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Zebra G105156

1. Ka A K Figure 3 9 Printer Mounting Table 3 6 M3 Metric Mounting Screw Length M3 Screw 1 5mm minimum Printer mounting surface 1 5mm Printer base plate thickness N lt xe 2mm maximum Penetration into circuit board area X Y minimum length X Y Z maximum length P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printer Overview 19 Design Your Own Mounting Design Your Own Mounting The illustration below gives an example of a printer mounting shelf Be Leaf spring 01473 000 156 mm 132 mm 90 8 mm 10 mm Min 100 mm E 0 EMEN are 8 Comte 10 mm 10 mm 20 mm 44mm Add material for corner radius Paper widt 10 mm 211 mm Figure 3 10 Printer Mounting Additional space is required for paper loading and service access Consider mounting the printer on a movable platform so that the printer can be maintained outside the printer enclosure Note We recommend making the output slot 97 mm wide This width should accommodate all paper widths that the KR403 printers can handle Caution NEVER use screws that go into the printer more than 4 mm This will damage the electronics inside 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 20 Printer Overview Print Modes Pri
2. 44 Basic Media Mounting Considerations 45 Media Supply Method 46 Media InputAperture 46 Mounting Orientations 48 Media Guide Required Accessory 50 Installing the Media Guide 50 Determining Thermal Media Types 52 Black Mark Media Reguirements 53 Preparing a Media Roll for Use 54 Automated Media Loading 56 Manual Media Loading 57 ClearingPaperJams 58 KR403 Hardware Integrator Guide P1016701 001 Rev B 9 24 2010 Contents Printing a Test Receipt 59 Di PCCOSSONCS aiaacawakckk a Qo setenv anes ken CR D 61 Accessories Overview 61 Nozzle Bezel P1011185 63 Nozzle Bezel Mounting Dimensions 64 Shutter Bezel 104591 eee 65 Shutter Mounting Dimensions 65 Small Core Media Adapter G105156 66 OGuick FitHubs 103939 67 Quick Fit Leaf Spring Retainer 01473 000
3. 67 Roll Support P1014124 68 Media Roll Low Sensor 69 Universal Roll Holder P1014125 70 Printer Mounting Plate 104208 74 Wall Mount Roll Holder P1014123 75 Printer Power Supply 808099 004 76 Attaching the Power Supply 77 Universal Serial Bus USB Cable P1027715 78 Large Media Roll Adapter P1026858 79 Attaching to the Printer 80 Loading Media eee 81 Mounting Plate for Large Media Roll Adapter P1027728 82 Attaching to the Printer 82 Using other Accessories with the Large Media Roll Adapter 83 Universal Roll Holder 83 Routing Cables with the Large Media Roll Adapter 84 Media Roll Low Sensor 84 PI IIIA ses 85 Serial USB and Ethernet Cables 85 7 Troubleshooting Ge 9 e ak KA a Ke RC a e e e 87 Status Light Descriptions 87 Application LED States 87 Application User Interface 89 Print Quality Problems
4. 90 Media Sensing Problems 91 Other Problems eee 93 Resetting the Factory Default Values 94 Contact Technical Support 94 KR403 Hardware Integrator Guide P1016701 001 Rev B Contents iv 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 1 Introduction KR403 Kiosk Receipt Printer 9 24 2010 The Zebra KR403 model is the best in class thermal kiosk printer with the widest range of features The KR403 printer provides direct thermal printing at speeds up to 150mm s 5 9 ips at a 203 dpi print density The KR403 supports the ZPL printer programming language and a wide variety of interface and feature options The KR403 printer features Patented Looping Presenter To reduce jamming and print image distortion caused by the user attempting to withdraw the receipt before imaging is finished the KR403 employs an innovative looping station The receipt is retained inside the print mechanism until imaging is complete then it is presented to the user for removal Media Pull Detection When the user grasps the receipt and applies force to remove it the KR403 senses the force and dispenses the receipt in a controlled fashion to prevent tearing or jamming Retract and Retain If the receipt is not taken within a specified time the KR403 withdraws it and dumps it out the bottom of the printer typically into a catch bin wit
5. 25 FeedButtonModes 28 AmbientLight 28 El EE Kerg Pe SRR ehh eee Bees ee ba ee 28 Manual Printer Reset 28 Printer Configuration Methods and Tools 28 Fonts and Your Printer 29 Identifying Fonts in Your Printer 30 Localizing the Printer with Code Pages 30 Asian fonts and Other Large Font Sets 30 Getting Asian Fonts 31 Stand Alone Printing 31 Aa Donne HOS 20 4 bar COCA dO AA hoe 33 Cabling and Cable Routing 33 Large Media Roll Adapter Accessory 33 Attaching POWOL 24a rx RE RU EROR od EUR OR BAG RR daw REDDE E Eee 34 Electrostatic Discharges and Earth Currents 35 Connecting the Printer to the Host 36 Interface Cable Reguirements 36 Communicating with the Printer 40 Edo sister AAA WAA AA AAA AAA AA WA AA owe ew ee 43 Designing Your Own Media Dispensing System 43 Designing a Roll Support 43 Designing Media Guides 44 Designing for Fan Fold Media
6. 78 Accessories Universal Serial Bus USB Cable P1027715 Universal Serial Bus USB Cable P1027715 The KR403 power USB Cable accessory can easily be incorporated into a kiosk design The cable easily be attached to the kiosk with tie wraps The USB cable has been tested to work with the KR403 printer and complies with all safety and compliance regulations P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 79 Large Media Roll Adapter P1026858 Large Media Roll Adapter P1026858 9 24 2010 The large media roll adapter is used to prevent excessive pulling force on the printer feed motor when large roll 250mm 10 inch media is used In some cases when a large media roll is used the feed motor may stall when slack has built up between the roll and the printer Note Make sure you have installed the correct media guide for the width of media selected before installing the adapter KR403 Hardware Integrator Guide P1016701 001 Rev B 80 Accessories Large Media Roll Adapter P1026858 Attaching to the Printer 1 Place the adapter on the printer at an angle as shown P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 81 Large Me
7. mode a set of manual setup and configuration operations used by the integrator Refer to Table 7 2 Application User Interface on page 89 Power Indicator The Power Indicator is green when the printer has the 24 VDC power applied to the printer P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printer Overview 25 Sensing Status and Error Reporting Status Indicator Immediately after power is applied to the printer a brief self test is performed and the status light will report the status of the printer Status conditions are reset and rechecked when The conditions causing them are removed The printer has power removed and reapplied The printhead is opened or closed Refer to Table 7 1 Application LED States on page 87 for condition descriptions Sensing Status and Error Reporting The KR403 has sensing and error reporting capability available to the printer for internal process control status reporting to the host and custom printer software development by the software integrator Many of these features and functions are supported directly by the Windows Driver and Zebra Designer via the driver The printer monitors the printhead motors cutter and a variety of internal main board functions The KR403 printer has virtual sensors and error flags that use combinations of sensors and status flags to create additional error reporting flags to simplify the software integrators task of m
8. Table 7 2 Application User Interface Status Flash Action Sequence One Flash then Solid Appears for one second This will print an internal self test Green page Appears for one second Performs system calibration must be started with paper out of presenter and from under printhead and with no error signaled Two Flash then Solid Green Appears for one second Performs a simulated USB cable connect and reconnect causing a USB plug and play event to occur Three Flash then Solid Green Appears for one second Sets all printer settings to the default with the exception of media guide calibration then it will perform the media guide calibration Four Flash then Solid Green Five Flash then Solid Appears for one second Prints a 50 gray pattern ejects it Green and then prints a diagonal line pattern and ejects it If the feed button remains pressed after the five flash sequence the status light goes off Printer status is also reported during normal operation when an error occurs or a status request can be sent to the printer via the Windows driver Refer to the Software integrator Guide for error codes reported by the Windows driver KR403 Hardware Integrator Guide P1016701 001 Rev B L 90 Troubleshooting Print Quality Problems Print Quality Problems No print on the label The media may not be direct thermal media or the thermal media coating is not facing upwar
9. Zebra KR403 Kiosk Receipt Printer Hardware Integrator Guide P1016701 001 Rev B 2010 ZIH Corp The copyrights in this manual and the software and or firmware in the printer described therein are owned by ZIH Corp Unauthorized reproduction of this manual or the software and or firmware in the 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 This product may contain ZPL ZPL and ZebraLink programs Element Energy Equalizer Circuit E and Monotype Imaging fonts Software ZIH Corp All rights reserved worldwide ZebraLink and all product names and numbers are trademarks and Zebra the Zebra logo ZPL ZPL Il Element Energy Equalizer Circuit and E Circuit are registered trademarks of ZIH Corp All rights reserved worldwide All other brand names product names or trademarks belong to their respective holders For additional trademark information please see Trademarks on the product CD Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation and its subsidiaries 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 express written permissio
10. P1016701 001 Rev B receipt use Typically used for printing liner backed labels that use black marks or black lines media to identify label gap boundaries Requires additional programming to ensure that only the media liner is cut Cutting labels and their adhesive backing will eventually jam the cutter and require a service technician to correct Prints the image and cuts the receipt Does not use the kiosk mode Looping or Vertical presenter functions Cut mode does not support the Retract media function Does not do partial cut in Cutter Mode Not Recommended for kiosk use Rewind Mode has a deceptive name it could be described as Rewind Disabled as it relates to other Zebra tabletop printers that share the ZPL programming language Rewind Mode does not allow cutting the media including Cut Now commands the kiosk mode Looping or Vertical presenter operations retract or eject command options 23 Printer Overview Controls Indicators and Sensors Controls Indicators and Sensors The KR403 printer has integrated controls indicators and sensors to enhance the usability of the printer for the client s kiosk experience the kiosk operator s service and maintenance duties and expand the developer s ability to provide printing and service information to the host kiosk system The controls indicators and sensors include Media Feed button with configuration and diagno
11. Refer to Application User Interface on page 89 Reload the media refer to the Hardware Integrator Guide for media loading procedures Load the media manually Refer to Manual Media Loading on page 57 The platen driver roller maybe losing traction due to e Foreign objects attached to its surface e The rubbery smooth surface has become polished and slippery The platen may need cleaning or replacement Refer to the Service Manual P1026223 for instructions The media sensor may be dirty or damaged Refer to the Service Manual P1026223 for instructions The printhead assembly is not closed e Check the status light on either side of the printer If the status light is showing four red flashes then the printhead is not closed Push down on the printhead assembly until it locks into place There is a jam under the printhead Refer to the Service Manual P1026223 for instructions The large media roll may be over torquing the feed motor Install the large media roll adapter See Large Media Roll Adapter P1026858 on page 79 The printer will not eject the media P1016701 001 Rev B The presenter rollers are dirty or damaged The presenter rollers are dirty Refer to the Service Manual P1026223 for instructions The presenter rollers are damaged Refer to the Service Manual P1026223 for instructions There is a jam under the presenter Refer to the Service Manual P1026223 for
12. Refer to the Service Manual P1026223 for instructions Check for the latest firmware and driver version There are no lights on the printer 9 24 2010 Make sure there is power applied to the printer The control panel may be dirty or damaged Refer to the Service Manual P1026223 for instructions The main logic board may be damaged Refer to the Service Manual P1026223 for instructions Check for the latest firmware and driver version KR403 Hardware Integrator Guide P1016701 001 Rev B 94 Troubleshooting Resetting the Factory Default Values A receipt format was sent to but not recognized by the printer fthe status LED is on or flashing refer to Table 7 1 Application LED States on page 87 Make sure the USB cable is correctly installed Refer to Connecting the Printer to the Host on page 36 Acommunications problem has occurred Perform a USB detect refer to the three flash sequence of Table 7 2 Application User Interface on page 89 The receipts are not cutting at the black mark Make sure you are using the appropriate media guide for the desired media width See Media Guide Required Accessory on page 50 Perform a media guide calibration Refer to the four flash sequence of Application User Interface on page 89 Make sure you are using the appropriate media See Determining Thermal Media Types on page 52 Use the Windows driver to set the printer to black mark mode
