Zebra industrial printers... maintanence, what to look for - Page 1
Forum section: electronics / general

author: marshallh
author_rank: Unknown
timestamp: August 15, 2014, 04:53:07 am
content: I'm looking to print a large amount of custom serial/ID labels on metallized polyester.My quick research shows I need a printer capable of Direct Transfer and the associated labels, ribbons and such things.Ebay shows I can get a used S4M with installed direct thermal option (takeup spool) for $400.What are the sorts of hardware issues I should watch out for? Are they all going to need a lot of consumable parts replaced, or they fine as is?I used these all the time for thermal barcodes at past job. Is this something I can maintain and run without breakingt he bank?

author: justanothercanuck
author_rank: Frequent Contributor
timestamp: August 15, 2014, 06:30:38 am
content: Upgrade the firmware as soon as you get it.We had issues with similar printers made by Datamax, where they would just stop accepting packets and require a power-cycle. Turns out there was a bug in the network card firmware. Since upgrading it on all our printers, we haven't had the issue since.Edit: A thermal printer shouldn't have any ribbon, all it needs is the labels, as long as they're designed for thermal printing. The print head takes care of the rest.

author: SL4P
author_rank: Super Contributor
timestamp: August 15, 2014, 08:36:17 am
content: Quote from: justanothercanuck on August 15, 2014, 06:30:38 amAgree with the firmware. I've used several different brands & models - these seem to live on firmware updates.: : :Quote from: justanothercanuck on August 15, 2014, 06:30:38 amNot strictly true.There are two main types of these thermal printer/printheads (as the OP seems to have identified)Some printers can do both - but they MUST be configured the right way.* Direct - the printhead burns the dot pattern into direct transfer media (labels etc)* Transfer - the printhead 'cooks' the content of an intermediate ribbon media onto the target label etc. - like an old typewriter!

author: PA0PBZ
author_rank: Super Contributor
timestamp: August 15, 2014, 08:41:15 am
content: The only thing I've seen failing on these is the printhead. It can be bought online and is easy to replace.If you want to play safe you could get a spare.

author: Rerouter
author_rank: Super Contributor
timestamp: August 15, 2014, 08:51:28 am
content: Ive repaired 2 of a similar zebra label printer over the past few years and in all cases it was from continuous operation in a dusty direct sunlight spot,First up was the dust had become conductive and was causing it to fail to boot / talk over USB, blowing it out and washing with IPA brought it good again, I then coated it in PCB lacquer and its been running strong for 2 years in the same conditions,Second unit was drawing lines, did the same clean and prep as the first one, but it turned out to be adhesive had built up and layered over the thermal print head, and took careful scraping with a spudger tool to get it working 100% reliably, (checker patterns etc)

author: wagon
author_rank: Frequent Contributor
timestamp: August 15, 2014, 12:41:36 pm
content: I've worked on a smaller version, used for printing labels in a jewelery shop. Seemed pretty solidly made. Clean the feed roller, and the printhead. You'll probably have no dramas.

author: SeanB
author_rank: Super Contributor
timestamp: August 15, 2014, 04:46:30 pm
content: The only issues i have had is build up on the print head ( clean with IPA on a cotton bud every so often to fix it) and the rollers building up adhesive residue, along with the feed path. Clean as above with IPA on a cloth. Once a year open it and clean the dust out, and you will be fine. If using the ribbons you will need to lubricate the spindle bearings and the gears every so often, using some SAE10 lubricating oil. Power supplies can and do fail, so open that up on a used unit and look for the swollen Capxon caps inside and replace with something better. As a plus most will work off 18V so a universal laptop power supply will do as a replacement. Was a lot cheaper than a new one from Zebra. I have had head issues, with fdlex pads debonding giving dead stripes, but that one was simply repurposed to a less demanding role where the odd blank line was fine.Another ( will tear down as it is getting in the way) unfortunately was not economical to replace the head, as it is only a 40mm head and a 10kg unit. But is is a complete PC XT inside and self contained.

author: Stonent
author_rank: Super Contributor
timestamp: August 15, 2014, 08:12:57 pm
content: Make sure of your quality of supplies. I've worked with Zebras off and on and sometimes the label makers have QC issues that cause printer problems. Like labels that from run to run are shifted a mm or two (or even a half mm) on the backing that cause things to have to be manually realigned.Also the other problem is the users who operate the printer have to make sure they don't forget to slide the alignment fence back over once the labels are changed or they will walk all over the place.And finally making sure the ink roll is installed correctly and not backwards or you'll have ink that flakes off because it's transferring from the wrong side.

author: marshallh
author_rank: Unknown
timestamp: August 16, 2014, 02:17:18 am
content: Thanks everyone. My last question is where to buy the print media. Is it absolutely necessary to buy Zebra/Brady media or can it be pretty much anything?

author: SeanB
author_rank: Super Contributor
timestamp: August 16, 2014, 05:50:09 am
content: For the thermal labels any make will do, as they are generally made only by a few large producers, and they are branded for customers. The wax ribbon though you will likely be stuck with OEM unless you find a compatible aftermarket one.

author: justanothercanuck
author_rank: Frequent Contributor
timestamp: August 16, 2014, 12:25:04 pm
content: Oh, I forgot to mention. After a print job, form feed one label and then tear it off, or else you run the risk of the roll wrapping itself around the roller, because the printers tend to reverse a little to find the top of the label before printing. It'll also help keep the label goo from getting all over the roller and the print head.

author: Stonent
author_rank: Super Contributor
timestamp: August 16, 2014, 09:13:29 pm
content: Also get the calibration procedure down. On the ones I've used it involves peeling off a few labels and rolling it back and letting it see the transition.

author: jancumps
author_rank: Unknown
timestamp: August 16, 2014, 10:01:34 pm
content: We're using Zebra's in our production facilities at work (soft drinks, juices, snacks production plants) - very high volume (on paper - not polyester).The environment in such plants is so harsh for label printers that I can safely say: If It Works For Us, It 'll Work For You.

author: marshallh
author_rank: Unknown
timestamp: August 22, 2014, 08:18:27 pm
content: After getting the printer I upgraded the firmware and had to tear it apart.Interesting to note that it runs a SH3. Date codes indicate late 2008 assembly.Huge image herehttp://imagizer.imageshack.us/a/img673/2265/XmAWl8.jpg

author: Stonent
author_rank: Super Contributor
timestamp: August 24, 2014, 05:24:35 am
content: We use Peak-Ryzek for our service if that helps you any.

author: justanothercanuck
author_rank: Frequent Contributor
timestamp: August 27, 2014, 04:27:18 pm
content: Looks like the ribbon needs a little tightening, it'll keep the labels from having gaps and whatnot.(Like the second T in butts)

author: marshallh
author_rank: Unknown
timestamp: August 27, 2014, 06:13:07 pm
content: After adjusting the darkness from 30 to 24, the ribbon stopped warping and I can print black reliably.Also working on direct thermal fine too. There is a small crack in the printhead about 3 inches out, causing halftones to print with a thick stripe. Don't know if it'll be worth fixing.

author: SeanB
author_rank: Super Contributor
timestamp: August 27, 2014, 06:51:39 pm
content: Cracks are not fixable if the head is cracked, but a debonded flex possibly can be fixed. Only cure for a cracked head is a new or used one.

author: Stonent
author_rank: Super Contributor
timestamp: August 29, 2014, 03:23:19 am
content: Such wow

author: justanothercanuck
author_rank: Frequent Contributor
timestamp: August 29, 2014, 07:38:09 am
content: Looks fine to me.