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Zebra P1026858

1. Under Position with Mounting Plate For illustration purposes High position media is not shown High position both roll supports are shown P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 57 Printer Power Supply 808099 004 Printer Power Supply 808099 004 The KR203 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 KR203 printer and complies with all of the same safety and compliance regulations and has the following specifications e Output voltage 24 VDC e 70 Watts 90 264 VAC at 47 63 Hz e Peak Power 243 Watts e Input Current 2 92 Amp max e 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 Attaching the Power Supply 1 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 2 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 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev
2. 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 jaand 2 1 a and b and 2 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Printer Overview Printer Mounting N eis M3 Screw Figure 3 8 Printer Mounting Table 3 4 M3 Metric Mounting Screw Length X 1 5mm minimum Printer mounting surface Y 1 5mm Printer base plate thickness Z 2mm maximum Penetration into circuit board area X Y minimum length X Y Z maximum length Mounting Orientations 10 26 2010 The printer can be mounted horizontally or vertically depending on the design of the kiosk 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 may affect operation Humidity temperature air circulation air in the kiosk and static buildup on adjacent kiosk components and surfaces etc Media considerations Receipt length partial cut of receipt in receipt design curl at the end of the media roll thickness and w
3. Zebra KR203 Kiosk Receipt Printer Hardware Integrator Guide SH P1028247 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 510 000 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 per
4. Not Required Remark When Short Circuit Protection or Over Current Protection is activated the power supply will shutdown automatically Once the abnormal condition resulting in the failure being removed the power supply will restart accordingly 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Connections 25 Attaching Power DC Power Plug Requirement The KR203 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 lt _ ___ Tyco 1445022 2 lt q Ground 24 VDC Figure 4 1 Power Plug Caution Never operate the printer and power supply in an area where they can get wet Serious personal injury could result 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 print
5. P1014125 a 53 Printer Power Supply 808099 004 a 57 Attaching the Power Supply 00 00 eee eee ee eee 57 Universal Serial Bus USB Cable P1027715 59 Large Media Roll Adapter P1026858 00 aaa 60 Attaching to the Printer 0 0 0 0 0 cee eee 61 Loading Mea 62 Mounting Plate for Large Media Roll Adapter P1027728 63 Attaching to the Printer 2 2 0 0 eee eee ee 63 Using other Accessories with the Large Media Roll Adapter 64 Universal Roll Holder 64 Routing Cables with the Large Media Roll Adapter 65 Media Roll Low Sensor 65 Power Cable naa ofc been Ee ee EN E e e beens 66 Data Clees rk ee abeidive hoe th hiteatieuers bh ee iads 66 Ze Troubleshooting ax seg nec ee BEBENG NS ELE ER 67 Status Light Descriptions ccc ee 67 Application LED Gates 67 Application User Interface 69 Print Quality Problems 0 0 aaan eee 70 Media Sensing Probleme 71 Other Problems 73 Resetting the Factory Default Values 0 a 74 Contact Technical Support 74 KR203 Hardware Integrator Guide P1028247 001 Rev B iv Contents P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 1 Introduction Who Should Use This Document This guide is intended for use by any person who needs to develop a kiosk using the KR203 printer operate or to troubleshoot problems with the printer How This
6. The Printer Mounting Plate preforms several functions e Provides a solid printer mounting base Designed to work with the Universal Roll Holder accessory page 53 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 250mm 10 inch diameter media rolls L 95mm 8mm gt lt 47mm o p O i ia L i VIN E E ZS tt E a d O Wen Zi Se tt O O 217mm l 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B Accessories 53 Universal Roll Holder P1014125 Universal Roll Holder P1014125 This roll holder can be fitted on the right or
7. range of printer in a given mounting orientation see Printer Mounting on page 16 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 44 Accessories Accessories Overview P1028247 001 Rev B 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 Universal Roll Holder This versatile mounting accessory supports three roll positions with the ability to mount it on either side of the printer Printer Power Supply 70 watts This printer accessory has been optimized for use with thermal printers and in particular your KR203 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 Large Media Roll Adapter and Mounting Plate Designed for use with the printer when using large 200 250mm media rolls to prevent excessive pulling force by the feed motor KR203 Hardware Integrator Guide 10 26 2010 Accessories 45 Nozzle Bezel Kit P1011185 Nozzle Bezel Kit P1011185 The nozzle bezel is used not only as a decorative accessory but also serv
8. 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 56 Accessories Universal Roll Holder P1014125 o N 3 3 13 mm L 308 mm High Position No Mounting Plate 410 mm 326 mm O O O ey _ lb 66 mm i EE A H a aa r dl o 1 WNS N Low Position with Mounting Plate Ki G 2180 mm 200 mm 252 mm 80 82 5 mm 2200 mm a 58 60 mm l L wN 250 mm 80 82 5 mm 66 mm
9. B 58 Accessories Printer Power Supply 808099 004 3 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 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 3 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 Printer Plug Varies k by Country Optional Power Supply Accessory Xt Active Power Light IEC 60320 C 13 Plug P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 59 Universal Serial Bus USB Cable P1027715 Universal Serial Bus USB Cable P1027715 10 26 2010 The KR203 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 KR203 printer and complies with all safety and compliance regulations KR203 Hardware Integrator Guide P1028247 001 Rev B 60 Accessories Large Media Roll Adapter P1026858 Large Media Roll Adapter P1026858 The large media roll adapte