13. Thermal Allowed Not Required Remark When short circuit protection or over current protection is activated the power supply will shutdown automatically Once the condition resulting in the failure is cleared the power supply will restart Automatic Recovery Over voltage protection is activated the power supply will shutdown The power supply is fully protected against short circuits and automatically recovers upon removal of the short without the need for re cycling the AC input voltage Note The printer does not have an integrated power switch P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Connections 35 Attaching Power DC Power Plug Requirement The KR403 printer uses a locking two pin connector The mating connector is Tyco part number 1445022 2 The wiring for this connector and to meet the power requirements should be 20 AWG insulated wiring UL type 1007 24 VDC Figure 4 12 Power Plug Electrostatic Discharges and Earth Currents The printer should have a dedicated earth ground connection Preventing ESD and earth currents from affecting the printer operation requires proper connection to the printer chassis via a 12 AWG wire to protective earth The ground wire should be connected to the printer as follows 1 Using a 8 Torx driver remove the screw O shown 2 Attach the 12 AWG ground wire with cable lug O to the printer chassis 3 Connect the other end of the ground wire to a prote
14. X 1 X head Sensor 2 Black mark 1 00000000 X X X X X X 2 X e E 1 00000000 X X X X X x 4 X head Sensor 4 loop ready 1 00000000 X X X X X X 8 X Sensor 5 presenter 1 00000000 X X X X X 1 X X Sensor 6 retract ready 1 00000000 X X X X X 2 X X Sensor 7 in retract 1 00000000 X X X X X 4 X X Sensor 8 at bin 1 00000000 X X X X X 8 X X c This error flag is supported only on KR403 printers 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B d Printer Overview Feed Button Modes Feed Button Modes Ambient Light There is an optical sensor 20 mm behind the paper exit at the front of the printer Other sensors can also be affected by internal lights and bright outside light sources entering through seams vents etc in the kiosk To ensure proper printer operation design the printer enclosure so that it prevents direct sunlight or light from indoor lamps from reaching the sensor through the paper exit See the Shutter Bezel 104591 on page 65 for an accessory option that has been used to shield the media output sensor from external light sources The printer needs space on both sides of the printer to allow for convection cooling of the printer This become more important with kiosk installing that have extreme environments and high printer use Manual Printer Reset The KR403 printer does not have a power switch or reset button T
15. allows the printer to automatically match the communication parameters of the host computer To Autobaud 1 Press and hold the feed button until the green status LED flashes once twice and then three times 2 While the status LED flashes send the xA xZ command sequence to the printer 3 When the printer and host are synchronized the LED changes to solid green No receipts will print during Autobaud synchronization ZPL SC Command Use the Set Communications sc 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 sc command to change the printer to the desired settings 2 Change the host computer settings to match the new printer settings Refer to the Software Integrator Guide P1026208 for more information about this command Resetting the Default Serial Port Parameters Do the following to reset the communications parameters on the printer to the factory defaults serial communication settings are 115k baud 8 bit word length NO parity 1 stop bit and XON XOFF data flow control 1 Press and hold the feed button until the green status LED flashes once waits a moment and flashes twice and then waits again before flashing three times release immediately 2 While the status LED rapidly flashes amber and green press the feed button Serial communications between the printer and the host computer can be set
16. by the ZPL sc command 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 40 Connections Connecting the Printer to the Host Ethernet Interface Refer to Figure 4 16 The USB Ethernet KR403 includes an RJ45 Ethernet connection resident on the main logic board 0 It is compatible with CAT5 CAT5e and CAT6 cables Cables are not supplied with the printer the integrator should supply an 802 3 compliant cable Figure 4 16 Ethernet Connection Communicating with the Printer The easiest way to begin using your complete kiosk printing solution is to utilize the Zebra Designer Windows Driver in PC based systems With the driver loaded you can test the kiosk printing system configure your printer send programming commands use Windows applications to print directly to the printer and download files fonts graphics logos update firmware etc The Zebra Designer driver works directly with the free suite of Zebra application software to design and create receipts Zebra Designer and manage one or more printers locally All are available on the Zebra Web site at www zebra com Use the Zebra Setup Utility to load the driver and configure your printer If the operating system automatically starts a Add new hardware wizard then close the wizard and continue installing the driver USB Printer Detection and Windows operating systems Windows XP Windows Vista Windows 7 Windows Server 2003 and Windows Server 2008
17. external light sources Cooling KR403 Hardware Integrator Guide 9 24 2010 Printer Overview Basic Printer Dimensions The illustration below outlines the basic printer mounting dimensions to install the printer in a kiosk These basic printer dimensions do not illustrate the unique integration requirements needed to use the printer with specific printer accessories operator servicing access media mounting power and cabling access and printer media handling L 143 122 8 45 8 25 ia ees p 25 di elle i H 107 4d hh as E o D 25 51 ECH EL a ER Kid Bl ke k75 114 H I ef okso us o E Figure 3 1 Printer Dimensions 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B Printer Overview Printer Orientation 10 ion inter Orientati Pr REAR lt S 5 E z FRONT Media Out Figure 3 2 Printer Orientation c 2 5 bal c o O x 9 ss E D e 1 Horizontal Mount Table 3 m E 5 o O o o gt Media Retract and Re
18. of the media stack away from the media guide and aligned to the center of the stack This allows the media to completely unfold and minimizes the chances of having it bind in other components or printing multiple receipt or tickets P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Media Basic Media Mounting Considerations Basic Media Mounting Considerations 9 24 2010 The KR403 printer has a few basic requirements for dispensing the media to the printer from a roll or fan fold media The KR403 printer exclusively uses direct thermal media and it is chemically treated to react to heat Some of these basic considerations include Align Printer with Media The center line of the media roll or fan fold stack should align with the center of the printer to provide the best image quality and keep the media un damaged Always use a media guide when printing Media Only Contacts Media Mounting and Printer in Kiosk The media should not touch cables other kiosk components or surfaces other than media guides or the fan fold media tray Do Not Blow Air on Media Air should be pulled out of the media area of the kiosk to keep dust shortens printhead life and affects print quality aerosol bourn chemicals such as cleaning solutions like ammonia and exhaust heat from other kiosk components and power supplies Direct Sunlight Incandescent or Infrared Lighting or Heat Sources These light sources can come from kiosk vents a
19. present Note Media guides are ordered separately Only the KR403 Demo Kit P1021954 contains all input guides available for the KR403 2 Open the printhead by pushing green printhead release push bar back towards the rear of the printer and lift up the printhead P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Media 51 Media Guide Required Accessory 3 Insert the media guide under the printhead Insert the T shaped tab of the media guide into the T hole slide it forward and fasten the screw The screw is pre installed at the factory on the printer One is included in the bag with the media guide in case the screw is damaged or lost Many times the installer will only need to loosen the attached screw 4 Close the printhead Push down on the push bar to securely latch the printhead closed Figure 5 23 Media Guide Installation 5 Re attach the printer s power if needed 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 52 Media Media Guide Required Accessory Determining Thermal Media Types The KR403 printer uses direct thermal media Direct thermal media has a chemically treated print surface that uses heat to expose or darken the area where heat is applied Thermal transfer media or ordinary un treated paper requires ribbon or ink for printing while direct thermal media does not To determine what type of media is being used and print surface of the media perform a
20. 0000000 X X X X x x 1 X emperature Cutter Fault 1 00000000 X X X X X X X 8 Head Open 1 00000000 X X X X X X X 4 Ribbon Out 1 00000000 X X X X X X X 2 Media Out 1 00000000 X X X X X X X 1 Clear Paper Path Failed 1 00000000 X X X X 8 X X X Paper Feed Error 1 00000000 X X X X A X X X Presenter Not Running 1 00000000 X X X X 2 X X X ri le ME 1 oo000000 X x X X X x xX etract Black Mark not Found 1 00000000 X X X 8 X X X X Black Mark Calibrate 12 0000000 X X X X X X X React Function timed 12 00000000 X X X 2a X X X X Pause 17 00000000 X X X 1 X X X X a This error flag is supported only on KR403 printers b This error is not supported by the KR403 printer P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printer Overview 27 Sensing Status and Error Reporting Table 3 10 Warning Flags HQES Group 2 Group 1 X Value can be any hexadecimal number 0 9 A F o Warning Flags Flag co YA st co e v 2 2 2 2 2 2 o 2 o a a a a a a a a 2 Z o 2 YA e 2 ia 2 Z Z Z Z Z z za Z 2 No Warning 0 00000000 0 0 0 0 0 0 0 0 Warning Present 1 00000000 X X X X X X X X Paper near end Sensor 1 00000000 X X X X X X X 8 Replace Printhead 1 00000000 X X X X X X X 4 Clean Printhead 1 00000000 X X X X X X X 2 Need to Calibrate Media 1 00000000 X X X X X X X 1 Sensor I Paper before 1c 90000000 X X X X X
21. 01 001 Rev B 58 Media Clearing Paper Jams Clearing Paper Jams Should a paper jam occur follow the procedure below 1 Cut or tear the media off the front of the printer 2 Open the printhead 3 Remove and discard the damaged media 4 Close the printhead and reload the media using the Auto Load media loading method page 56 Figure 5 29 Clearing Paper Jams P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printing a Test Receipt 9 24 2010 Media 59 Printing a Test Receipt 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 test printer configuration receipt 1 Make sure the media is properly loaded and Ready with the printhead closed Then turn the printer power on if you have not already done so If the printer initializes with the status light blinking green pause mode press the Feed button once to set the printer in Ready to print mode 2 Press the Feed button to print present and removal of receipts two to three times to allow the printer to calibrate the printer for the installed media The printer may feed several extra receipts during this process if media calibration needs to be adjusted this is an automatic printer feature 3 When the status light is solid green press and hold the Feed button until the status light flashes once 4 Release the Feed button A printer configur
22. 5 25 Full Turn Paper Removal P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Media 55 Preparing a Media Roll for Use 3 The loading process works best with the cut as a square straight edge Cut the paper in a Suitable angle If the media is not cut square and the operator does not have the ability to cut or tear a straight edge then the printer can fail to load the media or even cause a media jam The media should not make contact with the platen roller before the sensor detects the media The distance between the platen roller and media sensor is approximately 10 mm 0 39 inches Cut off at a 85 95 90 Thermal side to angle ep Auto Loads Narrow Media Auto Loads Fails Auto Load Vv Media Contact Leads Media Sensing Auto Loads Wide Media oad o Figure 5 26 Suitable Paper Edge for Auto Load Important The wide media sensor 88 and 82 5 mm and printer s power connector are both located on the right side of the printer when looking into the printer from the rear The media sensor for narrow media 58 and 60 mm is located on the left side when looking into the media input slot from the rear of the printer 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 56 Media Automated Media Loading Automated Media Loading The printer is designed to detect media when it is inserted into the empty media input slot at the front of the printer The printer begins turning the
