Zebra Technologies Expands Recall of Power Supply Units for Thermal Printers Due to Fire Hazard

What was recalled

Zebra Technologies has announced a significant expansion of its product recall concerning specific power supply units designed for thermal printers. This action, officially reported to the Consumer Product Safety Commission (CPSC) on August 2, 2018, addresses a widespread issue affecting industrial and commercial labeling equipment. It is important to understand that this is not an initial alert; the original recall was first announced in December 2016. However, the scope has been substantially widened to capture additional units that were previously excluded or missed in earlier notifications.

The core of this recall involves power supply units manufactured by the FSP Group between October 1, 2006, and December 31, 2012. These components serve as the critical power source for various models of Zebra-branded thermal industrial printers. These printers are commonly used in commercial settings to produce barcodes and other essential labels. The affected units were either sold separately as after-market kits or came pre-installed when consumers purchased specific printer models directly from Zebra.

The list of affected printers is extensive, covering a wide range of product lines including the APCES-1, APES-1, APS-1, BR100i, BR110i, BR120i, CN100i, CN110i, CN120i, GC420d, GC420t, GK420d, GK420t, GK888-DT, GK888-TT, GX420d, GX420t, GX42S, GX430d, GX430t, GT800, GT810, GT820, GT830, HC100, H 2824-Z, H 2844-Z, J100i, J110i, J110m, J120i, LP 2824, LP 2824-Z, LP 2824 Plus, LP 2824 Plus CVS, LP 2844, LP 2844-AP, LP 2844 e, LP-2844 L, LP-2844 Le, LP-2844-P, LP 2844ps, LP 2844-Z, LP 3842, LP 3842 SP, LP 3844-Z, LP384Z, P100i, P110i, P110m, P120i, PS4000, R2844, 2844-R, R2844-Z, R402, T208M, T212M, Thermal 2844, Thermal 2844 ATP, 2844 ATP, Thermal 2844 e, Thermal 2844 L, Thermal 2844 Le, TLP 2824, TLP 2824-Z, TLP 2824 Plus, TLP 2844, TLP 2844-P, TLP 2844-Z, TLP 3824, TLP 3842, TLP 3844-Z, WM120i, SC120i, ZP450, ZP450 ctp, ZP455, ZP455 atp, ZP455 ctp, ZP500, ZP500 EPL, ZP500 Plus, ZP500 Plus EPL, ZP500 Plus ZPL, ZP505, ZP505 EPL, ZP550, ZXP Series 1, ZXP Series 3, and ZXP Series 3C.

To identify if your specific unit is part of this expanded recall, you must check the power supply itself. Look for either the Zebra logo or the FSP North America logo printed on the device. Additionally, verify the date codes and part numbers against the detailed lists provided by Zebra. Date codes on these units range from 0639XX through 1253XX. Part numbers vary depending on the wattage and specific model but include identifiers such as 808113-001, P1028888-001, 808099-002, P1028888-006, 808101-001, and others listed in the official documentation. Because these printers are often used in busy commercial environments, verifying the exact part number is crucial for ensuring safety.

The hazard, explained

At the heart of this recall is a seemingly simple component that plays a critical role in keeping your thermal printer running: the power supply unit. While these units are designed to convert electrical current into the stable voltage your printer needs, the specific models involved in this expansion have a vulnerability related to their long-term durability. According to data from the Consumer Product Safety Commission (CPSC), the primary issue is that these power supplies can degrade and corrode over time, particularly when they are exposed to moisture. This is not just a matter of cosmetic wear; it is a structural failure of the internal components.

To understand why this matters, it helps to look at what happens inside the unit when corrosion sets in. Moisture acts as a conduit for electrical currents where they should not flow. As the internal parts corrode, the resistance within the power supply increases. In electronics, increased resistance generates heat. Normally, a well-designed power supply can dissipate this heat safely. However, as the degradation worsens, the unit can no longer manage its own temperature effectively. The result is overheating. This isn't just a warm casing; it is a significant rise in internal temperature that can ignite nearby flammable materials or the plastic housing of the unit itself.

