders. Pull the media guides open with your free hand and place the media roll on the roll holders and release the guides. Orient the media roll so that its printing surface will face up as it passes over the platen (drive) roller. 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
52 Printer Options Cutter Option 5. Pull and thread the media through the cutter so that it extends out of the front of the printer. Verify the roll turns freely. The roll must not sit in the bottom of the media compartment. Verify that media’s printing surface is facing up. 6. Push the media under both of the media guides. Under Media Guides 980643-001 Rev.
Printer Options Cutter Option 7. Adjust the media guides so that the both sides of the media are just touching the inside of the guides. Turn the media guide’s thumb wheel towards the front of the printer to made the guides tighter (narrower). 8. Close the printer. To lower the top cover, first press the top cover’s latching stand towards the center of the printer. Gently swing the top cover down onto the printer’s base.
54 Printer Options ZebraNet® 10/100 Internal (Wired) Print Server Option ZebraNet® 10/100 Internal (Wired) Print Server Option The ZebraNet® 10/100 Internal Print Server (PS) is an optional factory installed device that connects the network and your ZebraLinkTM-enabled printer. The print server provides you with a browser interface for printer and print server settings.
Printer Options ZebraNet® 10/100 Internal (Wired) Print Server Option Printer Network Configuration Status Label 2824 Plus printers with the ZebraNet® 10/100 Internal Print Server option on-board print an additional printer configuration status label for information needed to establish and trouble shoot network printing. The following printout is printed with the ZPL ~WL command.
56 Printer Options RTC and Full Flash Memory Option RTC and Full Flash Memory Option Printers with the factory installed RTC (Real Time Clock) and Full Flash Memory option allow you to create highly customize-able printer applications, improve printer productivity and flexibility, and provide extra memory to store more forms, graphics (logos), fonts, and the large Asian font sets.
Printer Options Asian Fonts - Printer Accessory Asian Fonts - Printer Accessory Asian font sets are downloaded into the printer by the user or integrator. Your 2824 Plus printer must have the RTC and Full Flash Printer Memory option installed to support the large Asian font files. The fonts are obtained separately from the printer.
58 Printer Options KDU — Printer Accessory KDU — Printer Accessory The KDU (keyboard display unit) is a small terminal unit that interfaces with the printer for accessing EPL label forms stored in the printer. Your 2824 Plus printer must include the serial port option to operate with the KDU. The KDU is strictly a terminal and does not have the capability to store data or set up parameters.
Printer Options KDU Plus — Printer Accessory KDU Plus — Printer Accessory The KDU Plus is a terminal device with memory for storing files and maintaining one or more remote printers. The KDU Plus has a larger laptop style keyboard than the Zebra’s original KDU design. Your 2824 Plus printer must include the serial port option to operate with the KDU Plus.
60 Printer Options KDU Plus — Printer Accessory Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________
5 Maintenance This section provides routine cleaning and maintenance procedures. Contents Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Path Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen Cleaning and Replacement . . . . . . . . . .
62 Maintenance Cleaning Cleaning When you clean the printer, use one of the following supplies that best suits your needs: Cleaning Supplies Order Quantity Intended Purpose Cleaning pens (105950-035) Set of 12 Clean printhead Cleaning swabs (105909-057) Set of 25 Clean media path, guides and sensors You can obtain cleaning supplies at www.zipzebra.com. The cleaning process takes just a couple of minutes using the steps outlined below.
Maintenance Cleaning Cleaning the Printhead Always use a new cleaning pen on the printhead (an old pen carries contaminants from its previous uses that may damage the printhead). Caution • The printhead becomes hot while printing. To protect from damaging the printhead and risk of personal injury, avoid touching the printhead. Use only the cleaning pen to perform maintenance. When you load new media, you can also clean the printhead. 1. Rub the cleaning pen across the dark area of the printhead.
64 Maintenance Cleaning Media Path Considerations Use a cleaning swab to remove debris or dust that has built-up on the holders, guides and media path surfaces. 1. Use the alcohol in the cleaning swab to soak the debris to break up the adhesive. 2. Wipe the ridges to remove accumulated debris. 3. Wipe the inside edges of both edge guides to remove any built-up residue. 4. Wait one minute before closing the printer. Discard the cleaning swab after use.
Maintenance Cleaning Sensor Cleaning Dust can accumulate on the media sensors. 1. Gently brush away dust; if necessary, use a dry swab to brush away dust. If adhesives or other contaminates remain, use an alcohol moistened swab to break it up. 2. Use a dry swab to remove any residue that may be left from the first cleaning. 3. Repeat steps 1 and 2 as required until all residue and streaks are removed from the sensor. .