23. 7 ASK ZEBRA 275 9327 E inquiry4 zebra com T 44 0 1628 556037 F 44 0 1628 556005 E mseurope zebra com E China GCmarketing zebra com All other areas APACChannelmarketing zebra co m Customer Service Department US Internal Sales Department UK For printers parts media and ribbon please call your distributor or contact us Key T Telephone F Facsimile E E mail 9 24 2010 T 1 877 ASK ZEBRA 275 9327 E clientcare 9 zebra com T 44 0 1628 556032 F 44 0 1628 556001 E cseurope zebra com KR403 Hardware Integrator Guide T 65 6858 0722 F 65 6885 0836 E China order csr zebra com All other areas csasiapacific zebra com P1016701 001 Rev B 5 6 Introduction Document Conventions Document Conventions IHO gt PPP Pr The following conventions and symbols are used throughout this document to convey certain information Alternate Color Cross references contain links to other sections in this guide If you are viewing this guide online click the blue text to jump to its location Caution Warns you of the potential for electrostatic discharge Caution Warns you of a potential electric shock situation Caution Warns you of a situation where excessive heat could cause a burn Caution Warns you of a situation where a cut could occur Caution Advises you that failure to take or avoid a specific action could result in phys
24. K codes are active It indicates the printer is functioning normally This code indicates that media is stuck in the presenter This error is set when 1 Paper Jam in the printer attempts to eject the media Presenter but cannot complete the operation This error is cleared by removing the media from the presenter sensor One Red Flash This code indicates that the printer could not find the cutter blade or could not properly manage its position The Two Red Flashes 2 Cutter Jam error is set when the printer attempts to cut but fails after three retries This error is cleared by cycling the power off and on 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 88 Troubleshooting Status Light Descriptions Three Red Flashes Four Red Flashes Table 7 1 Application LED States 3 Out of Paper 4 Print Head Lifted This code indicates that the selected EOP sensor has detected no media present This value is signaled wither when the mark engine has detected a mark larger than TOF marker length plus 5mm or when the A D reading of the EOP sensor drops below the End of paper threshold This error is cleared after successful media load either via calibration of via regular media load This code indicates that the print head has been lifted This error is cleared by returning the print head to its locked position Five Red Flashes 5 Paper Feed Error This code indicates that the pa
25. Refer to the Software Integrator Guide P1026208 for instructions on setting black mark mode Reload the media Refer to Automated Media Loading on page 56 Resetting the Factory Default Values Sometimes resetting the printer to the factory defaults may solve some problems Refer to the two flash sequence of Table 7 2 Application User Interface on page 89 Use the Windows driver to perform a printer reset Refer to the Software Integrator Guide P1026208 for instructions Contact Technical Support Technical Support via the Internet is available 24 hours per day 365 days per year www zebra com For questions on the operation of Zebra equipment and software please call your distributor For additional assistance contact us Please have your model and serial numbers available For contact information refer to Contacts on page 5 P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010
26. Shutter Bezel 104591 Supports vertical mounting orientations only Shutter Mounting Dimensions amp O 3 5 O 3 E O 8 Eg E a E 2 iD E o E e o be amp O 100p jo woyoa ww Zy dij jo doj ww gp ww OZ a Sun o O d Ore NG a des Z dO uO Q D 7f D wwz 6 mm ww 09 aa di ww zi ww 09 P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 66 Accessories Small Core Media Adapter G105156 Small Core Media Adapter G105156 The KR403 mounting becomes even more versatile if the Small Roll Media Roll Adapter accessory is used to guide the leading edge of receipt into the input of the media drive rollers This allows the printer to be mounted in a wider range of mounting orientations shown below The small core media roll adapter accessory is used to prevent the page curl that occurs at the end of a tightly wound media roll It is used to keep the media in position to feed into the presenter P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 67 Quick Fit Hubs 103939 Quick Fit Hubs 103939 The quick fit hubs 1 are d
27. and play design makes installation easy Multiple printers can share a single USB port hub Additionally the USB cable should include a ferrite located at the end of the cable closest to the host computer This is to prevent any electrical noise generated by the printer from affecting the host computer P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Connections 37 Connecting the Printer to the Host Refer to Figure 4 14 On the USB Ethernet configuration 0 the USB connection is to the left of the ethernet connection On the USB Serial configuration O the USB connection is to the right of the serial connection Figure 4 14 USB Connection When using a USB cable not supplied with your printer verify that the cable or cable packaging bears the Certified USB mark to guarantee USB 2 0 compliance The figure below displays the cable wiring required to use the printer s USB interface Pin Signal 1 Vbus N C 2 D 3 D 4 Not connected 5 Ground Shell Shield Drain Wire For printer supported operating systems and to download the latest driver visit the Zebra printer web site at http www zebra com 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 38 Connections Connecting the Printer to the Host Serial Communications Refer to Figure 4 15 The required cable must have a nine pin D type DB 9P male connector on one end which is plugged into the m
28. ating DB 9S serial port located on the back of the printer 0 The other end ofthis signal interface cable connects to a serial port at the host computer Depending on the specific interface requirements this will most likely be a Null Modem cross over cable Figure 4 15 Serial Connection The serial port communication settings between the printer and host typically a PC must match for reliable communication The Bits per second data or Baud rate and Flow control are the most common settings that get changed The host typically a Windows PC needs to have the data rate and data Flow control changed to match the printer s default communication method Bits per second 115K is the printer s default Baud Rate Bits per second The printer and host can not communicate unless these match Flow control Software and is noted by the printer s Host Handshake setting of Xon Xoff The printer may communicate if these do not match but it may not be reliable Data bits 8 Default Windows and printer Parity None Default Windows and printer Stop bits Doesn t care P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Connections 39 Connecting the Printer to the Host Serial communications between the printer and the host computer can be set by Autobaud synchronization ZPL programming sc command Resetting the printer to its default printer configuration Autobaud Autobaud synchronization
29. ation receipt will print example shown The configuration status receipt will print as two or more receipts if the receipt size is not large enough to contain all of the status information as shown above KR403 Hardware Integrator Guide 640 8 MM_FULL ee KS 17 12P25 d 5 081 60680 MAINT OFF HARDWARE ID CONFIGURATION RAM ONBOARD FLASH FORMAT CONVERT PRINTER CONF IGURATION Zebra Technologies ZTC KR403 0 0 DARKNESS PRINT SPEED TERR OFF 1 PRESENT Tiheout LOOP LEN LENGTH AGDITION 11 ORIENTATION MEDIA TYPE LABEL LENGTH MAXIMUM LENGTH USB COMM BAU DATA BITS HOST HANDSHAKE PROTOCOL CONTROL CHAR COMMAND CHAR DELIM CHAR ZPL MODE MEDIA POWER UP S GAIN MED S MEDIA GAIN MEDIA S MEDIA GAIN ABEL TAKE Li MODES ENABLED MODES DISABLED RESOLUTION FIRMWARE 5 2009 09 02 15 43 38 TIME STAMP FIRMWARE IN THIS PRINTER IS COPYRIGHTED Figure 5 30 Test Receipt P1016701 001 Rev B 60 Media Printing a Test Receipt P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 6 Accessorles Accessories Overview The KR403 printer has a wide range of accessories designed and tested to work with your printer The accessories can be used by themselves combined with other printer accessories or as part of your own unique printer integration design At the time of this guides release the following accesso
30. ccess the printhead 1 Press the green printhead release bar to unlock the printhead 2 Rotate the printhead assembly upward Figure 3 7 Opening the Printhead 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B Printer Overview 15 General Printing Information General Printing Information Printer control e Printer Control Panel Allows very basic printer configuration setup that include configuration status label receipt non default print widths print darkness density e ZPL Zebra Programming Language a page receipt description language The printer also supports the Zebra SGD Set Get Do printer configuration language that uses a natural language e Windows Driver and Zebra Setup Utility e Zebra Designer A receipt label design and print application for Zebra printers Designer include support for graphics and logos barcodes text downloading fonts etc e ZBI2 0 Zebra Basic Interpreter ZBI allows the software integrator to create custom commands and functions and emulate other programming languages Print method Direct thermal page printing using thermal sensitive media Resolution 8 dots mm 203 dpi Print speed 150 mm s 5 9 inches sec Default 127 mm sec 5 inches sec 101 6 mm sec 4 inches sec 76 2 mm sec 3 inches sec Note Printer media is rated for specific speed ranges and some media types and materials will print b
31. cessory shown in the illustration below make sure the power supply s AC power cord is unplugged Note the printer does not have an integrated power switch 2 Insert the 24 VDC power supply s power connector into the printer s power receptacle Verify the power plug s latch has locked to the connector by giving it a slow gentle pull 3 Insert the AC power cord into the power supply Plug the other end of the cord into an appropriate AC electrical outlet The active power light will go on if power is on at the AC outlet 4 With the power supply on and connected to the printer the printer s power status indicator will light up green The printer will begin the printer initialization process which takes approximately 25 seconds The printer will test the cutter and check for the presence media The status indicator will be green if media is loaded and flashing red single blink if media is not loaded jq Printer Plug Varies by Country Printer Power Connector Optional Power Supply Accessory d Active Power Light IEC 60320 C 13 Plug 70W Figure 6 31 Attaching Power o Note Ensure the appropriate power cord with a three 3 prong plug and an IEC 60320 y 7 C13 connector are used at all times These power cords must bear the relevant certification mark of the country in which the product is being used 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B
32. code pages For ZPL code page support including Unicode see the CI command in the ZPL programmer s guide Asian fonts and Other Large Font Sets Asian language pictographic fonts have large character sets with thousands of characters that support single language code page In order to support the large Asian character sets the industry adopted a double byte 67840 maximum character system instead of the single byte characters 256 maximum used by Latin based language characters to address large font sets In order to address multiple languages with a single font set Unicode was invented A Unicode font supports one or more code points relate these to code page character maps and is accessed in a standard method that resolves character mapping conflicts ZPL supports Unicode and has support for the large pictographic double byte character Asian font sets Asian language support requires additional memory support by the KR403 printer configured with the Full Flash Memory factory option The number of fonts that can be downloaded is dependent upon the amount of available flash memory not already in use and the size of the font to be downloaded P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printer Overview 31 Fonts and Your Printer Getting Asian Fonts Asian font sets are downloaded into the printer by the user or integrator The fonts are purchased separately from the printer Simplified and Traditional Ch
33. ctive earth ground Figure 4 13 Grounding 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 36 Connections Connecting the Printer to the Host Connecting the Printer to the Host The KR403 printer has a Universal Serial Bus USB an RS232 Serial port interface and an Ethernet interface be inserted into the power supply and the power receptacle on the back of the printer Caution Keep the kiosk OFF when attaching the interface cable The power cord must before connecting or disconnecting the communications cables Caution This printer complies with FCC Rules and Regulations Part 15 for Class B Equipment using fully shielded data cables Use of un shielded cables may increase radiated emissions above the Class B limits Interface Cable Requirements Data cables must be of fully shielded construction and fitted with metal or metallized connector shells Shielded cables and connectors are required to prevent radiation and reception of electrical noise To minimize electrical noise pickup in the cable Keep data cables as short as possible 6 foot 1 83 m recommended Do not tightly bundle the data cables with power cords Do not tie the data cables to power wire conduits Avoid fluorescent lighting and power supply components USB Interface Requirements Universal Serial Bus version 2 0 compliant provides a fast interface that is compatible with your existing PC hardware USBs plug