10. a continuous physical barrier separating the media and folds from binding in the cabling printer body kiosk chassis seams etc Figure 5 3 Media Aperture KR203 Hardware Integrator Guide P1028247 001 Rev B 34 Media Media Guide Media Guide The media guide is a required accessory and must be installed for the printer to work properly The media guide is available in four widths as shown below Figure 5 4 e 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 demo kit Part No P1021954 is available for the KR203 printer that includes all four media guides plus other accessories to complete your installation and operate the printer Installing the Media Guide A calibration routine is required after installing the appropriate media guide See Media Guide Calibration on page 35 for details Caution The printhead becomes hot while printing To protect from damaging the printhead and risk of personal injury avoid touching the printhead Use only the cleaning pen to perform maintenance gt Caution Always disable printer power by un plugging the printer from the kiosk power supply or turning off the printer and or kiosk power gt 1 Remove the screw securing the media guide 2 Open the printhead P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Media 35 Media Guide 3 Insert the media guide under t
11. all printer settings to the default Green with the exception of media guide calibration then it will perform the media guide calibration 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 KR203 Hardware Integrator Guide P1028247 001 Rev B A 70 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 upward See Determining Thermal Media Types on page 36 Is the media loaded correctly Is the thermal media coating facing upward Loading Media on page 40 The printhead may be dirty or damaged e The printhead is dirty Clean the printhead Refer to the Service Manual P1028249 for instructions e The printhead is damaged Replace the printhead Refer to the Service Manual P1028249 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 P1028
12. 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 e 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 300 mm s to help ensure receipt is removed undamaged The amount of media presented can be customized to account for differences in the thickness of the kiosk wall 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 20 Printer Overview Printing Page Modes The printer sets the following modes using the Windows driver The length of the page receipt varies with the contents Pages shorter than the minimum page receipt length will be extended to the minimum length Pages receipts longer than the maximum page receipt length will print the maximum page receipt length then place the extra data on additional pages receipts Variable Page Mode The length of the page receipt is fixed The printer will always create a page receipt of the defined length If the page receipt image is shorter than the defined length blank Fixed Page Mode media will be fed until the defined length is reached Any data beyond the defined length will be placed on subsequent pages receipts Between pages receipts the cut behavior full or partial specified for the print job will occur Marks o
13. damaged e The printhead is dirty Clean the printhead Refer to the Service Manual P1028249 for instructions e The printhead is damaged Replace the printhead Refer to the Service Manual P1028249 for instructions e 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 P1028249 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 Application User Interface on page 69 e Reload the media See Loading Media on page 40 Media Sensing Problems The KR203 printer default media mode is continuous The printer will remain in this mode until it is changed by the Windows Driver The KR203 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
14. damaged or worn Refer to the Service Manual P1028249 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 P1028249 for instructions The cutter tensioner may be worn or damaged Replace the cover plate assembly Refer to the Service Manual P1028249 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 P1028249 for instructions The cutter drive gear drive pin or cutter actuator may be damaged or worn Refer to the Service Manual P1028249 for instructions Check for the latest firmware and driver version Refer to the Software Integrator Guide P1028248 or see Contacts on page 2 There are no lights on the printer 10 26 2010 Make sure there is power applied to the printer Refer to Attaching Power on page 24 The control panel may be dirty or damaged Refer to the Service Manual P1028249 for instructions The main logic board may be damaged Refer to the Service Manual P1028249 for instructions Check for the latest firmware and driver version Refer to the Software Integrator Guide P1028248 or see Contacts on page 2 KR203 Hardware Integrator Guide P1028247 001 Rev B 74 Troubleshooting Resetting the Factory Defau
15. 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 P1028249 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 60 The printer will not eject the media e The presenter rollers are dirty or damaged P1028247 001 Rev B e The presenter rollers are dirty Refer to the Service Manual P1028249 for instructions e The presenter rollers are damaged Refer to the Service Manual P1028249 for instructions There is a jam under the presenter Refer to the Service Manual P1028249 for instructions The presenter sensor may be dirty or damaged e The presenter sensor is dirty Refer to the Service Manual P1028249 for instructions KR203 Hardware Integrator Guide 10 26 2010 Troubleshooting 73 Other Problems e The presenter sensor is damaged Refer to the Service Manual P1028249 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 e The presenter motor may need to be replaced Refer to the Service Manual P1028249 for instructions The presenter drive gears may be
16. left side of the printer The arm can be set at three different angles This makes make integration in the kiosk easy e 58mm 60mm 80mm and 82 5mm media widths can be used without adjustments e The universal roll holder supports up to 200mm rolls in the high and low arm positions and 250mm rolls in the under position with clearance for cabling e No other accessories are required for the high arm position while the Printer Mounting Plate page 52 with the inertia dampening spring guide and cable shield is needed in the two other positions e The optional media roll low sensor page 50 can be added to the roll support Mounts on either side 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 54 Accessories Universal Roll Holder P1014125 High Position No Mounting Plate 150 mm 200 mm Minimum Printhead Access Clearance E E mm E Se E to 251 mm 285 mm Low Position with Mounting Plate Minimum Printhead Access Clearance e Mounting Plate 5 150 mm 200 mm 77 mm P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 55 Universal Roll Holder P1014125 Under Position with Mounting Plate Minimum Printhead Access Clearance Mounting Plate E E e D A 3 l ao ESCH E E E 2250 mm S a ao 127 mm