This mechanism creates a serious fire hazard. The CPSC reports confirm that this physical process has already led to 30 incidents where these units overheated or caught fire. In some cases, the fire did not stay contained within the power brick. It spread from the connector directly into the printer, causing damage to the device and the surrounding workspace. This highlights the danger of leaving such a unit plugged in. Even if you are not actively using the printer, the power supply remains connected to a live electrical source, allowing the overheating process to continue unchecked until ignition occurs.

It is important to note that while no injuries have been reported to date, the risk is real and immediate. Thermal printers are often used in commercial environments—warehouses, retail stockrooms, or shipping departments—where they may be placed near paper, cardboard, or other combustible materials. A fire starting from a power supply can quickly escalate in these settings. The hazard is not just about losing a printer; it is about the potential for property damage and personal harm caused by an electrical fault that has progressed from corrosion to combustion. Because this degradation happens gradually, you might not see any warning signs until it is too late, which is why proactive replacement is the only safe course of action.

Who is most at risk

The primary group affected by this recall consists of commercial and industrial operators who rely on Zebra thermal printers for daily business operations. These are not typical home office devices; they are robust, high-volume machines used in warehouses, retail backrooms, manufacturing plants, and logistics centers. The people most directly at risk are the employees and facility managers who handle these printers regularly. Because these units are designed to print barcodes and commercial labels for inventory and shipping, they often run continuously or for extended periods. This constant operation, combined with the specific failure mode of the recalled power supply units, creates a unique environment where heat buildup is more likely to become critical. If you work in an environment where printers are tucked away in corners, behind racks, or inside enclosed printer stands, your risk increases significantly. These locations restrict airflow, which means that if a power supply begins to overheat due to the internal degradation described in the recall, the heat has nowhere to escape. It will concentrate around the unit much faster than it would on an open desk.

While the technical defect involves electrical components degrading and corroding when exposed to moisture, the people most vulnerable to the consequences are those who may not immediately recognize the subtle signs of failure. In busy industrial settings, a slight change in the smell of ozone or a minor increase in the hum of the power brick can easily be overlooked amidst the noise and activity of a workplace. The individuals at highest risk are therefore not just the owners of the equipment, but the maintenance staff and operators who are closest to the device when it fails. Since the recalled units have been reported to catch fire and spread flames from the connector to the printer itself, anyone standing nearby or working on adjacent equipment could be exposed to sudden smoke inhalation or burns. Although no injuries have been reported in the 30 incidents documented by Zebra, the potential for harm is real because the failure involves an uncontrolled thermal event.

It is important to note that this hazard does not discriminate based on age or physical ability in the way a chemical spill might. However, individuals who are less familiar with the specific maintenance protocols of industrial printing equipment may be at greater risk. For example, a temporary worker or a new hire who has not been trained to inspect power supplies for corrosion or unusual heat might continue to use a defective unit longer than an experienced technician would. Furthermore, because these printers are often used in environments with varying humidity levels—such as cold storage areas where condensation can form on warm electronics—the risk of the moisture-induced degradation that triggers this recall is higher for facilities that do not strictly control their climate. Therefore, the "most at risk" category includes both the physical proximity to the device during a failure and the operational context in which the device is used. If your business relies on these Zebra models for critical labeling tasks, and you are operating in a humid or poorly ventilated space, you fall into the highest priority group for immediate remediation.

How to tell if you have the recalled item

Identifying whether your thermal printer is part of this specific recall requires a bit of detective work, but the process is straightforward once you know where to look. Because Zebra Technologies manufactures these industrial printers under various brand names and configurations, the physical appearance of the unit alone may not be enough to confirm if it is affected. Instead, you must verify the internal power supply unit (PSU) that serves as the power source for your device. This is a critical distinction because the recall targets specific components manufactured by the FSP Group during a defined window of time, rather than every Zebra printer ever made.

Your first step is to locate the power supply brick itself. These units are typically black, rectangular boxes that connect to the back of your printer via a cable. Look closely at the label printed directly on the side or top surface of this power supply unit. You need to find three specific pieces of information: the logo, the date code, and the part number. The label will clearly display either the Zebra logo or the FSP North America logo. If you see a different manufacturer’s logo, this recall likely does not apply to your unit. However, if you see one of those two logos, you must proceed to check the alphanumeric codes printed nearby.