34. d Determining Thermal Media Types on page 52 Is the media loaded correctly Is the thermal media coating facing upward Determining Thermal Media Types on page 52 The printhead may be dirty or damaged The printhead is dirty Clean the printhead Refer to the Service Manual P1026223 for instructions The printhead is damaged Replace the printhead Refer to the Service Manual P1026223 for instructions The printhead wiring may be damaged or not connected properly e Check the wiring connections at the printhead and the main logic board Refer to the Service Manual P1026223 for instructions e Check for damage to the wiring Replace the wiring if damaged Refer to the Service Manual P1026223 for instructions The printed image does not look right P1016701 001 Rev B The printhead is dirty Clean the printhead Refer to the Service Manual P1026223 for instructions The printhead has worn out The printhead is a consumable item and will wear out due to friction between the media and printhead Using unapproved media may shorten life or damage your printhead Replace the printhead Refer to the Service Manual P1026223 for instructions Adjust the print darkness and or print speed Refer to the Software Integrator Guide P1026208 for instructions e The Windows printer driver or application software may change these settings and may require a change to optimize print quality The media being used is inco
35. d a width of 5 0 10 0mm when the black mark is centered on the sensor In the figure below the No Print Zone is the area on the backside of the media where no marks other than the black marks for sensing should be printed For media that has both perforations and black marks perforations should be positioned in the middle of the black mark By default the printer will cut the media in the middle of the black mark oe IM aa eee oen e o Feed Feed I Direction Direction puri mn nan Y IM MI MESE Cut Line No Print Zone 58 and 60mm 80 and 82 5mm Media Width Media Width Example shown from printed side Black marks shown are on opposite side Dimension 58 and 60mm Width 80 and 82 5 Width 22 mm 30mm e 2 5mm 9 0mm 2 5mm 9 0mm 5 0mm 10 0mm 5 0mm 10 0mm o 92mm 600mm 92mm 600mm KR403 Hardware Integrator Guide P1016701 001 Rev B Media Preparing a Media Roll for Use 54 Preparing a Media Roll for Use 1 Orient the roll as shown below Temperature sensitive coating O SW96074C Figure 5 24 Paper Roll Orientation 2 Tear off a full turn of paper from the new roll some type of glue or self adhesive substance that might otherwise cause paper jam or Caution This is important since the outer end of the paper is usually fixed to the roll with even print head damage Glue or similar substance SW96075C Figure
36. dia Roll Adapter P1026858 Loading Media 1 Open the adapter tensioner assembly by pushing the locking tab 0 2 Insert the media through the adapter and into the printer For narrow media the printer will load automatically For wide media manual media loading may be reguired see Manual Media Loading on page 57 3 Close and lock the adapter tensioner assembly 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 82 Accessories Mounting Plate for Large Media Roll Adapter P1027728 Mounting Plate for Large Media Roll Adapter P1027728 When the large media roll adapter is used with the printer the standard mounting plate cannot be used Attaching to the Printer Attach the plate to the printer and the adapter using the screws as shown P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories Using other Accessories with the Large Media Roll Adapter 83 Using other Accessories with the Large Media Roll Adapter Universal Roll Holder The universal roll holder page 70 can be attached to either side of the large media roll adapter Additionally the media roll low sensor page 69 can still be used in this configuration see Routing Cables with the Large Media Roll Adapter on page 84 1 Attach the mounting block Qio the large media roll adapter as shown using the two sc
37. ds Can be used in a printer configuration workstation to send configuration files firmware updates and files programming graphics logos and receipt forms Use the full featured ZebraNet Bridge instead for everything but ZBI activation ZebraNet Bridge Zebra Net Bridge is a printer maintenance tool for use with local and network based printers The KR403 printer can only be managed as a locally connected printer the KR403 printer does not have a Ethernet printer option This Windows application is the ideal tool to use as a workstation for configuring your printer prior to installing it into a kiosk Use it to duplicate configurations send configuration files firmware updates and files programming graphics logos and receipt forms At the time of release the KR403 Windows driver or the Setup Utility can not be loaded in the PC when using ZebraNet Bridge It is scheduled for an update to remove the conflict with the driver and local printer management in 2010 Fonts and Your Printer 9 24 2010 The KR403 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 KR403 printer s font capabilities are programming language dependent The ZPL programming language provides advanced font mapping and scaling technology to support outline fonts TrueType or OpenType and Unicode charact
38. e This Document 3 How This Document Is Organized 4 Contacts IA ener cag eran eds abe Seana WA IA Aedes aa 5 Document Conventions 6 2 Design Overview 7 Design Considerations OvervieW 7 35 Printer Overview 9 Basic Printer Dimensions 9 Printer Orientation naana a 10 Printer Features 11 Opening the Printer 14 General Printing Information 15 KR403 Media Types 16 Basic Printer Mounting printer only 17 Design Your Own Mounting 19 Print MOGGS Ec 20 Looping Presenter Kiosk Mode 21 Vertical Presenter Kiosk Mode 22 Receipt Page ImagingModes 23 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 9 24 2010 Contents Controls Indicators and Sensors 24 Feed Button Control 24 Power Indicator aaaea aaea 24 Status Indicator 25 Sensing Status and Error Reporting
39. ensor for use with Zebra and custom media roll mounting Large Media Roll Adapter to prevent motor strain when using large media rolls Full Flash 64MB memory for storing large Unicode font sets multiple fonts graphics and programming Asian Language support with printer configuration options for the large Simplified and Traditional Chinese Japanese Korean or Thai character sets Zebra s ZBI 2 0 Zebra BASIC Interpreter programming language ZBI allows you to create custom printer operations and software language emulation This integrators guide provides information you will need to install and operate your printer on a daily basis To create receipt label formats refer to your programming guides or receipt label design applications such as Zebra Designer Your printer when connected to a host computer functions as a complete system for printing receipts and labels Note Many printer settings may also be controlled by your printer s driver or receipt NI label design software Refer to the Software Integrator Guide P1026208 for more information P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Introduction Package Contents Package Contents The KR403 printer Warranty information s Note To minimize cost and reduce waste the KR403 does not include unneeded components or accessories Additional items are required to make the printer operational Unpack and Inspect the Printer When y
40. er mapping as well as basic bitmapped fonts and character code pages The ZPL programming guide describes and documents fonts code pages character access listing fonts and limitations of ZPL See the printer programming guides for information on Text Fonts and Character support The KR403 printer includes utilities and application software that support font download into the printer for both printer programming languages KR403 Hardware Integrator Guide P1016701 001 Rev B 30 Printer Overview Fonts and Your Printer Identifying Fonts in Your Printer Fonts and memory are shared by the programming languages in the printer Fonts can be loaded in many memory areas in the KR403 printer ZPL programming can recognize EPL and ZPL fonts See the respective programmer guides for more information on fonts and printer memory To manage and download fonts for ZPL print operation use ZebraNet Bridge To display all of the fonts loaded in your KR403 printer send the printer the ZPL command WD See the ZPL Programmers Guide for details Bitmap fonts in the various printer memory areas are identified by the FNT file extension in ZPL e Scalable fonts are identified with the TTF TTE or OTF file extensions in ZPL The six fonts LMu FNT through LMz FNT are EPL Line Mode fonts and are not available for use Localizing the Printer with Code Pages The KR403 printer supports localization with common international character map
41. esigned to use the printer s mounting holes when mounted on a sheet metal surface 1 5 mm thick See the Design Your Own Mounting on page 19 for more details Quick Fit Leaf Spring Retainer 01473 000 The leaf spring retainer is designed to be used as a locking mechanism when using the quick fit hubs on a custom mounting surface 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 68 Accessories Roll Support P1014124 Roll Support P1014124 The roll support bracket and mounting are designed and tested to mount to a sheet metal wall 1 5 mm thick for media rolls up to 250 mm O D Outer Diameter with media roll cores of 25 4 mm I D Inner Diameter The wider approved media roll widths 80 and 82 5 mm align to the vertical centerline of the roll support bracket The diagrams below show the how the narrower approved media roll widths are offset lower by 3 2 mm To install a roll of media in the printer the roll must clear the lip The media roll needs to move up nearly 4 mm above the centerline of the roll support bracket for loading Wide Narrow C E G G Wide Media San aen 7 58 amp 60 NA ya T KR ge 25 4 Roll Core ID 51 6 HI2 used for Media Low Sensor mounting P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 69 Media Roll Low Sensor Media Roll Low Sensor 9 24 2010 The media roll low sensor is available
42. etter at slower speeds Present speed 300 mm s in kiosk mode the uses the Looping or Vertical Presenter modes Non kiosk modes presenter speed matches the print speed Print duty cycle Up to 33 Media Sensors Out of paper paper in presenter paper in retract path black mark and an optional external paper low sensor Maximum print width 80 mm 640 pixels Auto Selected Print Widths 58 and 60mm guide 58 mm 464 pixels maximum 80 and 82 5mm guide 80 mm 640 pixels maximum 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 16 Printer Overview General Printing Information KR403 Media Types Receipt Media Supply Type Outside Wound Continuous Roll Plain receipt receipt with black marks and pre printed receipt media with black marks Fanfold Stacked receipt media with black marks and pre printed receipt media with black marks Outer Roll diameter 250 mm 9 84 inches maximum Note The maximum roll diameter is dependent upon roll holder in use and the kiosk design Spindle core diameter 25 mm minimum typical core size 40 mm maximum 12 mm minimum with Small Core Media Roll Adapter Paper width 58 60 80 and 82 5 mm common receipt roll widths Paper Thickness or Caliper 0 054 0 11 mm Paper Density or Grammage 55 110 g m or gsm Note This is an approximate area density measurement that varies by country paper type and measurement method appl
43. g large 200mm media rolls to prevent excessive pulling force by the feed motor KR403 Hardware Integrator Guide 9 24 2010 Accessories 63 Nozzle Bezel P1011185 Nozzle Bezel P1011185 9 24 2010 The nozzle bezel is used not only as a decorative accessory but also serves to prevent customers from unknowingly inserting payment cards into the printer which could cause damage to the printer and the customer s payment card The nozzle bezel is installed on the front of the printer at the media exit using two 2 5mm hex screws The nozzle bezel kit comes with screws and 10 bezels per kit Q Media Exit e Media Exit Horizontal Mounting Vertical Mounting KR403 Hardware Integrator Guide P1016701 001 Rev B 64 Accessories Nozzle Bezel P1011185 Nozzle Bezel Mounting Dimensions U EST E ZA O E i H QO H O E E j O pa E CN 8 i 16 5 mm e amp O EU 6mm 10mm 35 mm 9 5 mm 100 mm P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 p Accessories Shutter Bezel 104591
44. hin the kiosk The number of retracts are counted and reported back to the host Easy Media Loading Automatic media loading and preparation for printing Optional supply low sensing Flexible Media Support Supports continuous fanfold and black line receipt media and label media with automatic media sensing and calibration Flexible Mounting Horizontal and vertical printer mounting covering 180 of printer orientation and up to 360 with optional media adapter Printhead Life Monitoring Printhead element testing and print length odometer reporting KR403 Hardware Integrator Guide P1016701 001 Rev B 2 Introduction KR403 Kiosk Receipt Printer Industry Leading Bar Code Support Largest set of common and specialized linear and 2 dimensional bar code symbologies resident in a kiosk printer Powerful Font Support One scalable and 16 bitmap fonts resident with support for downloadable and Unicode fonts Interface Support The KR403 is available with two interface configurations USB Serial and USB Ethernet Storage 4MB of flash memory with the largest in class 1 5MB available for programming graphics and fonts with 8MB of SDRAM for fast image processing The KR403 printers offer a wide range of printer options and accessories 58 60 80 and 82 5mm media guide widths 70 watt external printer power module Multiple printer media roll mounting accessory configurations and options Media Roll Low S