66 Maintenance Cleaning Platen Cleaning and Replacement The standard platen (drive roller) normally does not require cleaning. Paper and liner dust can accumulate without effecting print operations. Contaminates on the platen roller can damage the printhead or cause the media to slip or stick when printing. Adhesive, dirt, general dust, oils and other contaminates should be cleaned immediately off the platen.
Maintenance Cleaning 3. Lift the platen out of the printer’s bottom frame. 4. Clean the platen with the alcohol moistened swab. Clean from the center out. Repeat this process until the all of the roller surface has been cleaned. If there has been heavy adhesive build-up or label jam, repeat with a new swab to remove residual contaminates. Adhesives and oils, for example, may be thinned by the initial cleaning but not completely removed. 5. Install the platen in the printer.
68 Maintenance Replacing the Printhead Replacing the Printhead If you need to replace the printhead, read the procedure and review the removal and installation steps before actually replacing the printhead. Caution • Prepare your work area by protecting against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself.
Maintenance Replacing the Printhead 3. Use the spring to pry the printhead clip off the right side of the carriage. 4. Pull the printhead and bracket forward. 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
70 Maintenance Replacing the Printhead 5. Use a #2 Phillips driver to remove the screw that holds the ground wire. 6. Gently but firmly pull the two printhead cable bundles’ connectors off of the printhead. Replacing the Printhead 1. Detach the wire cover. 2. Detach the ribbon take-up hub and spring. 3. Align the printhead and bracket to plug the left and right connectors into the black and white wire bundles. 4. Attach the ground wire and secure it with the screw.
Maintenance Replacing the Printhead 11. Clean the printhead. Use a new pen to wipe body oils (finger prints) and debris off the printhead. Clean from the center of the printhead to the outside. See Cleaning the Printhead on page 63. 12. Reload media and ribbon. Plug in the power cord, turn on the printer and print a status report to ensure proper function. See Printing a Test (Printer Configuration) Label on page 23.
72 Maintenance Replacing the Printhead Notes • ___________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ ___________________
6 Troubleshooting This section provides information about printer error reporting that you might need for printer troubleshooting. Assorted diagnostic tests are included. Contents Status Light Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Light Error Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74 Troubleshooting Status Light Descriptions Status Light Descriptions What the Status Light is Telling You 980643-001 Rev.
Troubleshooting Status Light Error Resolutions Status Light Error Resolutions 1. The printer is not receiving power. • Have you turned on the printer power? • Check power connections from the wall outlet to the power supply, and from the power supply to the printer. Check the power supply’s power indicator light. See Attaching Power on page 12. • Disconnect the printer from the wall outlet for 30 seconds and then reconnect the printer to the wall outlet. 2. The printer is on and in an idle state.
76 Troubleshooting Status Light Error Resolutions 5. The media is out. • Follow the instructions for Loading Roll Media on page 13 in the Getting Started section, and then press the Feed button to resume printing. The ribbon is out. • The printer has sensed the end of the ribbon roll. Replace the ribbon. The printhead is open. • Close the top cover and then press the Feed button to resume printing. 6. The printer is paused. • Press the Feed button to resume printing. 7.
Troubleshooting Print Quality Problems Print Quality Problems No print on the label. • The media may not be direct thermal media when printing without ribbon (i.e. thermal transfer). See the test procedure Determining Thermal Media Types on page 35. • For thermal transfer printers, the media may not be outside wound or approved for use in the 2824 Plus printer. See the following ribbon test procedures: Ribbon Test with Adhesive on page 38 and Ribbon Scratch Test on page 39.
78 Troubleshooting Print Quality Problems There are long tracks of missing print (blank vertical lines) on several labels. • The printhead is dirty. Clean the printhead. • The printhead elements are damaged. The printing does not start at the top of the label or misprinting of one to three labels. • The media may not be threaded correctly. Follow the instructions for Loading Roll Media on page 13 in the Getting Started section. • The printer needs to be calibrated.
Troubleshooting Print Quality Problems A EPL label format was sent to, but not recognized by, the printer. • Is the printer in pause mode? If so, press the Feed button. • If the printer has label dispensing enabled, the printer may be waiting for the label to be removed. The liner/web must be properly threaded through the label dispenser mechanism (peeler) to correctly operate in label dispense mode, refer to Label Dispenser Option on page 46.