17. securely with an audible click on P both locking tabs 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 14 Printer Overview Printer Information Printer Information Printer control Printer Control Panel Allows very basic printer configuration setup that includes a test page Print method Direct thermal page printing using thermal sensitive media Resolution 8 dots mm 203 dpi 152 mm s 6 0 inches sec Default 127 mm sec 5 inches sec 101 6 mm sec 4 inches sec Print speed 76 2 mm sec 3 inches sec Note Printer media is rated for specific speed ranges and some media types and materials will print better at slower speeds Present speed 300 mm s 11 81 inches sec The KR203 uses the Looping Presenter modes In pass through presenter mode loop size set to zero presenter speed matches the print speed Print duty cycle Up to 33 Media Sensors Out of paper paper in presenter black mark and an optional external paper low sensor Maximum print width Auto Selected Print Widths 80 mm 640 pixels 58 and 60 mm guide 60 mm 480 pixels maximum 80 and 82 5 mm guide 80 mm 640 pixels maximum P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Media Types 10 26 2010 Receipt Media Supply Type Printer Overview 15 Printer Information Outside Wound Continuous Roll Plain receipt receipt with black marks and pre printe
18. to heat The printer has several basic requirements for dispensing the media to the printer from a roll or fan fold media which 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 A media guide is a required accessory for printing see Media Guide on page 34 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 Refer to Media Input Aperture on page 32 for clearance requirements 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 born 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 and other kiosk components Incandescent light bulos 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 see Lar
19. 0 26 2010 Printer Overview 21 Buttons Indicators and Sensors Buttons Indicators and Sensors The KR203 printer uses 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 e Printer control and indicators on each side of the printer to provide the integrator greater flexibility for designing printer mounting and servicing the printer e Media Feed button with configuration functionality e Media detection and control sensors e Cutter home position sensing and jam detection e Media output pull detection sensing e Support for an external low media roll detection sensor accessory option See Media Roll Low Sensor on page 50 Feed Button The feed button has thee functions Power On Press and Release After power has been applied to the printer it will perform a brief self test Pressing and releasing the feed button will feed media cut and present a blank receipt In black mark mode the cut will be synchronized with the next black mark Power On User Interface Mode After power has been applied to the printer it will perform a brief self test Pressing and holding the feed button will access the user interface features See Table 7 2 Feed Button User In
20. 249 for instructions e Check for damage to the wiring Replace the wiring if damaged Refer to the Service Manual P1028249 for instructions The printed image does not look right P1028247 001 Rev B The printhead is dirty Clean the printhead Refer to the Service Manual P1028249 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 P1028249 for instructions Adjust the print darkness and or print speed Refer to the Software Integrator Guide P1028248 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 incompatible 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 e Foreign objects attached to its surface e The rubbery smooth surface has become polished and slippery KR203 Hardware Integrator Guide 10 26 2010 Troubleshooting 71 Media Sensing Problems e The platen may need cleaning or replacement Refer to the Service Manual P1028249 for instructions There are long tracks of missing print blank vertical lines on several labels e The printhead may be dirty or
21. 38 E China tschina zebra com All other areas tsasiapacific zebra com Inquiry Department For product literature and distributor and dealer information T 1 877 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 P1028247 001 Rev B T 1 877 ASK ZEBRA 275 9327 E clientcare zebra com T 44 0 1628 556032 F 44 0 1628 556001 E cseurope zebra com KR203 Hardware Integrator Guide T 65 6858 0722 F 65 6885 0836 E China order csr zebra com All other areas csasiapacific zebra com 10 26 2010 Introduction Document Conventions Document Conventions IHO gt PPP Pr 10 26 2010 The following conventions 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 he
22. Connection of the printer to the host computer Media Handing The design of the kiosk should consider the type of media to be used roll or fan fold media the appropriate media dispensing system the location of the media in the kiosk relative to the printer and the overall size of the media package roll diameter or stack height Operator Access The operator needs access to e The printer s control panel for status lights and also access to view and press the feed button while observing the status lights for media loading setup and servicing the printer See Buttons Indicators and Sensors on page 21 e Open and clean the printhead or remove jams see Clearing Paper Jams on page 42 e 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 e Service and printer replacement Access to mounting hardware e Designing for the operator ideas for a more intuitive media loading media preparation and use of media loading labels and documents Ambient Lighting and external light sources which can affect printer sensors Cooling The printer needs space on both sides of the printer to allow for convection cooling of the printer This becomes more important with kiosk installations that are in extreme environments or have high printer usage KR203 Hardware Integrator Guide P1028247 001 Rev B 7 8 Design O
23. 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 resolutions for status indicator codes and poor print quality 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B Introduction Contacts Contacts Technical Support via the Internet is available 24 hours per day 365 days per year Web Site www zebra com E mail Back Technical Library e E mail address emb zebra com e 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 Lincol
24. OW SENSOR 300MM CBL e 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 NI conditions Die Paper roll Paper low J1 sensor Near a end py gcc ty Roll holder shaft DE New P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 51 Small Core Media Roll Adapter P1027727 Small Core Media Roll Adapter P1027727 10 26 2010 The KR203 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 KR203 Hardware Integrator Guide P1028247 001 Rev B 52 Accessories Printer Mounting Plate 104208 Printer Mounting Plate 104208