45. ia roll media thickness and weight perforations on fan fold or receipt media etc Other considerations that affect your printer mounting are also in this section include media mounting media path media access printer maintenance cabling etc Horizontal Vertical Acceptable Verify Operation Unacceptable P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 9 24 2010 Media 49 Basic Media Mounting Considerations The areas of primary concern are the horizontal operation s loop area and waste bin and vertical operations receipt presented storage waste bin and open loop area with no loop These two areas can require special attention when designing the inside of the kiosk The printer needs the space to store the printed receipt before presenting it to the customer The longer the receipt the greater the area needed When mounting the printer at angles other than the nominal vertical or horizontal orientations simulated receipt printing operations should be observed with ideally the chosen media for use in the kiosk and in the environmental conditions that it will operate on site The KR403 mounting becomes even more versatile if the Small Roll Media Roll Adapter accessory is used to guide the leading edge of receipt into the input of the media drive rollers This allows the printer to be mounted in a wider range of mounting orientations shown below Figure 5 21 Smal
46. ical harm to you Caution Advises you that failure to take or avoid a specific action could result in physical harm to the hardware Caution Advises you need to wear protective eyeware Important Advises you of information that is essential to complete a task Note Indicates information that emphasizes or supplements important points of the main text P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 2 Design Overview Design Considerations Overview The kiosk designer needs to consider how the printer is being used operated media supply and maintenance serviced integrated with other kiosk components and integrated into the enclosure itself The KR403 printer needs some basic design elements to function properly safely and easily for the operator The general issues are The KR403 printer should always be installed in some kind of locking enclosure The customer or untrained personnel should not operate or service the printer Mounting orientation use of the Looping or Vertical Presenter modes and media waste bin considerations See Print Modes on page 20 Simple mounting of the printer to the kiosk See Basic Printer Mounting printer only on page 17 The printer base plate must be mounted to a flat surface in the kiosk e Max screw penetration 4mm see Basic Printer Mounting printer only on page 17 Printer power requirements use of wired kiosk power see Attachi
47. ied P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Basic Printer Mounting printer only Printer Overview 17 Basic Printer Mounting printer only The printer can only be mounted to the kiosk using the four printer mounting screw holes shown in the illustration below The printer is most secure when using all four of the mounting positions connecting the printer s base to a rigid metal base plate in the kiosk The kiosk s metal printer mounting plate should be connected to the kiosks electrical earth ground for purposes of controlling static discharge and electrical noise Mounting Positions Ta ID Figure 3 8 Printer Mounting Table 3 5 Mounting Configuration Kiosk s Print Base Full coverage of printer s base plate Mounting Variation Details Minimum mount positions Supports the Quick Fit Hubs Supported by most Zebra accessory mounting solutions o and e and and Partial and Full coverage of the printer s base plate Minimum three point mounting to fight torsional forces For information on ordering accessories refer to Contacts on page 2 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 18 Printer Overview Basic Printer Mounting printer only 9557 ey
48. in two lengths 01890 300 KIT PAPER LOW SENSOR 300MM CBL 01890 500 KIT PAPER LOW SENSOR 500MM CBL The sensor alerts the system when a fixed level of media is remaining on the roll The media roll low sensor operates by reflecting a light against the white side of a media roll to detect it When the media is low no light is reflected After three successive media low conditions are noted by the printer a media low flag is set Installing a new roll of media will reset the flag Note Black marks or dirt on the side of the media roll may signal false media low conditions External Media Low Sensor Port Sensor Cable Paper roll i I Paper low J10 sensor Near gt WI end iis Roll holder shaft Mounts on top of the Roll Support as show here KR403 Hardware Integrator Guide P1016701 001 Rev B 70 Accessories Universal Roll Holder P1014125 Universal Roll Holder P1014125 This roll holder can be fitted on the right or left side of the printer The arm can be set at three different angles This makes make integration in the kiosk easy e 58 mm 60 mm 80 mm and 82 5 mm media widths can be used without adjustments The universal roll holder supports up to 0200 mm rolls in the high and low arm positions and 9250 mm rolls in the under position with clearance for cabling e No other accessories are required for the high arm position while the Printer M
49. inese Japanese JIS and Shift JIS mappings Korean Thai Stand Alone Printing Your KR403 printer can be configured to work without being attached to a computer The printer has the ability to automatically run a single receipt form One or more downloaded receipt forms can be accessed and run with a terminal or wedge device to call a receipt These methods allow the developer to incorporate data input devices such as scanners or weight scales to the printer via the serial port Receipt formats can be developed and stored in the printer to support receipts that have One or more data variables to be entered via the terminal or wedge device The receipt will print after the last variable data field has been input One or more receipts formats that are called by scanning bar codes containing programming to run a receipt form Receipt forms designed to work as a process chain with each receipt including a bar code containing the programming to run the next receipt in the process sequence The printer supports a special receipt form that will automatically run after a power cycle or reset The ZPL looks for a file named AUTOEXEC ZPL The files must be deleted from the printer followed by a reset or a power cycle to completely remove the file 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 32 Printer Overview Fonts and Your Printer P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 4 Con
50. ing Plate For illustration purposes High position media is not shown High position both roll supports are shown 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 74 Accessories Printer Mounting Plate 104208 Printer Mounting Plate 104208 The Printer Mounting Plate preforms several functions Provides a solid printer mounting base Designed to work with the Universal Roll Holder accessory for the Low and Under the printer mounting positions This plate or an equivalent custom design is required to protect the cables and media from interfering with each other and the operator when the media roll is mounted under the printer Includes a inertia dampening spring roller to optimize printer performance when using the large 250 mm diameter media rolls 95 mm Bm 47 mm ECL Em ana mij pc im LI dL 120 mm 112 mm P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 75 Wall Mount Roll Holder P1014123 Wall Mount Roll Holder P1014123 The Wall Mount Roll Holder attaches at the front face of the printer to the kiosk wall It is designed to handle 150 mm diameter media rolls 58 mm 60 m
51. instructions The presenter sensor may be dirty or damaged KR403 Hardware Integrator Guide 9 24 2010 Troubleshooting 93 Other Problems The presenter sensor is dirty Refer to the Service Manual P1026223 for instructions The presenter sensor may be damaged and need to be replaced Refer to the Service Manual P1026223 for instructions The presenter has not cleared the previous receipt e Check the status light on either side of the printer If the status light is showing one red flash then the printer is reporting media in the presenter Remove any media that may be in the presenter The presenter motor may need to be replaced Refer to the Service Manual P1026223 for instructions The presenter drive gears may be damaged or worn Refer to the Service Manual P1026223 for instructions Other Problems The receipts are not cutting properly The cutter blade may be worn Replace the cutter blades Refer to the Service Manual P1026223 for instructions The cutter tensioner may be worn or damaged Replace the cover plate assembly Refer to the Service Manual P1026223 for instructions Check the Cutter Mode setting and the Partial Cut Width setting in the Windows driver Refer to the Software Integrator Guide P1026208 The cutter motor may need to be replaced Refer to the Service Manual P1026223 for instructions The cutter drive gear drive pin or cutter actuator may be damaged or worn
52. jams and printer stalls in the worst case conditions The media should never touch or rest on cabling kiosk walls and components exhaust fans dust and heat heat sinks etc The media should be easy to reach and see inside the kiosk Do not force the operator to bend or extend their arms too far into the kiosk to load media or service the printer Optional Media Storage Media stored in the kiosk should have a dark cool area separate from the rest of the kiosk enclosure that can be closed off from the heat of the kiosk components moisture and cleaning chemical vapors used near the kiosk Designing a Roll Support The design elements needed for a good media roll support are Simple design with no loose parts that can get misplaced installed incorrectly or require special techniques that can when done incorrectly or carelessly have the operator drop the media in the kiosk 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 44 Media Designing Your Own Media Dispensing System Minimal drag Do not use wires cables or bars as a roll holder all of these cause the roll to stop and start and rock back and forth Narrow radius roll supports case these behaviors to a lesser extent Some media vendors use roll cores made of fiberboard that can have seams The KR403 Roll Support accessory minimizes the media contact area only makes contact with the outside edges and a large enough radius to smooth over
53. l Core Media Adapter Horizontal Vertical KR403 Hardware Integrator Guide P1016701 001 Rev B Media Guide Required Accessory 50 Media Media Guide Required Accessory For the printer to operate correctly at minimum you must order and install at least one of the four 4 media guides listed below Figure 5 22 Media Guide Width mm Part Number Width mm Part Number 58 09170 058 3 80 09170 080 3 60 09170 060 3 82 5 09170 082 3 A printer evaluation kit is available for the KR403 printer that includes all four media guides Installing the Media Guide A L The media guide configures the printer to one of four 4 common roll paper widths 58 60 80 or 82 5 mm The printer senses which media guide is installed and adjusts the default print width to match it automatically narrow 58 or 60 mm or wide 80 or 82 5 mm The printer is delivered without a paper guide installed Caution Before proceeding always disconnect the printer from power If the printer is installed in the kiosk then all kiosk power should be turned off This is to prevent accidentally having the screw or media guide bracket fall into the printer or other powered up kiosk components The screw or bracket may fall and bounce into kiosk components mounted adjacent to or mounted below the printer 1 Select the media guide that matches the width of the media you want to use for your application Loosen or remove the media guide screw if
54. m 80 mm and 82 5 mm media widths can be used without adjustments Include the Quick Fit printer release and mounting system The service tech can pull the leaf spring latch to unlock the printer and quickly slide it out for easy replacement or service 135 115 Roll center 150 105 Media Roll Support Leaf Spring Hub Lock 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 76 Accessories Printer Power Supply 808099 004 Printer Power Supply 808099 004 The KR403 power Supply accessory can easily be incorporated into a kiosk design The power supply is easily attached to the kiosk with tie wraps The power supply has been tested to work with the KR403 printer and complies with all of the same safety and compliance regulations See Attaching Power on page 34 for a simple power connection illustration P1016701 001 Rev B e Output voltage 24 VDC e 70 Watts 90 264 VAC at 47 63 Hz e Peak Power 330 Watts e Input Current 1 5 Amp max Inrush Current 40 Amp max 115 VAC or 80 Amp max 230 VAC The DC power filter and cable length is a minimum of 174 mm Power ON LED EMI Power Filter KR403 Hardware Integrator Guide 9 24 2010 Accessories 77 Printer Power Supply 808099 004 Attaching the Power Supply 1 Make sure the printer s power supply is turned off Or if you are using the optional power supply ac