80 Troubleshooting Manual Calibration Manual Calibration Manual calibration is recommended whenever you are using pre-printed media or if the printer will not correctly auto calibrate. 1. Make sure media is loaded. 2. Turn on the printer power. 3. Press and hold the Feed button until the green status light flashes once, then twice and then continuing until the flash groups reach the group of seven flashes. Release the Feed button. 4. The printer will set the media sensor for the label backing being used.
Troubleshooting Troubleshooting Tests Troubleshooting Tests Printing a Configuration Label To print out a listing of the printer’s current configuration, refer to the one-flash sequence in Feed Button Modes on page 84 in this section Recalibration Recalibrate the printer if it starts to display unusual symptoms, such as skipping labels. Refer to the two-flash sequence in Feed Button Modes on page 84 in this section. 3/31/09 TLP 2824 Plus™ User Guide 980643-001 Rev.
82 Troubleshooting Resetting the Factory Default Values Resetting the Factory Default Values Sometimes, resetting the printer to the factory defaults may solve some problems. Refer to the four-flash sequence in Feed Button Modes on page 84 in this section. Communications Diagnostics If there is a problem transferring data between the computer and printer, try putting the printer in the communications diagnostics mode.
Troubleshooting Communications Diagnostics The following example of a communications DUMP mode printed out. The printout displays hexadecimal data 00h-FFh (0-255 decimal) with a unique character for each hexadecimal value displayed above the hexadecimal data. The blank lines between the lines of data are where serial port and Bluetooth data handling errors get logged.
84 Troubleshooting Feed Button Modes Feed Button Modes Power Off Mode (Communications Diagnostics Mode) With the printer power off, press and hold the Feed button while you turn on the power. Flash Sequence Rapid Red Flashing Action Firmware Download Mode - The printer starts rapidly flashing red to denote entry into the Firmware Download mode. Releasing the Feed button here will start initializing the printer for download.
Troubleshooting Feed Button Modes Power On Modes With the printer power on and top cover closed, press and hold the Feed button for several seconds. The green status LED will flash a number of times in sequence. The explanation at the right (Action) shows what happens when you release the key after the start specific number of flashes and before the next flash sequence starts. Flash Sequence Action * Configuration Status - Prints a detailed printer configuration status label.
86 Troubleshooting Using the Printer’s Reset Button Using the Printer’s Reset Button The printer’s reset button can restore the printer or network (the internal print server) to factory default configuration. By pressing and holding the reset button for one (1) or more seconds, the printer will enter a reset sequence and the status light will begin blinking every second until released. Releasing the button at the appropriate time tells the printer which reset function to perform.
A Appendix This section provides printer interface connection information. Contents Universal Serial Bus (USB) Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethernet Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Port Interface . . . . . . . . . . . . . . .
88 Universal Serial Bus (USB) Interface Universal Serial Bus (USB) Interface The figure below displays the cable wiring required to use the printer’s USB interface. The printer requires cable or cable packaging that bears the “Certified USB™” mark to guarantee USB 2.0 compliance.
Parallel Interface Parallel Interface The printer’s parallel interface uses the IEEE 1284-A to 1284-C parallel interface cables. the host connector has a DB-25 pin male connector. The printer connector is a Centronics style connector. HOST DB-25 Pin No. STROBE~ DATA 0 DATA 1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 ACK~ BUSY PAPER ERR. SELECT AUTOFD~ ERROR~ N/A N/A N/A SIG. GND SIG. GND SIG. GND SIG. GND SIG. GND SIG. GND SIG.
90 Ethernet Interface Ethernet Interface This interface requires a UTP RJ45 Ethernet cable rated CAT-5 or better. The table below provides the cable’s pinout assignments. Signal Tx+ TxRx+ — — Rx— — Pin 1 2 3 4 5 6 7 8 Signal Tx+ TxRx+ — — Rx— — 5 6 7 8 4 3 2 1 980643-001 Rev.
Serial Port Interface Serial Port Interface Pin 1 2 3 4 5 6 7 8 9 Description Not used RXD (receive data) input to the printer TXD (transmit data) output from the printer DTR (data terminal ready) output from the printer -- controls when the host may send data Chassis ground DSR (data set ready) input to the printer RTS (request to send) output from the printer -- always in the ACTIVE condition when the printer is turned on CTS (clear to send) - Not used by the printer +5 V @ 0.
92 Serial Port Interface Connecting the Printer to a DTE Device DB-25S Connector to DTE Device (PC) DB-9P Connector to Printer DB-9S Connector to DTE Device (PC) DB-9P Connector to Printer Connecting the Printer to a DCE Device DB-25S Connector to DCE Device 980643-001 Rev.