25. able 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 Data 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 H 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 Solid Green 0 OK This code is reported when no other codes are active It indicates the printer is functioning normally One Red Flash 1 Paper Jam in This code indicates that media is stuck Presenter in the presenter This error is set when the printer attempts to eject the media but cannot complete the operation This error is cleared by removing the media from the presenter sensor Two Red Flashes 2 Cutter Jam This code indicates that the printer could not find the cutter blade or could not properly manage its position The error is set when the printer attempts to cut but fails after three retries This err
26. age Contents cee tt tenes 6 Unpack and Inspect the Printer 0 eee 6 Design Considerations Overview 00 cee eee 7 3 Printer Overview NN EEENRNIEK KN REENERT E KEEN ER 9 Printer DIMENSIONS 00 00 eee 9 Printer Orientation 10 Printer Features 11 Opening the Prirthead eee 13 Opening the Presenter 0 000 e eee eee 13 Printer Information te eee 14 Media Tvpes 0 cece eee eens 15 Printer MOUNTING 1 aman da kale Wee ee AL eo LA deed 16 Mounting Orientations cee ee 17 Design Your Own Mounting 0 0 0 eee eee eee 18 PANUNG Ima nida 234 ee Seaweed demas aye E Ee 19 Looping Presenter 0 0 cee eee tee 19 Page Modee 2 0 5 ER beta ond eee Whe bes badd kuba hulang 20 Printer Configuration Methods and Tools 20 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B ii Contents Buttons Indicators and Sensors 21 Feed BUON ER BAKA KEANNA dees nee seen esa nba ee es 21 Power Indicator 21 Sensing and Error Reporting 0 eee eee eee eee 22 Manual Printer Heset 00000 cece ee eee 22 4 CONNECHONG si dows iw PD sews towne eee ied ae wes 23 Cabling and Cable Routing 23 Large Media Roll Adapter Accessory 23 Attaching Power 24 Electrostatic Discharges and Earth Currents 25 Connecting the Printer to the Host cece eee 26 Interface Cable Requirements a 26 USB Interface R
27. ardware Integrator Guide P1028247 001 Rev B 48 Accessories Wall Mount Roll Holder P1014123 1 Install the quick fit hubs O to the bottom of the printer 2 Install the leaf spring retainer to the underside of the wall mount E 3 Attach the wall mount to the desired position in the kiosk 4 Slide the printer onto the wall mount and engage the retainer P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 49 Roll Support Roll Support The roll support is 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 media roll widths 80 and 82 5mm fit to the larger offsets while the narrow media widths 58 and 60mm fit to the narrow offset The roll support can also accommodate the media roll low sensor A mi Sr H Media Widths 80 amp 82 5 cg fi NNN N IT Na A I SS ISI SS CO KN NY KE Roll Core ID 83 8 54 1 a S 99 kalo 1 6 HI used for Media Low Sensor mounting 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 50 Accessories Media Roll Low Sensor Media Roll Low Sensor The media roll low sensor is available in two lengths e 01890 300 KIT PAPER L
28. ark o HE a a Ga 4 Feed Feed Direction Direction pee EEEE y EE EE ne 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 Gb 22 mm 30mm 2 2 5mm 9 0mm 2 5mm 9 0mm 5 0mm 10 0mm 5 0mm 10 0mm 4 92mm 600mm 92mm 600mm 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B Media Preparing a Media Roll for Use 38 Preparing a Media Roll for Use 1 Turn the new media roll as shown below Temperature sensitive coating O Figure 5 6 Paper Roll Orientation 2 Tear off a full turn of the media from the roll some type of glue or self adhesive substance that might otherwise cause paper jam or A 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 Figure 5 7 Full Turn Paper Removal P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Media 39 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 co
29. ary to route cables differently when using this accessory See Routing Cables with the Large Media Roll Adapter on page 65for additional information 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 24 Connections Attaching Power Attaching Power The KR203 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 KR203 printer Refer to Printer Power Supply 808099 004 on page 57 If a non Zebra supplied power supply is used with the KR203 it must comply with the following requirements Table 4 1 Power Supply Output Characteristics Output Rating 24 0 Volts 2 92 Amps 5 to 40 C Voltage 24 0 Vdc 5 2 Initial Tolerance No Load Current 2 92A Maximum 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 0 5 over AC input operation range Ripple 8 Noise 240mVpp at lout 2 92 Amps Resistive Load 4 7uF 50V ceramic Cap On output 20MHz BW Transient Load Response lt 5mS Recovery 40 to 80 Load Change Overshoot Power Ip 10 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 Thermal Allowed
30. at 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 physical 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 KR203 Hardware Integrator Guide P1028247 001 Rev B 3 4 Introduction Document Conventions P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 2 Design Overview KR203 Kiosk Receipt Printer 10 26 2010 The Zebra KR203 model is the best in class thermal kiosk printer with a good range of features The KR203 printer provides direct thermal printing at speeds up to 150mm s 5 9 ips at a 203 dpi print density The KR203 supports a driver based printing protocol The KR203 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 KR203 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 applie
31. d 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 be inserted into the power supply and the power receptacle on the back of the printer A Caution Keep the kiosk OFF when attaching the interface cable The power cord must before connecting or disconnecting the communications cables Equipment using fully shielded data cables Use of un shielded cables may increase Important This printer complies with FCC Rules and Regulations Part 15 for Class B radiated emissions above the Class B limits P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Connections 27 Connecting the Printer to the Host To minimize electrical noise pickup in the cable e Keep data cables as short as possible 6 foot 1 83 m recommended Do not tightly bundle the data cables with power cords e Do not tie the data cables to power wire conduits e Avoid fluorescent lighting and power supply components Communicating with the Printer The only way to begin using your complete kiosk printing solution is to utilize the Windows Driver With the driver loaded you can test the kiosk printing system configure your printer and view printer error codes Refer to the Software Integrator Guide P1028248 for installation instructions The latest driver can be found at www zebra com 10 26 2010 KR203 Hardware Integrator G
