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Zebra DA402 - page 1
Rev . 2 Customer order # 52005L Manufacturer part # 52005LB DA 40 2 User s Guide ' Stripe Series Direct Thermal P rinter ® ...
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Zebra DA402 - page 2
Proprietary Statement This manual contains proprietary information of Zebra Technologies Corporation. 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 exp ...
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Zebra DA402 - page 3
I have determined tha t the Zebra printers ide ntified as the Stripe Series 402 and 402 ® DA T manufactured by : Zebra T echnologies Corporation 333 C orporate W o ods P arkway V ernon Hills, Illinois 60061-3109 U.S.A. have been shown t o comply with th e applicable tech nical standar ds of the FCC for Home, Office, Commercial, and Industrial use ...
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Zebra DA402 - page 4
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Zebra DA402 - page 5
Contents Introduction Hello! ..................................1 What’s in the Box ............................1 Unpacking and Inspection ........................2 Reporting Damage ..........................2 DC Power Supply ............................3 Printer Overview (illustration) .....................4 Gettin g Read y t o Print Loadin g th ...
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Zebra DA402 - page 6
Troubleshooting Wha t th e Statu s LE D i s Tellin g Yo u .................. 2 5 Prin t Qualit y Problem s ......................... 2 6 Manua l Calibratio n ........................... 2 8 Troubleshootin g Test s ......................... 2 9 Printin ga Configuratio n Labe l ................... 2 9 Recalibratio n ............................ 2 9 R ...
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Zebra DA402 - page 7
Introduction Hello! Thank you for choosing the Zebra DA 402 Printer. This rugged little printer is certain to become a productive and efficient addition to your workplace! n This user’s guide provides the information you will need to operate and maintain the printer. n To create and print label formats, take a look at the ZPL II Programmi ...
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Zebra DA402 - page 8
Unpacking and Inspection Inspect the printer for possible shipping damage: n Check all exterior surfaces for damage. n Rais e th e to p cove r (refe r t o “Loadin g th e Media ” o n pag e 5 ) an d inspect the media compartment for damage. In case shipping is required, save the carton and all packing material. Reporting Damage If you discover sh ...
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Zebra DA402 - page 9
WARNING: NEVER OPERATE THE PRINTER AND POWER SUPPLY IN AN AREA WHERE THEY CAN GET WET. SERIOUS PERSONAL INJURY COULD RESULT! DC Power Supply Refer to Figure 1. 1. The DC power supply has a barrel connector on one end that must be inserted into the power supply receptacle on the back of the printer. 2. Insert the separate AC power cord into the powe ...
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Zebra DA402 - page 10
Printer Overview 4 Media Hangers Printhead P eel- Off Option T ear Bar P eel Bar P eel Roller Cutter Unit Release Lever Release Lever Platen Roller Media Guide Adjuster Media Guides Lock - down Screw Status LED F eed Button Cutter Option Figure 2 ...
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Zebra DA402 - page 11
Getting Ready to Print Loading the Media You can operate this printer in three different modes: tear-off, peel-off, or with a cutter. n Tear-off mode allows you to tear off each label (or a strip of labels) after it is printed. n In peel-off mode, the backing material is peeled away from the label as it is printed. After this label is removed, the ...
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Zebra DA402 - page 12
2. Separate and hold open the media hangers (refer to Figure 4). 3. Place the media roll onto the media hangers, ensuring that it is tightly woun d (refe r t o Figur e 5 ). NOTE : Refe r t o Figur e 6 . I f yo u ar e usin g labels , mak e sur e the media unwinds from the top of the roll. Tags unwind from the bottom of the roll. 6 Media Hanger Media ...
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7 Figure 5 Labels T ags Figure 6 ...
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4. Refer to Figure 7. Thread the media through the media guides. NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 7). The media guides should just touch, but not restrict, the edges of the media. 5. Close the top cover and turn on the printer or press the feed butt ...
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Zebra DA402 - page 15
Peel-Off Mode (optional) 1. Unlatch the top cover by pulling the two green release levers toward you (refer to Figure 8). Then, lift the top cover to expose the media compartment. 9 Release Lever Release Lever Figure 8 ...
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2. Separate and hold open the media hangers (refer to Figure 9). 3. Place the media roll onto the media hangers, making sure it is tightly woun d (refe r t o Figur e 10 ). 4. Open the peel-off unit by pulling down on its textured top surface (refer t o Figur e 11 ). 5. Activate the peel-off unit by moving the peel-off switch to the left (refe r t o ...