The date code is your primary filter for eligibility. The expanded recall covers power supply units manufactured between October 1, 2006, and December 31, 2012. On the label, look for a code that begins with "06" through "12" followed by two digits (format: 06XX through 12XX). For example, a date code of 0845 would fall within this range and indicate the unit was made in 2008. If your date code starts with "13" or higher, or "05" or lower, it is outside the scope of this specific expansion.

Next, cross-reference the part number with the list of affected models provided by Zebra. The recall affects a wide array of printer models, including but not limited to the APCES-1, BR100i, CN100i, GC420d, GK420d, GX420d, GT800 series, LP 2824 series, LP 2844 series, P100i series, R2844 series, TLP 2824 series, WM120i, ZP450 series, and ZXP Series printers. Your power supply part number will generally be one of the following: 808099-001, 808099-002, 808099-003, 808101-001, 808102-001 or P1028888-002, 808113-001 or P1028888-006, or 808113-002 or P1028888-007. If your printer model is listed above and your power supply has one of these part numbers within the specified date range, you have a recalled item.

If you are unsure about any of these details, do not guess. The safest approach is to visit the official recall page at www.zebra.com and click on “Power Supply Recall” for verified information, or contact Zebra directly at 800-658-3795. They can help you confirm whether your specific serial configuration is included in this safety expansion.

What to do — step by step

Your refund, repair, or replacement options

If you have identified that your thermal printer contains one of the recalled power supply units, you do not need to worry about bearing the cost of this safety correction. Zebra Technologies has structured the remedy for this recall specifically to make it as seamless and cost-free as possible for affected customers. The company is offering a free replacement power supply unit to any owner who contacts them through their designated recall channels. This means that you will not be charged for the new hardware, nor will you incur shipping fees for sending your defective unit back or receiving the replacement. The goal of this program is to remove every financial barrier so that you can restore your equipment to a safe operating condition without hesitation.

To initiate this process, you must reach out directly to Zebra Technologies. They have established specific contact methods exclusively for this recall expansion, which includes units manufactured by the FSP Group between October 1, 2006, and December 31, 2012. You can call their dedicated support line at 800-658-3795. This phone line is available around the clock, Monday through Friday, allowing you to speak with a representative during your most convenient business hours. Alternatively, if you prefer written communication or need to send documentation regarding your purchase or serial numbers, you can email PSUrecall@zebra.com. For those who prefer to navigate the process digitally, Zebra has set up a dedicated section on their website. Simply visit www.zebra.com and click on “Power Supply Recall” to find detailed instructions, forms, and further information about the replacement program.

It is important to understand why the remedy focuses on replacement rather than repair or refund of the original printer purchase. The hazard here stems from the internal degradation and corrosion of the power supply components themselves when exposed to moisture over time. Because this damage occurs within the sealed electronics of the brick-style adapter, it cannot be safely fixed by opening the unit. Attempting to repair a corroded power supply is extremely dangerous and could lead to immediate electrical failure. Therefore, the only safe and effective solution is to swap out the entire defective component for a new, certified one that does not carry the same manufacturing flaw. This ensures that the electrical insulation and structural integrity are restored to factory standards.

When you contact Zebra, be prepared to provide specific details about your unit to ensure you receive the correct replacement. The recall covers a vast array of printer models, from the APCES-1 and BR100i series to the GX420d and ZP500 series. You will likely need to confirm the model number of your printer and, crucially, the part number and date code printed on the power supply unit itself. These identifiers are typically located next to the Zebra or FSP North America logos on the brick. By providing this precise information, you help Zebra verify that your specific unit falls within the affected date codes (0639XX through 1253XX) and part numbers listed in the recall notice. This verification step ensures that you receive a replacement that is fully compatible with your printer’s wattage requirements, whether your original unit was a 50-Watt, 60-Watt, 70-Watt, or 100-Watt brick.

While waiting for your free replacement to arrive, the most critical step you can take is to stop using the recalled power supply immediately. Do not attempt to use it again, even temporarily, as the risk of overheating and fire remains active until the unit is removed. Once your new power supply arrives, follow the installation instructions provided by Zebra carefully. This remedy not only protects your workplace from potential fire damage but also ensures that your commercial labeling operations can continue safely without the constant worry of electrical hazards.