32. d 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 For information on ordering media refer to Contacts on page 2 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 applied KR203 Hardware Integrator Guide P1028247 001 Rev B 16 Printer Overview Printer Mounting Printer Mounting 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 la and 1b Figure 3 7 e Printer Mounting Table 3 3 Mounting Configuration
33. e Printer When you receive the printer open the package immediately and inspect the contents for shipping damage e Save all packing materials e Check all exterior surfaces for damage e 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 e Keep all packaging material for shipping company inspection e Notify your authorized Zebra reseller P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Design Overview Design Considerations Overview Design Considerations Overview 10 26 2010 The kiosk designer needs to consider how the printer will be used operated media supply and maintenance serviced integrated with other kiosk components and integrated into the enclosure itself The KR203 printer requires some basic design elements to function properly safely and easily for the operator The general issues are Locking Enclosure The KR203 printer should always be installed in a secure enclosure The user or untrained personnel should not have access to operate or service the printer Mounting orientation Mounting of the printer to the kiosk Printer Power Requirements and DC power connector
34. e kiosk components moisture and cleaning chemical vapors used near the kiosk 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 30 Media Designing Your Own Media Dispensing System Designing a Roll Support The design elements needed for a good media roll support are e 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 e 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 KR203 Roll Support accessory page 49 minimizes the media contact area only makes contact with the outside edges and a large enough radius to smooth over seams The larger the roll more mass the greater the effect it has on drag see Large Media Roll Adapter P1026858 on page 60 e 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
35. ed cut and present in order to verify media is loaded properly P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Media 41 Loading Media Manual Media Loading Manual media loading is intended for maintenance operations such as printhead cleaning and removing media jams Please use the automated media loading procedure page 40 to load media for normal operations 1 Open the printhead 2 Insert the media through the rear of the printer and under the open printhead Pull the media just past the cutter and platen drive roller Do not insert the media past the presenter or rest the media on top of the presenter as it will not feed properly and an error will occur Figure 5 10 Manual Media Loading 3 Close the printhead Push down on the push bar to securely latch the printhead closed 4 The printer will then feed cut and eject a blank receipt and then go to a ready state solid green status indicator 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 42 Media Clearing Paper Jams Clearing Paper Jams Should a paper jam occur follow the procedure below Clearing the printhead Caution The printhead becomes hot while printing To protect from damaging the printhead and risk of personal injury avoid touching the printhead Caution Always disable printer power by un plugging the printer from the kiosk power supply or turning off the printer and or kiosk power 1 Carefully c
36. eight perforations on fan fold or receipt media etc Other considerations Media mounting media path media access printer maintenance cabling etc Note In vertical mounting orientation the small core media adapter page 51 may be used to ensure that media enters the present path The area of primary concern is the loop area this area requires special attention when designing the kiosk The printer requires 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 the chosen media for use in the kiosk and in the environmental conditions that it will operate on site KR203 Hardware Integrator Guide P1028247 001 Rev B 18 Printer Overview Design Your Own Mounting Design Your Own Mounting The illustration below gives an example of a printer mounting shelf pr Leaf spring 01473 000 Min 100 mm x 5 Pi D a 5 a dd material for corner radius Figure 3 9 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 KR203
37. equirements 0 0 0 c eee eee eee 26 Communicating with the Printer 0 002 aa 27 5eMedid isi sas eisai ees een sehen AA 29 Designing Your Own Media Dispensing System 29 Designing a Roll Support 30 Designing Media Guides 30 Designing for Fan Fold Media eee eeeee 30 Media Mounting Considerations 31 Media Supply Method 32 Media Input Aperture 32 Media Guide 34 Installing the Media Guide 0 000 cece ee 34 Media Guide Calibration 0 0 0 ee ee 35 Determining Thermal Media Types 36 Black Mark Media Requirements 00 c eee eee eee ee 37 Preparing a Media Roll for User 38 Loading Media 00 0 cece ee eee 40 Automated Media Loading a 40 Manual Media Loading 00 e eee eee eee 41 Clearing Paper Jomes 42 Printing a Test Receipt eee ee 42 Ex ACCESSONGS cam NG AA AKA BAKA AA 43 Accessories Overview 43 Nozzle Bezel Kit P1011185 0 00 00 eee 45 Quick Fit Hubs 103939 EE 46 Quick Fit Leaf Spring Retainer 01473 000 46 Wall Mount Roll Holder P1014123 aaa 47 Roll SUpPOrt na wa ma NG Bea NING NAN LALA NANA EG PA ane 49 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 10 26 2010 Contents Media Roll Low Sensor 50 Small Core Media Roll Adapter D IO2 42 a 51 Printer Mounting Plate 104208 a 52 Universal Roll Holder
38. er as follows 1 Using a 8 Torx driver remove the screw O shown 2 Attach the 12 AWG ground wire with cable lug 2 to the printer chassis 3 Connect the other end of the ground wire to a protective earth ground Figure 4 2 e Grounding 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 26 Connections Connecting the Printer to the Host Connecting the Printer to the Host 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 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 USB Interface Requirements Universal Serial Bus version 2 0 compliant provides a fast interface that is compatible with your existing PC hardware USBs plug and play design makes installation easy Multiple printers can share a single USB port hub When using a USB cable not supplied with your printer verify that the cable or cable packaging bears the Certified USB mark see below to guarantee USB 2 0 compliance 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 Groun