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Zebra DA402 - page 17
11 Figure 10 P eel- off Switch ON OFF Figure 11 ...
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Zebra DA402 - page 18
7. Refer to Figure 12. Thread the label backing through the media guides and over the peel bar. NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 12). The media guides should just touch, but not restrict, the edges of the media. 12 Media Guides Media Guide Adjuster ...
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Zebra DA402 - page 19
8. Thread the label backing between the black platen roller and white peel roller until it comes out of the slot beneath the peel-off unit (refer to Figure 13). 9. Close the peel-off unit by pushing in on its smooth side surface. 10. To remove any slack, rewind media onto the roll. 11. Close the top cover and turn on the printer or press the feed b ...
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Zebra DA402 - page 20
Cutter Mode (optional) NOTE: The cutter is designed to cut through paper labels or the backing between labels, not the adhesive backing of the label. Adhesive build-up on the cutter blade may cause the cutter to jam. 1. Unlatch the top cover by pulling the two green release levers toward you (refer to Figure 14). Then, lift the top cover to expose ...
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Zebra DA402 - page 21
15 Figure 16 Media Hanger Media Hanger Figure 15 ...
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4. Refer to Figure 17. Thread the media through the media guides. NOTE: If the media guides must be changed to accommodate the width of the media, turn the green media guide adjuster (refer to Figure 17). The media guides should just touch, but not restrict, the edges of the media. 5. Refer to Figure 17. Thread the media through the cutter unit. 6. ...
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Zebra DA402 - page 23
Fanfold Media Fanfold media loads from the outside of the printer. Refer to Figure 18. 1. Thread the media through the access slot in the back of the printer. 2. Separate and hold open the media hangers. 3. Lock the media hangers in position by tightening the screw located on the right media hanger. CAUTION: Do not overtighten the screw! Overtighte ...
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Zebra DA402 - page 24
Auto Calibration NOTE: If you are using pre-printed labels, pre-printed label backing , o r continuou s media , se e “Manua l Calibration ” on page 28. A n aut o calibratio n i s performe d whe n th e printe r i s turne d o n (i f medi a is loaded) or after a media error is cleared. When it is auto calibrating, the printer sets the sensor level ...
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Zebra DA402 - page 25
Operator Controls Refer to Figure 19. Power Switch n Press to turn on and turn off the printer. CAUTION: The power should be turned off before connecting or disconnecting the communications and power cables. Feed Button n Forces the printer to feed one blank label. n Takes the printer out of a “pause” condition. (The printer is put into “paus ...
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Zebra DA402 - page 26
Printing a Test Label Before you connect the printer to your computer, make sure that the printer is in proper working order. You can do this by printing a configuration label: 1. Make sure the media is properly loaded and the top cover of the printer is closed. Then, turn the printer power on if you have not already done so. 2. When the status LED ...
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Zebra DA402 - page 27
Paralle l Interfac e Requirements Th e require d cabl e (IEE E 1284-complian t i s recommended ) mus t hav e a standar d 36-pi n paralle l connecto r o n on e end , whic h i s plugge d int o the paralle l por t locate d o n th e bac k o f th e printe r (refe r t o Figur e 20 ) . The othe r en d o f th e paralle l interfac e cabl e connect s t o th ...
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Zebra DA402 - page 28
Communicating with the Printer Via the Serial Port Serial communications between the printer and the host computer can be set by either autobaud synchronization or the ^SC command. Autobaud Autobaud synchronization allows the printer to automatically match the communication parameters of the host computer. To autobaud: 1. Press and hold the feed bu ...
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Zebra DA402 - page 29
Using ZPL II For detailed information about creating labels using ZPL II, refer to the ZP L I I Programmin g Guid e o r visi t ou r we b sit e a t www.zebra.com . Adjusting the Print Width Print width must be calibrated when: n You are using the printer for the first time. n There is a change in the width of the media. Prin t widt h ma y b e se t b ...
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Zebra DA402 - page 30
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Zebra DA402 - page 31
Troubleshooting What the Status LED is Telling You RESOLUTIONS: 1. The printer is not receiving power. n Have you turned on the printer power? n Check power connections from the wall outlet to the power supply, and from the power supply to the printer. 2. The printer is on and in an idle state. 3. The printer has failed its power on self test (POST ...
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Zebra DA402 - page 32
5. The media is out. n Loa da rol l o f media , followin g th e instruction s i n “Loadin g the Media ” o n pag e 5 . Then , pres s th e fee d butto n t o resum e printing. The printhead is open. n Close the top cover. Then, press the feed button to resume printing. The cutter is jammed. n Turn off the printer and remove any jammed labels from ...