55. media scratch test 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 Direct thermal media is chemically treated to print expose when heat is applied This test method uses friction heat to expose the media 2 Did a black mark appear on the media If a black mark Then the media is Does not appear on the media Thermal transfer A ribbon or ink is required and is not support for use by the KR403 Appears on the outside of the Direct thermal No ribbon or ink are required media The KR403 printer only uses outside wound roll media or fan fold media The print surface faces away from the center of the printer Media with black marks P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Media 53 Black Mark Media Requirements Black Mark Media Requirements 9 24 2010 The printer is optimized to detect black marks printed with IR sensitive ink and ignore pre print in IR blind ink For 80 and 82 5mm media the black marks will be centered 30mm to the right of the paper center when viewing the imaged side of the receipt and print direction is downward for 58 and 60mm media the black marks will be centered 22mm to the left of the paper when viewing the imaged side of the receipt and the print direction is downward The printer will support media with black mark thickness in printing direction of 2 5 9 0mm an
56. mpatible with the printer Be sure to use the recommended media for your application and always use Zebra approved media The platen driver roller maybe losing traction due to Foreign objects attached to its surface e The rubbery smooth surface has become polished and slippery KR403 Hardware Integrator Guide 9 24 2010 Troubleshooting 91 Media Sensing Problems The platen may need cleaning or replacement Refer to the Service Manual P1026223 for instructions There are long tracks of missing print blank vertical lines on several labels The printhead may be dirty or damaged The printhead is dirty Clean the printhead Refer to the Service Manual P1026223 for instructions The printhead is damaged Replace the printhead Refer to the Service Manual P1026223 for instructions The printhead has worn out The printhead is a consumable item and will wear out due to friction between the media and printhead Using unapproved media may shorten life or damage your printhead Replace the printhead Refer to the Service Manual P1026223 for instructions The printing does not start at the top of the receipt or misprinting of one to three receipts The printer needs to be calibrated refer to the two flash sequence of Table 7 2 Application User Interface on page 89 Reload the media Automated Media Loading on page 56 or Manual Media Loading on page 57 Media Sensing Problems The KR403 printe
57. n 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 Liability Disclaimer Zebra Technologies takes steps to ensure 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 Limitation of Liability 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 consequential damages including loss of business profits business interruption or loss of business information arising out of the use of the results of use of or inability to use such product even if Zebra Technologies has been advised of the possibility of such damages Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Contents Ua NOU paaa yd e Ka RC sede ROCA GRACIA HORROR en we 1 KR403 Kiosk Receipt Printer 1 Package Contents 0 0 pini terrera tt eres 3 Unpack and Inspect the Printer eee eee 3 Who Should Us
58. nd other kiosk components Incandescent light bulbs and heat sinks are examples of heat sources that shouldn t be near the printer media or media storage areas Media Dispensing Must Be Smooth and Easy Roll media must be able to turn with little or no drag and allow the printer to smoothly pull media without jerking and stopping Larger heavier media rolls are more susceptible to these issues Minimize roll to roll holder contact and avoid sharp contact surfaces Fan fold media must have sufficient room to unfold and not bind on media guide surfaces or at the perforations or sides The printer can get distorted print e g compressed print short receipts etc motor stalls and jamming if media dispensing to the printer is not smooth and easy for the printer KR403 Hardware Integrator Guide P1016701 001 Rev B 45 46 Media Basic Media Mounting Considerations Media Supply Method The KR403 printer supports two basic media supply method types outside wound roll mount and stacked fan fold receipt media The media printing surface faces up towards the top of the printer and away from the body of the printer Top of Printer Any Orientation Printing Surface Printing Surface Figure 5 17 Media Supply Media Input Aperture P1016701 001 Rev B KR403 Hardware Integrator Guide The KR403 printer has a wide aperture to support a wide range of media mounting locations The media can enter the printer directly o
59. nections Cabling and Cable Routing Always tie cable down use locking connectors where possible allow for kiosk component servicing and avoid electrical noise sources Tie all cables to the kiosk chassis or printer mounting hardware that are near the printer the media path or media The operator can accidentally disconnect the printer or other kiosk components when maintaining the kiosk Cabling must not interfere with the proper operation of the printer and media The operator can become caught on cabling and drop heavy media damaging the kiosk or hurting themselves Service Loops There should be enough slack in the cabling to not put pressure on the cable connectors or the circuit boards Also enough slack is needed to disconnect the printer or their kiosk components for servicing Allow for movement needed to access the cable locks or slide the printer out when using the Quick fit hubs Avoid electrical noise sources fluorescent lighting and ballast power supplies fans AC power lines CRT monitors etc Avoid twisting power and communication cables together This can cause spurious noise on the communication port or raise emissions levels Large Media Roll Adapter Accessory The large media roll adapter accessory adds an additional 10cm to the front of the printer It is therefore necessary to route cables differently when using this acessory See Routing Cables with the Large Media Roll Adapter on page 84 for additional i
60. nformation 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 34 Connections Attaching Power Attaching Power Caution Never operate the printer and power supply in an area where they can get wet Serious personal injury could result The KR403 printer has unique power requirements to operate efficiently safely and within safety and compliance regulation guidelines To achieve optimum performance an approved power supply should be used to operate the KR403 printer Refer to Printer Power Supply 808099 004 on page 76 If a non Zebra supplied power supply is used with the KR403 it must comply with the following requirements Table 4 11 Power Supply Output Characteristics Output Rating 24 0 Volts 2 92 Amps and 2 5 Amps 5 to 40 C Voltage 24 0 Vdc 5 2 Initial Tolerance No Load Current 2 92A and 2 5AMaximum Output Requirement When Printing worst case conditions Max Output Power 24 0 Vdc x 2 92A 70 Watts typical Peak Power 90VA Cin 47Hz 243W Output Regulation Line Regulation 10 596 over AC input operation range Ripple amp Noise 240mVpp at lout 2 92 Amps Resistive Load 4 7uF 50V ceramic Cap On output 20MHz BW Transient Load Response 5mS Recovery 40 to 80 Load Change Overshoot Power Ip 1096 Max at power on or power off Holdup Time 20ms Minimum Rated DC Load 120VAC 60Hz Over Voltage Output Limited to 28V max Fuse Yes
61. ng Plate 410 mm 326 mm o o o prem r 1 SCH 11 R le d p E d AA a E ES E d E s i i La I E I He fact Hf E EE EE EES aaa aa E ha l l E j i NN omm 2 AA d E een cad Al ebe EES e E o oJ Low Position with Mounting Plate 2150 mm 58 60 mm Mounting Plate 200 mm 252 mm 80 82 5 mm I HH 200 mm FE M FAC 58 60 mm I H 1 Tel 2250 mm 80 82 5 mm O 4 Under Position with Mount
62. ng Power on page 34 or use of the 70 watt power supply accessory Printer Power Supply 808099 004 on page 76 Media Handing Roll or fan fold roll mounting or fan fold tray and media and printer mounting design your own or use a KR403 printer mounting accessory See Accessories on page 61 Media location in the kiosk relative to the printer and its effects on maximum media roll diameter 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 8 Design Overview Design Considerations Overview P1016701 001 Rev B Operator access to the printer The operator needs to view service and maintain the printer The operator needs access to The operator needs to be able to see the printer s control panel for status lights and also press the Feed button while observing the status lights for media loading setup and servicing the printer see Controls Indicators and Sensors on page 24 Open and clean the printhead or remove jams Refer to the Service Manual P1026223 The media path between the printer and media roll or fan fold A minimum clearance of 250 mm on one or the other side of the printer printer controls and media is needed Service and printer replacement access to mounting hardware Designing for the operator ideas for a more intuitive media loading media preparation and use of media loading labels and documents Cabling power and electrical noise sources Ambient Lighting and
63. nt Modes The KR403 is a versatile printer and can print in several modes Kiosk the default horizontal with looping presenter or configurable vertical presenter mode rewind receipt only with no cut or kiosk mode features supported and cutter simple mode to support label media many kiosk features are supported except looping retract and partial cut modes In Kiosk mode the printer stores the printed receipt in the loop area horizontal mounting or hanging below the printer vertical mounting while finishing printing and cutting the receipt The printer then presents the receipt to the kiosk client When the client pulls the receipt the printer immediately detects the roller movement and causes the printer to accelerate the receipt out of the printer This helps prevent damage to the receipt The kiosk mode also has programable options to retract the forgotten receipt back into the kiosk s internal waste bin below the printer e o Qo Figure 3 11 e Printing Sequence Table 3 7 Printing Sequence Media Input Use Auto or Manual media loading procedures O Printhead and Platen Drive Roller o Loop area horizontal mode stores Media Drive Roller and Loop Stop printed receipt is complete O forward only Media Present and Retract Roller e Roller pivots on change of direction Q Detects a media pull with motor Media Cutter Full or partial media cuts at receipt page o
64. o manually reset the printer disconnect the power from the printer Wait a few seconds for the Power LED to turn off and reconnect the power plug The printer will take around a 25 seconds to reboot and initialize The printer can also be reset with the ZPL JR command when sent by the kiosk application This is equivalent to cycling the printer power for the printer s internal programming Printer Configuration Methods and Tools The KR403 printer has many printer configuration methods for the software and hardware integrator Each is designed to assist you with various kiosk design and integration tasks These integration tasks include printer startup proof of concept receipt design status reporting multi printer configuration and kiosk application design The configuration methods from hardware to programming application include Media Guides Sets the printer s maximum print width See Media Guide Required Accessory on page 50 and Installing the Media Guide on page 50 Control Panel The printer s control panel when using the Feed Button modes provides the access or settings to automated media calibration routines print darkness print width on receipt automated serial port setup and resetting the printer to factory defaults See the Feed Button Modes on page 28 and the Printing a Test Receipt on page 59 for a view of one printer s printer configuration status label Windows Zebra Setup Utility and Windows D
65. onitoring the printer The KR403 printer also has an odometer for maintenance alerts for printhead cleaning and printhead low life warning printhead will need replacement soon This feature is off by default The KR403 printer also does power up printhead testing printhead critical fault testing for safety and has a programming accessible printhead pixel test that reports the functionality of individual pixels This feature is off by default The following tables and illustration shows an excerpt from ZPL programmers manual of the the error tables for the HQ status report Please see the ZPL programmers guide for more details and related commands 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 26 Printer Overview Sensing Status and Error Reporting Table 3 9 Error Flags HQES Group 2 Group 1 p X Value can be any hexadecimal number 0 9 A F o Error Flags Flag co N Lo st o e v o o E o Q o E 2 o a a a a a a a a o o 2 o 2 o 2 o 2 2 2 2 2 2 2 2 2 2 2 No Error 0 00000000 0 0 0 0 0 0 0 0 Error Present 1 00000000 X X X X X X X X Printhead Thermistor Open 1 00000000 X X X X X 2 X X Invalid Firmware Config 1 00000000 X X X X X 1 X X Printhead Detection Error 1 00000000 X X X X X X 8 X Bad Printhead Element 1 00000000 X X X X X X 4 X Motor Over Temperature 1 00000000 X X X X X X 2 X d 1 0