39. es 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 Media Exit 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 46 Accessories Quick Fit Hubs 103939 Quick Fit Hubs 103939 The Quick Fit hubs are designed to use the printer s mounting holes when mounting the printer to a custom sheet metal surface 1 5 mm thick When installed the quick fit hubs allow quick installation to and removal from the surface See Design Your Own Mounting on page 18 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 47 Wall Mount Roll Holder P1014123 Wall Mount Roll Holder P1014123 The wall mount roll holder enables mounting of the printer to the wall of a kiosk Included is the quick fit hubs and leaf spring retainer The holder can accommodate media rolls up to 150mm in diameter and 58 60 80 and 82 5mm media widths without adjustments Roll center 105 10 26 2010 KR203 H
40. ge Media Roll Adapter P1026858 on page 60 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 produce a distorted print e g compressed print short receipts etc motor stalls and jamming if media dispensing to the printer if the media transition is not smooth and easy for the printer 31 32 Media Media Mounting Considerations Media Supply Method The KR203 printer supports two media supply types outside wound roll mount and stacked fan fold media The media printing surface faces up towards the top of the printer and away from the body of the printer Figure 5 1 e Media Supply Media Input Aperture The KR203 printer has a wide aperture to support a range of media mounting locations The media can enter the printer directly or indirectly with the addition of custom media guides or printer roll mounting accessory kits Minimum Clearance Area for Printer Power and Cabling Figure 5 2 Media Input Aperture P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 10 26 2010 Media 33 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 e po coe go oe This area should have
41. he printhead Insert the T shaped tab of the media guide into the T slot slide it forward and fasten the screw Figure 5 5 Media Guide Installation 4 Close the printhead Media Guide Calibration 10 26 2010 When the media guide is changed the printer will signal media present even when none is You must instruct the printer to detect the sensor it should use again This is accomplished with the two flash function see Table 7 2 Feed Button User Interface on page 69 This process must be done without media in the printer If the process is attempted with media in the printer an error will occur Upon successful detection of the guide guide settings are stored KR203 Hardware Integrator Guide P1028247 001 Rev B 36 Media Determining Thermal Media Types Determining Thermal Media Types The KR203 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 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 me
42. incorrect receptacle on the printer P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 4 Connections Cabling and Cable Routing Always use cable tie downs use locking connectors where possible allow for kiosk component servicing and avoid electrical noise sources e All cables that are near the printer media path or media should be tied to the kiosk chassis or printer mounting hardware 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 e 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 e Avoid electrical noise sources fluorescent lighting and ballast power supplies fans AC power lines CRT monitors etc e 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 necess
43. lock the adapter tensioner assembly P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 63 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 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 64 Accessories Using other Accessories with the Large Media Roll Adapter Using other Accessories with the Large Media Roll Adapter Universal Roll Holder The universal roll holder page 53 can be attached to either side of the large media roll adapter Additionally the media roll low sensor page 50 can still be used in this configuration see Routing Cables with the Large Media Roll Adapter on page 65 1 Attach the mounting block QO io the large media roll adapter as shown using the two screws 2 Attach the universal roll holder 9 to the mounting block with the screw Note Printer not shown attached for clarity o SO MGa ili jo P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 65 Routing Cables with the Large Media Roll Adapter Rou
44. lt Values A receipt format was sent to but not recognized by the printer e Ifthe status LED is on or flashing refer to Application User Interface on page 69 e Make sure the USB cable is correctly installed Refer to Connecting the Printer to the Host on page 26 e A communications problem has occurred Perform a USB detect refer to the three flash sequence of Application User Interface on page 69 The receipts are not cutting at the black mark e Make sure you are using the appropriate media guide for the desired media width See Media Guide on page 34 e Perform a media guide calibration Refer to the four flash sequence of Application User Interface on page 69 e Make sure you are using the appropriate media See Determining Thermal Media Types on page 36 e Use the Windows driver to set the printer to black mark mode Refer to the Software Integrator Guide P1026208 for instructions on setting black mark mode e Reload the media See Loading Media on page 40 Resetting the Factory Default Values e Sometimes resetting the printer to the factory defaults may solve some problems Refer to the two flash sequence of Application User Interface on page 69 e 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 Fo
45. mission 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Contents 14 introduction e A8 REENERT EE RER 1 Who Should Use This Document 1 How This Document Is Organtzed a 1 El 2 Document Conventions e eee eee 3 2 DGSIGN OVEIVIEW 2G EE 5 KR203 Kiosk Receipt Printer a 5 Pack
46. n the paper set the form length Black mark mode can work with either fixed or variable length pages receipts In fixed page mode the printer will force a cut at every black mark and multiple pages can be imaged for one document In variable page mode the printer will cut ar the next black mark after the end of the data Black Mark Mode Printer Configuration Methods and Tools The KR203 printer has a variety of 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 e Media Guides Sets the printer s maximum print width See Media Guide on page 34 and Installing the Media Guide on page 34 e Control Panel The printer s control panel Feed Button provides access self test media guide detection test prints and resetting the printer to factory defaults See the Feed Button on page 21 e Windows Drivers Quickly allows the developer to use the printer test configuration options send programming commands or files and print directly from Windows applications Refer to the Software Integrator Guide P1028248 for additional information P1028247 001 Rev B KR203 Hardware Integrator Guide 1