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Zebra DA402 - page 33
n Adjust the print darkness and/or print speed. Refer to the six-flash sequenc e i n “Fee d Butto n Modes ” o n pag e 31 , o r th e ^P R an d ~SD commands in the ZPL II Programming Guide . n The media being used is incompatible with the printer. Be sure to use the recommended media for your application, and always use Zebra-approved labels and ...
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Zebra DA402 - page 34
Manual Calibration Manual calibration is recommended whenever you are using pre-printed labels (or label backing) or if the printer will not correctly auto calibrate. 1. Turn on the printer power. 2. Remove approximately 4” (102 mm) of labels from a section of backing material. Load the media so that only the backing material is threaded through ...
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Zebra DA402 - page 35
Troubleshooting Tests Printing a Configuration Label To print out a listing of the printer’s current configuration (an example is show n i n Figur e 22) , refe r t o th e one-flas h sequenc e i n “Fee d Button Modes ” o n pag e 31. Recalibration Recalibrate the printer if it starts to display unusual symptoms, such as skippin g labels . Se e ...
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Zebra DA402 - page 36
Resetting the Factory Default Values Sometimes, resetting the printer to the factory defaults solves some of the problems . Follo w th e four-flas h sequenc e instruction s i n “Fee d Button Modes ” o n pag e 31. Communications Diagnostics If there is a problem transferring data between the computer and printer, try putting the printer in the c ...
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Zebra DA402 - page 37
Feed Button Modes 31 Power Off Mode (Communications Diagnostics Mode) With the printer power off, press and hold the feed button while you turn on the power . Th e printe r print s ou ta listin g o f it s curren t configuratio n (se e Figur e 22 ). After printing the label, the printer will automatically enter a diagnostic mode in whic h th e print ...
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Zebra DA402 - page 39
Maintenance Cleaning CAUTION: Use only the cleaning agents indicated. Zebra Technologies Corporation will not be responsible for damage caused by any other cleaning materials used on this printer. I f necessary , refe r t o Figur e2 fo r par t locations. Lubrication CAUTION! No lubricating agents of any kind should be used on this printer! Some com ...
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Zebra DA402 - page 40
34 1 2 3 4 5 6 7 8 9 Figure 24 ...
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Zebra DA402 - page 41
Parts List Refe r t o Figur e 24 . 35 Item Number Description Part Number 1 Feed Switch Assembly (set of 3) 105910-004 2 Printhead and Latch Assembly 105910-003 3 Printhead Assembly 105910-010 4 Media Sensor PCB Assembly (set of 3) 105910-011 5 Platen Roller Kit, Standard (set of 3) 105910-001 Platen Roller Kit, Linerless 105910-002 6 Front Bezel, ...
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Zebra DA402 - page 42
Replacing the Printhead Removing the Printhead 1. Turn printer power off and unplug the printer. 2. Refer to Figure 25. Remove the four screws that secure the printhead and latch assembly to the top cover. 3 . Refe r t o Figur e 26 . Slid e th e tensio n ba r al l th e wa y t o th e righ t i n its mounting bracket (1). Then, while gently pressing o ...
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Zebra DA402 - page 43
37 T ension Bar T ension Bar Mounting Bracket T ension Bar Mounting Bracket 1 2 3 Figure 26 Printhead Bracket Lip Printhead Screw and W asher Screw and W asher Connector Connector Receptacle (shown hidden) Receptacle (shown hidden) Figure 27 ...
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Zebra DA402 - page 44
Installing the Printhead 1. Ensure that the printer is turned off and unplugged. 2. Refer to Figure 28. Route the two printhead wire harness connectors as shown. Then, insert the connectors into their receptacles. 3. Insert the printhead into the printhead bracket. 4 . Refe r t o Figur e 29 . Reinstal l th e tw o screw s an d washer s tha t secure ...
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Zebra DA402 - page 45
39 Printhead Bracket Printhead Screw and W asher Green Grounding Cable Screw and W asher Figure 29 T ension Bar “V ” of T ension Bar Printhead Bracket Notch 1 2 Figure 30 ...
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Zebra DA402 - page 47
Specifications NOTE: Printer specifications are subject to change without notice. Printing Specifications 41 Print Density 203 dots/inch (8 dots/mm) Print Speed 1.5” (38 mm), 2” (51 mm), and 2.5” (64 mm) per second Print Width 1” to 4.09” (25.4 mm to 104 mm) 1” to 2.25” (25.4 mm to 57 mm) for tag stock Print Length .005” to 22” (. ...