66. operating systems support the USB port communications with this printer when using the Zebra Setup Utility or the ZD Zebra Designer Windows Driver P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Connections Connecting the Printer to the Host These operating systems automatically detect the printer when connected via the USB interface The operating system automatically starts a Add new hardware wizard when connecting the printer for the first time to the PC Close the wizard Install the printer following the wizard The latest driver is found at www zebra com Select the USB and then media size closest match Click on the Print test page button to verify a successful installation The Windows operating system will detect and re link a previously installed printer if it is reconnected to the USB interface or power is turned on after the PC has finished its restart of the operating system Ignore the new device detected warnings and close the Task bar prompts Wait several seconds for the operating system to match the printer to the driver software The warnings will quit and the printer now should be ready to begin printing Serial Port and Windows operating systems The Windows operating system default settings for the serial port communication closely match the printer s defaults settings with two exceptions the data Baud Rate and Flow Control settings The Windows default data Baud Rate Bits per second se
67. ou receive the printer immediately unpack it and inspect for shipping damage e Save all packing materials e Check all exterior surfaces for damage Open and close the printer and remove any media or test prints in the printer If you discover shipping damage upon inspection e Immediately notify the shipping company and file a damage report Zebra Technologies Corporation is not responsible for any damage incurred during shipment of the printer and will not cover the repair of this damage under its warranty policy Keep all packaging material for shipping company inspection e Notify your authorized Zebra reseller Who Should Use This Document This guide is intended for use by any person who needs to develop a kiosk using the KR403 printer and operate or troubleshoot the printer 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 3 4 Introduction How This Document Is Organized How This Document Is Organized The manual is set up as follows Chapter Description Introduction What is covered in this document contact information Design Overview Introduction to the KR203 Printer and package contents design considerations overview Printer Overview Dimensions orientation and other features Connections Power and communication connections Media Loading mounting and feed angles Accessories Available options to enhance the kiosk design Troubleshooting Covers operational issues and resol
68. ounting Plate with the inertia dampening spring guide and cable shield is needed in the two other positions The optional media roll low sensor can be added to the roll support High and Low 150 mm max roll Under 200 mm max roll Arm Positions High and Low 200 mm max roll Under 250 mm max roll Arm Positions Mounts on either side 4 200 mm Roll and Low Roll Support Position Shown P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 71 Universal Roll Holder P1014125 High Position No Mounting Plate 150 mm 2200 mm Minimum Printhead Access Clearance T E E 9 E LO o LO 1 251 mm 285 mm Minimum Printhead Access Clearance E Mounting Plate E To 200 mm N N Low Position with Mounting Plate 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 72 Accessories Universal Roll Holder P1014125 Under Position with Mounting Plate Minimum Printhead Access Clearance Mounting Plate E X E g D X ae dnd E E E E 2250 mm a ae Y 127 mm P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories 73 Universal Roll Holder P1014125 13 mm 9 7 mm 308 mm High Position No Mounti
69. per failed to reach the presenter sensor within the expected amount of time The error is signaled if the media does not reach the presenter sensor after feeding the length from the cuter to the sensor plus 15mm This error is cleared by opening and closing the print head or by cycling power off and on Yellow Flashing 6 Head Temperature Error This code indicates that the print head has exceeded the maximum permitted temperature This status code is set when the print head temperature exceeds 65 C 149 F When this condition occurs the printer feeds 100mm 4 inches of blank media cuts and presents This error is cleared automatically when the print head temperature falls below 55 C 131 F Rapid Amber Flashing P1016701 001 Rev B Firmware missing or corrupt KR403 Hardware Integrator Guide This code indicates that the bootware has detected an incorrect or missing checksum in the firmware This error is cleared when the firmware is reloaded or updated Refer to the Software Integrator Guide for firmware upload procedure 9 24 2010 Troubleshooting 89 Status Light Descriptions Application User Interface 9 24 2010 With the printer power on press and hold the feed button Continue holding the feed button until the status indicator flash sequence occurs The next flash sequence occurs after completion of the previous flash sequence The flash sequences perform the following functions
70. platen drive roller when the leading edge of the media passes over the media sensor 1 Insert the paper through the paper entry opening at the front of the printer The printer will now feed cut and eject a blank receipt or a printout of the last print job in the print buffer and then automatically go to a Ready state solid green status indicator Insert Media Media Feeds to Presenter Cut Media Media Presented Remove presented media to print or feed media Figure 5 27 Automated Media Loading P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Media 57 Manual Media Loading Manual Media Loading Manual media loading is intended for maintenance operations such as printhead cleaning and removing media jams Please use the Auto Load procedure page 56 to load media for normal operations 1 Open the printhead 2 Insert the media through the front of the printer and under the open printhead Pull the media just past the cutter and platen drive roller 3 Close the printhead Push down on the push bar to securely latch the printhead closed 4 Press the Feed button once to get the printer out of Pause mode double blinking green status indicator The printer will feed 70 mm of media and cut the media Discard the receipt scrap Pressing the Feed once more will reprint that image to the proper paper size Figure 5 28 Manual Media Loading 9 24 2010 KR403 Hardware Integrator Guide P10167
71. r cut immediate Internal Media Drive Roll Ejects the media out of the printer when retracting horizontal mode Ejects the paper when pulled vertical mode 9 Retract to Waste Bin Exit horizontal mode Media Present Exit vertical mode Media Present Exit horizontal mode Printed Media Storage and Retract to 8 Waste Bin vertical mode P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printer Overview 21 Looping Presenter Kiosk Mode Looping Presenter Kiosk Mode The loop generating presenter mechanism has many benefits Loop Print It handles documents of various lengths by storing the printed paper in a loop Print It holds the printout until fully printed and cut before presenting the completed printout to the customer This eliminates issues many other printers have when the kiosk client tries to remove media before printing has finished Cut A portion of the printout is presented When the e b customer takes the receipt the printer detects a movement and issues the rest of the receipt at 300 mm s to help ensure receipt is removed ZAR undamaged The amount of media presented can be customized to account for differences in the kiosk wall The retract and retain function can retract uncollected printouts and throw them in a wastebasket inside the kiosk Retracts are Retract reported to the driver so any remaining data for that p
72. r default media mode is Continuous The printer will remain in this mode until it is changed by the Windows Driver The KR403 printer has automatic media calibration capability for black mark media 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 page to page on a roll and from roll to roll of media The printer will automatically initiate a media length calibration if the expected media length or the page to page gap distance has exceeded the acceptable variation range when starting a print job or feeding media If the printer does not detect blacklines or notches with black mark sensing after feeding the media the default maximum label length distance of 24 inches 610mm then the printer will report a media error Optionally the printer can be set to do a short media calibration after loading media or when closing the printhead with power on The printer will then feed up to three labels while calibrating 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 92 Troubleshooting Media Sensing Problems The printer will not load the media The media has changed or a different media guide has been installed Make sure the appropriate media guide is installed for the media being used Refer to Media Guide Required Accessory on page 50 Perform the two flash procedure to recalibrate the printer
73. r indirectly with the addition of custom media guides or printer roll or mounting accessory kits Side Panel Cut Away a 25 ooo Minimum Clearance Area for Printer Power and Cabling Figure 5 18 Media Input Aperture 9 24 2010 9 24 2010 Media 47 Basic Media Mounting Considerations The direct media input or angle of contact with media guides not shown here will change as the media is being consumed Minimum Clearance Area for Printer Power and Cabling R d mb 9 oo Sg This area should have a continuous physical barrier separating the media and folds from binding in the cabling printer body kiosk chassis seams etc Figure 5 19 Media Aperture KR403 Hardware Integrator Guide P1016701 001 Rev B 48 Media Basic Media Mounting Considerations Mounting Orientations The printer has two basic kiosk operation modes and orientations Horizontal and Vertical Horizontal Vertical Figure 5 20 Mounting Orientations The maximum angle that the printer can operate from the nominal vertical or horizontal orientations is dependent upon environmental conditions and the media in use Environmental conditions that can affect operation include humidity and temperature circulating air in the kiosk static buildup on adjacent kiosk components and surfaces etc Media considerations can include length of receipt partial cut of receipt in receipt design media curving at the end of the med
74. rews 2 Attach the universal roll holder to the mounting block with the screw Note Printer not shown attached for clarity o SO MGa ili jo 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 84 Accessories Routing Cables with the Large Media Roll Adapter Routing Cables with the Large Media Roll Adapter Media Roll Low Sensor When the universal roll holder is attached to the large medial roll adapter the 500mm media roll low sensor should be used see Media Roll Low Sensor on page 69 Left Side Routing 1 Plug the media roll low sensor into the printer 2 Secure the wiring to the tie down point on the large media roll adapter using a plastic cable tie 3 Route the wiring under and to the outside of the universal roll holder and secure it using plastic cable ties eo 4 Attach the sensor to the roll support using the screw P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Accessories Routing Cables with the Large Media Roll Adapter Right Side Routing 1 Plug the media roll low sensor into the printer 2 Secure the wiring to the tie down points on the large media roll adap
75. ries are available for your printer Nozzle Bezel A translucent media exit bezel styled after common credit card input bezels used in ATM Asynchronous Transfer Mode machines and other kiosks Shutter Bezel The shutter bezel is a light weight door designed to prevent the kiosk user from easily inserting foreign objects into the printer dust or block external light sources from interfering with the printer s ability to detect when is media exiting the printer Small Core Media Roll Adapter Designed to guide the leading edge of receipt into the input of the media present rollers Allows the use of media roll inside diameters less than 25 mm typically POS media and increases the operational range of printer in a given mounting orientation see Mounting Orientations on page 48 e Quick Fit Printer Mounting A quick printer release mounting system that can be used with KR403 mounting accessories or with your own design The service tech can pull the leaf spring latch to unlock the printer and quickly slide it out for easy replacement or service the parts can be ordered separately as e Quick Fit Hubs Flanged hubs and printer mounting screws e Leaf Spring Retainer Spring and two M3 x 3 mm screws e Roll Support A rugged media roll support bracket designed to provide minimal friction and self centering of the media roll 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 62 Accessorie
76. rinter Overview Receipt Page Imaging Modes Receipt Page Imaging Modes The printer sets the following modes with programming commands or with the Windows driver The KR403 printer uses ZPL Page mode programming to assemble and print receipts Page mode printing describes the receipt margins and the image to be placed between the margins and then printed The image is assembled in the image memory buffer and then printed as one continuous print Continuous Kiosk Mode Table 3 8 Receipt Imaging Modes Prints the image buffer and cuts the media at the end of the image defined by Label Length parameter Continuous Variable Default Kiosk Mode If the image is larger that the preset image buffer size then the printer expands the image buffer to accommodate the larger image up to the printer s maximum allowed size set by programming available memory and print with The printer then prints the larger image with print margin and cut the receipt The next receipt will return to the preset image receipt size if the next image is the same size or smaller Black Mark or Line Prints receipts that match the receipt length set by the Kiosk Mode distance between the black marks or lines and cuts the receipt at the black mark or line by default Cut Only Can be used for printing labels but it is not recommended for Cutter Mode Basic Printing Rewind mode 9 24 2010 KR403 Hardware Integrator Guide