47. ned with other printer accessories or as part of your own unique printer integration design Some of the accessories are available for your printer include e Nozzle Bezel A translucent media exit bezel styled after common credit card input bezels used in ATM machines and other kiosks e Quick Fit Printer Mounting A quick printer release mounting system that can be used with KR203 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 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 e Roll Support A rugged media roll support bracket designed to provide minimal friction and self centering of the media roll e Media Roll Low Sensor Optical sensor designed to mount into the Roll Support accessory or other KR203 printer mounting accessory and plug directly into the rear of the printer e 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
48. 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 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 72 Troubleshooting Media Sensing Problems The printer will not load the media e The media has changed or a different media guide has been installed e Make sure the appropriate media guide is installed for the media being used See Media Guide on page 34 e Perform a two flash procedure to recalibrate the printer then perform a four flash to reset the printer defaults refer to Application User Interface on page 69 e Load the media manually refer Manual Media Loading on page 41 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 P1028249 for instructions The media sensor may be dirty or damaged Refer to the Service Manual P1028249 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
49. nshire 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 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 SXF United Kingdom T 44 0 1628 556000 F 44 0 1628 556001 T 44 0 1628 556039 F 44 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 65 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 08
50. ntact with the platen roller before the sensor detects the media Cut off at 90 6 0 a 85 95 Thermal side to angle tap Auto Loads Narrow Media Auto Loads Fails Auto Load Vv Media Contact Leads Media Sensing Auto Loads Wide Media ad lo Figure 5 8 Suitable Paper Edge for Loading Media Important The wide media sensor 80 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 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 40 Media Loading Media Loading Media Automated Media Loading The printer is designed to detect media when it is inserted into the empty media input slot at the rear of the printer The printer begins turning the platen drive roller when the leading edge of the media passes over the media sensor The printer will then feed cut and eject a blank receipt and then go to a ready state solid green status indicator Figure 5 9 Automated Media Loading Sequence Table 5 1 Media Loading Sequence Sequence Number Action Paper is inserted into printer Feed rollers move media to presenter Media is cut Al Cut media is moved through presenter and ejected Press and release the feed button several times to fe
51. 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 47 and the Universal Roll Holder P1014125 on page 53 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 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Media Media Mounting Considerations Media Mounting Considerations 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B The KR203 printer uses direct thermal media which is chemically treated to react
52. or is cleared by cycling the power off and on 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 68 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 paper 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 feed
53. printers can handle Caution NEVER use screws that go into the printer more than 4 mm This will damage or destroy the electronics inside See Printer Mounting on page 16 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Printer Overview 19 Printing The printing sequence starts with the leading edge of the media resting at the cut position after loading media or printing a previous receipt The printer begins printing the page upon completion of the transfer of the image to the printer When the page has finished printing the printer cuts the receipt to finish 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 O O Figure 3 10 Printing Sequence Table 3 5 Printing Sequence Media Input Use Auto or Manual media loading procedure 2 Printhead and Platen Drive Roller Loop area stores receipt until Media Drive Roller and Loop Stop printing completed 4 forward only Media Cutter Full or partial media Media Present Detects a media pull cuts O with motor Looping Presenter The looping presenter mechanism has many benefits e It handles documents of various lengths by storing the printed paper in a loop e It holds the printout until fully printed
54. r 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 P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Accessories 61 Large Media Roll Adapter P1026858 Attaching to the Printer 1 Place the adapter on the printer at an angle as shown 2 Rotate the adapter upwards as shown and install the screws to 1 Install screws on both sides 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 62 Accessories Large Media Roll Adapter P1026858 Loading Media 1 Open the adapter tensioner assembly by pushing the locking tab O 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 required see Loading Media on page 40 3 Close and
55. r questions on the operation of Zebra equipment and software please call your distributor For additional assistance contact us see Contacts on page 2 Please have your model and serial numbers available P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010
56. res Printhead Release Bar Figure 3 3 Printer Features Table 3 1 Printer Features 2 Cutter Bar Printhead Platen drive Roller Media Present Sensor Control Panel 0000 10 26 2010 KR203 Hardware Integrator Guide O O Cutter Media Sensors P1028247 001 Rev B 5 52 co 22 bo Oo LU 25 E e Ben Oo aad 12 Printer Features continued Figure 3 4 Printer Features Table 3 2 Printer Features 2 Power Input 1 USB Port Media Roll Low Sensor Input 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B Printer Overview 13 Printer Features Opening the Printhead When cleaning or servicing the printer it is sometimes necessary to access the printhead 1 Press the green printhead release bar to unlock the printhead 2 Rotate the printhead assembly upward Figure 3 5 Opening the Printhead Opening the Presenter When cleaning or servicing the printer it is sometimes necessary to access the presenter 1 Squeeze the two presenter locking tabs O together to unlock the presenter assembly 2 Rotate the presenter assembly upward Figure 3 6 Opening the Presenter z Note When closing the presenter make sure to close