What can happen if you ignore it

It is completely understandable why you might hesitate to stop using your thermal printer right now. These machines are often critical to your daily workflow, whether you are shipping packages in a warehouse, labeling inventory in a retail backroom, or managing documents in an office. The idea of unplugging equipment that “seems to be working fine” can feel inconvenient, especially if you have a deadline approaching. However, ignoring this recall is not just about voiding a warranty; it is about accepting a significant and unnecessary risk to your physical safety and your property.

The core issue with these recalled Zebra power supply units is that they are prone to degrading and corroding when exposed to moisture over time. This isn’t a sudden failure that happens out of nowhere; it is a slow, silent process. As the internal components corrode, the electrical resistance increases, causing the unit to generate excessive heat. What starts as a minor inefficiency can quickly escalate into a serious fire hazard. You might not see any warning signs initially. The printer may continue to print labels perfectly well while the power brick underneath or beside it becomes dangerously hot. By the time you notice the plastic casing is warped or smell burning insulation, the damage to the internal electrical pathways may already be severe.

The consequences of continuing to use these units are real and have already been documented. Zebra has received reports of these specific power supplies overheating and actually catching fire. In several instances, the fire did not stay contained within the small power brick itself. Instead, the flames spread from the connector into the main body of the printer. This means you aren’t just risking the loss of a $50 power adapter; you are risking the destruction of the entire industrial printer, which can cost thousands of dollars to replace. Furthermore, the reports indicate that the fire has damaged surrounding workspaces. If your printer is sitting on a desk, inside a cabinet, or near flammable materials like paper stacks or plastic packaging, a small electrical fire can quickly become a larger structural hazard.

While it is a relief to know that no injuries have been reported in these specific incidents, relying on that statistic is dangerous. Electrical fires are unpredictable. They can ignite at any moment, day or night, and can spread rapidly in commercial environments filled with paper, cardboard, and other combustible materials. The fear of inconvenience should never outweigh the certainty of preventing a potential disaster. By ignoring this recall, you are essentially gambling with your workplace safety and your business assets for no reason, given that Zebra is providing a free replacement to eliminate this risk entirely.

Staying safe: broader tips

While this specific recall addresses a manufacturing defect in certain Zebra thermal printer power supplies, the underlying issue—electrical components degrading and overheating due to environmental factors like moisture—is a universal concern for anyone who uses electronic equipment. Power supplies are often the unsung heroes of our daily tech, quietly converting wall outlet electricity into the stable power your devices need. However, because they handle high-voltage input and generate heat during operation, they are natural points of failure if not properly maintained or installed. Understanding how to protect your broader ecosystem of electronics can prevent fires, equipment damage, and potential injuries long after any single recall has been resolved.

One of the most critical habits you can adopt is regular visual and physical inspection of your power bricks and cables. Over time, insulation on cords can become brittle, connectors can loosen, and plastic housings can crack due to heat cycling or physical wear. Look for discoloration, melting, or a burnt smell coming from any power adapter in your home or office. If you notice these signs, stop using the device immediately. Do not attempt to repair the cord yourself; instead, replace the entire unit with a manufacturer-approved replacement. Keeping your electronics in a dry, well-ventilated area is equally important. Moisture is a primary enemy of electrical safety, as it can accelerate corrosion on metal contacts and create pathways for short circuits. Avoid placing power supplies directly on wet surfaces or in areas prone to condensation.

Beyond physical inspections, consider the age and usage context of your equipment. Electronics have a lifespan, and components inside power supplies degrade over time, even if they appear to be working fine. If you are using older industrial or consumer-grade printers, label makers, or similar devices that have been in service for many years, proactively check the manufacturer’s website for any updated safety notices or voluntary recalls. Manufacturers often issue updates or replacements for older models once they identify long-term failure patterns that weren’t apparent at launch. Signing up for official recall alerts from agencies like the Consumer Product Safety Commission (CPSC) can also keep you informed before a hazard becomes a common occurrence.

Finally, never overload electrical outlets or use damaged extension cords to power sensitive equipment. Using surge protectors with appropriate ratings can help shield your devices from voltage spikes, which can stress power supplies and lead to premature failure. By treating your power infrastructure with respect—keeping it dry, clean, and within its rated capacity—you significantly reduce the risk of fire hazards in your workspace or home. Safety is not just about reacting to a recall; it is about building consistent, mindful habits around how you power the technology you rely on every day.