77. rintout can be deleted Retraction can be SES initiated by an internal timer or issued directly I by the application I s I Waste Bin I 1 Area Lied 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 22 Printer Overview Vertical Presenter Kiosk Mode Vertical Presenter Kiosk Mode The vertical presenter operation has many benefits It handles documents of various lengths by storing the printed paper below the printer It holds the printout until fully printed and cut before presenting the completed printout to the kiosk client This eliminates print issues caused by kiosk clients trying to remove media before printing has finished It stores the entire receipt to re orient the printout to face up for presentation to your client A portion of the printout is presented When the customer takes the receipt the printer detects a movement and issues the rest of the receipt at a speedy 300 mm s to help ensure receipt is removed undamaged The amount of media presented can be customized to account for differences in the kiosk wall The retract and retain function can retract uncollected printouts and throw them ina wastebasket inside the kiosk Retraction can be initiated by an internal timer or issued directly by the application po P1016701 001 Rev B KR403 Hardware Integrator Guide Media In Print Cut Store Retract Waste Bin Area 9 24 2010 P
78. rivers Quickly allows the developer to use the printer test configuration options send programming commands or files and print directly from Windows applications P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Printer Overview 29 Fonts and Your Printer Zebra Designer A receipt and label design program that works with the Windows printer driver to help you quickly develop receipt layouts and manage fonts and objects graphics logos and receipt forms during proof of concept process ZPL SGD Set Get Do and ZBI Zebra Basic Interpreter Programming Languages The ZPL printer programming printer page description language allows the application developer to configure and control all aspects of your printer with ASCII based text programming The SGD object based programming language is used to set and check printer configuration status and configuration These three programming languages should be used in separate command lines or files when sending commands to your printer The ZPL Programming Guide for the KR403 printer covers all three languages in a single manual at this time See the KR403 Software Integrator s Guide for assistance in quickly developing and integrating the printer ZebraLink File and Firmware Downloader This tool is used to initialize ZBI programming capability and download files to the printer ZBI allows the software developer to emulate other programming and create custom comman
79. s Accessories Overview P1016701 001 Rev B Media Roll Low Sensor Optical sensor designed to mount into the Roll Support accessory or other KR403 printer mounting accessory and plug directly into the rear of the printer Universal Roll Holder This versatile mounting accessory supports three roll positions with the ability to mount it on either side of the printer Printer Mounting Plate for roll holder mounted below printer This mounting plate assembly is designed to work with the Universal Roll Holder accessory when the roll is in the Low and Under holder positions It includes a inertia dampening spring roller to optimize printer performance when using the large 250 mm diameter rolls Wall Mount Roll Holder The wall mount supports a maximum media roll diameter of 150 mm The wall mounting bracket attaches at the front of the printer flush to the kiosk wall Printer Power Supply 70 watts This printer accessory has been optimized for use with thermal printers and in particular your KR403 printer It has been designed and tested to meet or exceed most international safety and compliance standards Please check for more detailed safety and compliance information for the printer and this power supply at the Zebra Web site www zebra com USB Cable This accessory has been thoroughly tested for use with the 2824 Plus printer Large Media Roll Adapter and Mounting Plate Designed for use with the printer when usin
80. seams see Roll Support P1014124 on page 68 The larger the roll more mass the greater the effect it has on drag Leave plenty of access room to load media when designing the area for your roll support Leave additional clearance for the roll swinging on the support and hands that hold the media to load it Designing Media Guides The media guides need to have a minimum radius of 10 mm The surface should be smooth and not touch the edges of the media causes drag or edge damage The media should only touch radius surface and not the edge of the radius for all roll sizes that may be used full or nearly empty See the Wall Mount Roll Holder P1014123 on page 75 and the Universal Roll Holder P1014125 on page 70 side views to illustrate roll size and contact with a media guide Designing for Fan Fold Media Fan fold media creates unique challenges It has square edges that can get caught and the stack can fall into other components and cabling Make a tray to hold the fan fold media unless it is being pulled straight up Always test and observe with the actual media Fan fold media can un fold erratically and act differently at the beginning and end of the stack Design a tray a little higher than the height of a full stack of media Fan fold media tray should keep the media stacked and never allow the media to be pulled into the kiosk When using a media guide the guide should ideally be twice the distance of the length
81. stic functionality Media detection and control sensors Printhead temperature sensor operation failure and printhead testing Cutter operation sensing and jam detection Media output pull detection sensing Support for an external low media roll detection sensor accessory option Virtual sensing and report of printer operations to the host to simplify reporting and kiosk integration and design process Programming configurable maintenance and service warnings for printhead cleaning printhead life printer life and count of media retracted back into the kiosk These features are off by default and must be set by Set Get Do SGD or ZPL programming The printer has redundant printer control and indicator panels on each side of the printer to provide the integrator greater flexibility for designing printer mounting for servicing the printer Feed Button Control The Feed button has several functions Press and Release will feed media cut and present a complete receipt page in the default kiosk mode All the other integrator set modes and variations of the kiosk mode will at minimum feed a page length of media when the Feed button is pressed and released e Any data in the print buffer will be printed If the buffer is empty the page will be blank In black mark mode the page will be synchronized with the black mark Press and Hold with the Printer ON will cause the printer to enter the user interface
82. tain Media Exit and Present Media Exit and Present Media Retract and Retain 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B Printer Overview 11 Printer Features Printer Features Figure 3 3 Printer Features Table 3 2 Printer Features Printhead Retractor Platen drive Roller Control Panel right Cutter Retract Sensor Presenter Media Sensors ao OOOO 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 5 9 ev T Oo LU 25 E e Ben OU aad 12 Printer Features continued Serial USB Figure 3 4 Printer Features USB Ethernet Figure 3 5 Printer Features Printer Features Table 3 3 Ao o o c E e O ei aa s SIS oO IS l o 2 5 Elle Sue le Clas Benn d lo 3 59 Cc O lalo n n JO c Ao m o Q o O zit o lols c lolo SET bed O Q 0 JHIE o la S Oo D 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B Printer Overview 13 Printer Features Printer Features continued Figure 3 6 Printer Features Serial USB Table 3 4 Printer Features Opa 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B Printer Overview Printer Features 14 Opening the Printer When cleaning or servicing the printer it is sometimes necessary to a
83. ter using plastic cable ties as shown 3 Route the wiring under and to the outside of the universal roll holder and secure it using plastic cable ties 4 Attach the sensor to the roll support using the screw Power Cable Because of the ferite attached to the power cable accessory it is necessary to route it so that it does not interfere with the function of the large media roll adapter When using a power source other than the power supply accessory routing the wiring is done along the left side of the large media roll adapter using a plastic cable tie at the tie down point Serial USB and Ethernet Cables Data cables are routed along the right side of the large media roll adapter Secure the cables to the tie down point on the large media roll adapter using plastic cable ties 9 24 2010 KR403 Hardware Integrator Guide P1016701 001 Rev B 85 86 Accessories Routing Cables with the Large Media Roll Adapter P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 7 Troubleshooting Status Light Descriptions Application LED States Immediately after power is applied to the printer a brief self test is performed and the status light will report the following conditions Table 7 1 Application LED States This code is reported when no other Solid Green 0 O
84. tting is 9600 The KR403 printer requires data Baud Rate set to 115k The Windows default data Flow Control setting is NONE The KR403 printer requires data Flow Control set to Software Note The KR403 printer does not support Windows Serial Port Plug and Play PnP device detection at this time Ethernet Port and Windows operating systems 9 24 2010 Windows XP Windows Vista Windows 7 Windows Server 2003 and Windows Server 2008 operating systems support the ethernet port communications with this printer when using the Zebra Setup Utility or the ZD Zebra Designer Windows Driver KR403 Hardware Integrator Guide P1016701 001 Rev B 41 42 Connections Connecting the Printer to the Host P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Media Designing Your Own Media Dispensing System Properly dispensing the media to the printer is critical to the operation of the printer and quality print The media roll or fan fold needs to flow smooth and free with minimal drag or binding Ideally it should have a clean and cool location for dispensing and storing media Loading or dispensing media to the printer should not have interference or access restrictions with the kiosk enclosure or internal components The media entering the printer should be aligned to the center of the printer The printer and roll media should be level to prevent drag on the side of the roll and damage to the receipt edges This can cause
85. utions for status indicator codes and poor print quality This manual will be updated from time to time as printer functions and features may be added or amended You will always find the latest edition on our web site http www zebra com If you require information for functions not found in this manual edition please contact Technical Support for your region or the Zebra partner the printer was purchased from P1016701 001 Rev B KR403 Hardware Integrator Guide 9 24 2010 Contacts Introduction 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 e E mail address emb zebra com Subject line Emaillist Self Service Knowledge Base www zebra com knowledgebase Online Case Registration www zebra com techrequest Which Department Do You Need Regional Headquarters Technical Support For questions on the operation of Zebra equipment and software please call your distributor For additional assistance contact us Please have your model and serial numbers available Repair Service Department For back to base service and repair The Americas Zebra Technologies International LLC 475 Half Day Road Suite 500 Lincolnshire IL 60069 USA T 1 847 634 6700 Toll free 1 866 230 9494 F 1 847 913 8766 T 1 877 ASK ZEBRA 275 9327 F 1 847 913 2578 Hardware ts1 zebra com Software ts3
86. zebra com Kiosk Printers T 1 866 322 5202 kiosksupport zebra com T 1 877 ASK ZEBRA 275 9327 F 1 847 821 1797 E repair zebra com To request a repair in the U S go to www zebra com repair Europe Africa Middle East India Zebra Technologies Europe Limited Dukes Meadow Millboard Road Bourne End Buckinghamshire SL8 5XF United Kingdom T 44 0 1628 556000 F 44 0 1628 556001 T 444 0 1628 556039 F 444 0 1628 556003 E Tseurope zebra com T 44 0 1772 693069 F 44 0 1772 693046 New requests ukrma zebra com Status updates repairupdate zebra com Asia Pacific Zebra Technologies Asia Pacific Pte Ltd 120 Robinson Road 06 01 Parakou Building Singapore 068913 T 65 6858 0722 F 65 6885 0838 T 465 6858 0722 F 65 6885 0838 E China tschina zebra com All other areas tsasiapacific zebra com T 65 6858 0722 F 65 6885 0838 E China tschina zebra com All other areas tsasiapacific zebra com Technical Training Department For Zebra product training courses T 1 847 793 6868 T 1 847 793 6864 F 1 847 913 2578 E ttamerica zebra com T 44 0 1628 556000 F 44 0 1628 556001 E Eurtraining zebra com T 65 6858 0722 F 65 6885 0838 E China tschina zebra com All other areas tsasiapacific zebra com Inquiry Department For product literature and distributor and dealer information T 1 87

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