57. s 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 P1028247 001 Rev B Firmware missing or corrupt 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 KR203 Hardware Integrator Guide 10 26 2010 Troubleshooting 69 Status Light Descriptions Application User Interface 10 26 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 Table 7 2 Feed Button User Interface Status Flash Action Sequence One Flash then Solid Appears for one second This will print an internal self test Green page Two Flash then Solid Appears for one second Performs system calibration must Green be started with paper out of presenter and from under printhead and with no error signaled Three Flash then Appears for one second Performs a simulated USB cable Solid Green connect and reconnect causing a USB plug and play event to occur Four Flash then Solid Appears for one second Sets
58. s force to remove it the KR203 senses the force and dispenses the receipt in a controlled fashion to prevent tearing or jamming Easy Media Loading Automatic media loading and preparation for printing Optional media low sensing Flexible Media Support Supports continuous fanfold and black line receipt media with automatic media sensing and calibration Flexible Mounting Horizontal and vertical printer mounting covering 90 of printer orientation Bar Code Support Will image any font barcode and graphic supplied by the application through the printer driver Interface Support USB v1 1 2 0 compatible KR203 Hardware Integrator Guide P1028247 001 Rev B 6 Design Overview Package Contents The KR203 printers offer a wide range of printer options and accessories e 58 60 80 and 82 5mm media guide widths e 70 watt external printer power module e Multiple printer media roll mounting accessory configurations and options e Media Roll Low sensor for use with Zebra and custom media roll mounting This integrators guide provides information you will need to develop a kiosk using the KR203 printer and accessories Package Contents The KR203 package comes with the following items e The KR203 printer e Warranty information 2 Note To minimize cost and reduce waste the KR203 does not include unneeded y 7 components or accessories Additional items are required to make the printer operational Unpack and Inspect th
59. terface on page 69 for user interface features Power Indicator The Power Indicator is green when the printer has the 24 VDC power applied to the printer 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 22 Printer Overview Manual Printer Reset Sensing and Error Reporting The KR203 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 See Table 7 1 Application LED States on page 67 for error codes e The printer monitors the printhead cutter and a variety of internal main board functions e The printer also monitors the media position via IR sensors that can be used to detect some issues with motors Manual Printer Reset The KR203 printer does not have a power switch or reset button To manually reset the printer disconnect the 24 VDC power from the printer Wait a few seconds for the Power LED to turn off and reconnect the power plug The printer will reboot and initialize ldeally the printer power should be connected to a dedicated switch to prevent removing other cables when disconnecting power Additionally when certain accessories are installed and because of the proximity of other receptacles having a dedicated power switch to the printer will prevent reattaching the power to the
60. thod uses friction heat to expose the media Did a black mark appear on the media If a black mark Does not appear on the media Then the media is Thermal transfer A ribbon or ink is required and is not support for use by the KR203 Appears on the outside of the media Direct thermal No ribbon or ink are required P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Media 37 Black Mark Media Requirements Black Mark Media Requirements 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 and 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 m
61. ting 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 50 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 4 Attach the sensor to the roll support using the screw 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B 66 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 adapter 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 ferrite attached to the power c
62. uide P1028247 001 Rev B 28 Connections Connecting the Printer to the Host P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 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 e The media entering the printer should be aligned to the center of the printer Use a media guide appropriate to the width of the desired media see Media Guide on page 34 e 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 jams and printer stalls in the worst case conditions e The media should never touch or rest on cabling kiosk walls and components exhaust fans dust and heat heat sinks etc e 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 e 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 th
63. ut the media at the rear of the printer 2 Open the printhead see Opening the Printhead on page 13 3 Remove and discard the damaged media 4 Close the printhead and reload the media using the Automated Media Loading method page 40 Clearing the Presenter 1 Open the presenter see Opening the Presenter on page 13 2 Remove and discard the damaged media 3 Close the presenter securely 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 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 2 Press the feed button to feed cut and present media Repeat two to three times to allow the printer to properly 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 self test will print P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 6 Accessories Accessories Overview The KR203 printer has a wide range of accessories designed and tested to work with your printer The accessories can be used by themselves combi
64. verview Design Considerations Overview P1028247 001 Rev B KR203 Hardware Integrator Guide 10 26 2010 Printer Overview 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 USE M3 SCREWS FRO FASTENING PRINTER MAX LENGTH 4MM INSIDE PRINTER me 45 l8 THE PAPER PATH i 25 IS CENTERED AROUND 197 50 d Ee HE ae i e d J e 1 PAPER ji ES EXIT i een A ba 145 sg d tt PRINTHEAD yp ha 5 3 EXIT GUIDE nai N CL PAPER ENTRY iy I 3 NA GE Figure 3 1 Printer Dimensions 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B Printer Overview Printer Orientation 10 Printer Orientation REAR zZ O 5 E FRONT Media Out Figure 3 2 Printer Orientation 10 26 2010 KR203 Hardware Integrator Guide P1028247 001 Rev B Printer Features Printer Overview 11 Printer Featu

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