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Zebra DA402 - page 48
Label/Tag Specifications 42 Label/Tag Width 1” to 4.25” (25.4 mm to 108 mm) 1” to 2.25” (25.4 mm to 57 mm) for tag stock Label/Tag Length 0.5” to 22” (13 mm to 559 mm) with standard memory Interlabel Gap 0.08” to 0.16” (2 mm to 4 mm) 0.118” (3 mm) recommended Label/Tag Thickness .003” to .007” (.08 mm to .18 mm) .003” to .00 ...
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Zebra DA402 - page 49
Font/Bar Code Specifications Physical/Environmental/Electrical Specifications 43 Fonts Available ü CG Triumvirate Bold Condensed scalable smooth (0) ü Zebra fonts A-H, GS, P-V ü IBM Code Page 850 International Symbols Bar Codes Available (1D) ü Codabar (supports ratios of 2:1 to 3:1) ü Code 11 ü Code 128/USD 8 (supports serialization in all s ...
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Zebra DA402 - page 50
Agency Approvals n UL 544 Medical Equipment Standard Part 42.5 n CSA 22.2 No. 950-95 Canadian Safety Standard n IEC 950/EN 60950 International Safety Standard n FCC Class B n UL 1950 Domestic Safety Standard, 3rd Ed. n Canadian DOC Class A n EN50082-1:1997 International Immunity Standard n EN55022 Class B European Electromagnetic Radiation Standard ...
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Zebra DA402 - page 51
Serial (RS-232) Connector Technical Information NOTES: The maximum current available through the serial and/or parallel port is not to exceed a total of 0.75 Amps. When XON/XOFF handshaking is selected, data flow is controlled by the ASCII control codes DC1 (XON) and DC3 (XOFF). The DTR control lead will have no effect. Interconnecting to DTE Devic ...
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Zebra DA402 - page 52
46 Connecting the P rinter to a DTE Device DB -25S Connector to DTE Device (PC) DB -9S Connector to DTE Device (PC) DB -9P Connector to Printer DB -9P Connector to Printer 2 3 4 5 6 7 8 20 22 1 2 3 4 5 6 7 8 9 TXD TXD RXD RXD RTS RTS CTS CTS DSR DSR GND GND DCD DCD DTR DTR 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 TXD TXD RXD RXD RTS RTS CTS CTS DSR DSR ...
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Zebra DA402 - page 53
47 Connecting the P rinter to a DCE Device DB -25S Connector to DCE Device DB -9S Connector to DCE Device DB -9P Connector to Printer DB -9P Connector to Printer 2 3 4 5 6 7 8 20 22 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 TXD TXD TXD TXD RXD RXD RXD RXD RTS RTS CTS CTS CTS CTS RTS RTS DSR DSR DTR DTR GND GND GND GND DCD DCD DCD DCD DT ...
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Zebra DA402 - page 54
Parallel Interface Technical Information NOTE: The maximum current available through the serial and/or parallel port is not to exceed a total of 0.75 Amps. 48 Pin No. Description 1 nStrobe/Host Clk 2-9 Data Bits 1-8 10 nACK/PtrClk 11 Busy/Per Busy 12 PError/ACK Data Req. 13 Select/Xflag 14 nAuto Fd/Host Busy 15 Not Used 16 & 17 Ground 18 +5 V @ ...
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Zebra DA402 - page 55
A Adjustments Prin t darknes s ........ 2 3 Prin t spee d ......... 2 3 Prin t widt h ......... 2 3 Agenc y approval s ........ 4 4 Aut o calibratio n ......... 1 8 Autobau d ............ 2 2 C Calibration Aut o ............. 1 8 Manua l ........... 2 8 Cleaning Cutte r ............ 3 3 Exterio r ........... 3 3 Interio r ........... 3 3 Pee l ba r ...
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Zebra DA402 - page 56
M Maintenanc e part s ........ 3 5 Manua l calibratio n ....... 2 8 Medi a loading Cutte r mod e ......... 1 4 Fanfol d ........... 1 7 Peel-of f mod e .........9 Tear-of f mod e ........5 O Operato r control s ........ 1 9 Option s ............. 4 4 P Paralle l connecto r pinout s ... 4 8 Part s lis t ............. 3 5 Peel-of f mod e ..........9 ...
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