What was recalled
In December 2016, the U.S. Consumer Product Safety Commission (CPSC) announced a significant recall involving power supply units manufactured by Zebra Technologies. These are not standard household electronics but specialized components designed for industrial and commercial environments. Specifically, the recall targets power supplies used in Zebra-brand thermal printers, which are essential tools for businesses that need to produce barcodes, shipping labels, inventory tags, and other commercial identification materials. If your workplace relies on these machines to keep track of shipments or manage stock, it is crucial to verify whether the power unit feeding electricity to your printer is part of this specific safety notice.
The scope of this recall covers a wide range of Zebra printer models, as the faulty power supplies were either sold separately as aftermarket kits or included directly with the sale of new printers. The affected devices span several distinct series, including the G-Series (specifically models GK420D/T and GX420D/T, GX430D/T), the GT Series (GT800, GT810, GT820, and GT830), the ZP455, the HC100 medical printer, the P1XX Series (P100, P110, P120), and the ZXP3. Because these printers are ubiquitous in warehouses, retail back offices, and healthcare facilities, the potential reach of this recall is substantial for business continuity.
To determine if your specific unit is affected, you must look closely at the power supply itself rather than just the printer model number, as part numbers can vary even within the same printer series. The recalled units are identified by their part numbers and date codes. For example, the GK420d, GT800 through GT830 models typically used the 808099-001 part number (a 70W Brick), while the GX420d/t and GX430d/t models used the 808101-001 part number (a 100W Brick). The HC100 medical printer used the 808099-003, and the P1XX series used the 808099-002. The ZXP3 also utilized the 808101-001 unit. Crucially, the recall applies to power supplies with date codes falling between 1039XX through 1052XX and 1101XX through 1152XX. These units bear either the Zebra logo or the FSP North America logo.
The exact number of units involved in this recall is not explicitly stated in the CPSC record, but given the widespread use of Zebra industrial printers across global supply chains, the volume is likely significant. These products were sold through various channels, including direct sales from Zebra and third-party retailers who offered them as aftermarket replacements. The recall was initiated on December 20, 2016, following reports of the units failing safely under normal conditions but degrading over time when exposed to moisture.
The hazard, explained
When we talk about a fire hazard in electronics, it is easy to imagine a dramatic explosion or an immediate flash of flame. However, with the Zebra thermal printer power supply units recalled by the Consumer Product Safety Commission (CPSC), the danger is more subtle and insidious. It begins not with a sudden failure, but with slow, invisible degradation. The core issue lies in the internal components of these specific power supplies, which are designed to convert electrical current from your wall outlet into the steady, lower-voltage power that your industrial printer needs to operate. Over time, particularly when these units are exposed to moisture in their environment, the metal contacts and circuitry inside can begin to corrode.
Corrosion is essentially rust on a microscopic scale. As the metal parts degrade, they lose their ability to conduct electricity efficiently. Think of it like a clogged pipe; the water still tries to push through, but it meets resistance. In electrical terms, this resistance generates excess heat. Normally, power supplies have built-in safeguards to manage temperature, but when corrosion creates uneven pathways for the current, localized hot spots can form. These spots become significantly hotter than the rest of the unit, a process known as overheating. The recall notice confirms that this physical breakdown is exactly what has been observed in the field, with units reaching temperatures high enough to ignite nearby materials.
The severity of this hazard is underscored by the fact that Zebra has received three reports of these units actually catching fire. In one particularly concerning instance, the heat was intense enough that the fire spread from the power supply connector directly into the printer itself. This is a critical detail because it illustrates how quickly a small electrical fault can become a structural threat. The power supply is often plugged directly into the device; when it fails catastrophically, the flames do not stay contained within the plastic casing of the adapter. Instead, they travel along the connection point, engulfing the printer and potentially damaging the surrounding workspace, such as desks, shelving, or other equipment.
It is important to understand that this is not a defect in the initial manufacturing quality per se, but rather a vulnerability to environmental conditions. Industrial environments where these thermal printers are used—such as warehouses, hospitals, or shipping centers—often have varying levels of humidity. While these power supplies are built for durability, prolonged exposure to moisture accelerates the corrosion process that leads to overheating. The good news is that no injuries have been reported in connection with this specific hazard. This suggests that while the property damage risk is real and serious, the window of time between the unit starting to overheat and it catching fire may provide enough warning for users to notice unusual heat or smells before a fire starts. Nevertheless, the potential for significant property loss makes immediate action essential.
Who is most at risk
To understand who is truly at risk in this recall, we first need to look at the environment where these Zebra thermal printers are typically used. Unlike household electronics that sit quietly on a desk or nightstand, these specific power supply units are designed for industrial and commercial settings. They serve as the vital power source for heavy-duty machines that print barcodes, shipping labels, and other commercial tags. Consequently, the people most likely to be in contact with these devices are not average consumers, but rather warehouse workers, logistics coordinators, retail staff in busy distribution centers, and healthcare professionals who rely on them for labeling medications or patient files. The risk is less about accidental mishandling by a general public member and more about the intense, continuous usage patterns found in professional environments.
The primary danger here stems from the specific nature of the hazard: overheating due to degradation and corrosion caused by moisture exposure. In industrial workplaces, conditions can be harsh. Warehouses may have fluctuating temperatures and humidity levels, while medical or laboratory settings often involve cleaning agents and frequent sanitization. Workers in these roles are at a higher risk because their equipment is constantly exposed to the very elements that accelerate the power supply’s deterioration. When a worker plugs in a printer that has been subjected to high humidity or accidental splashes over months of use, they are unknowingly engaging with a device that may be silently degrading. The electrical components inside can corrode, leading to excessive heat buildup that standard office environments simply do not generate.
When we consider physical vulnerability, it is important to note that no injuries have been reported in this specific recall case so far, but the potential for harm remains significant. While children and the elderly are often the most vulnerable groups in home-related recalls involving fire or electrical shocks, they are unlikely to be the primary users of these industrial-grade Zebra printers. However, adult workers are not immune to severe injury. If a power supply unit catches fire, the flames can spread from the connector directly to the printer and, crucially, to the surrounding workspace. For a worker standing nearby at their station, this poses a direct threat of burns or smoke inhalation. Furthermore, the sudden loss of power or the destruction of the printer could lead to secondary accidents, such as dropping heavy objects or disrupting critical workflows in sensitive areas like hospitals or busy shipping docks.
Therefore, the group most at risk is anyone who operates these specific G-Series, GT Series, ZP455, HC100, P1XX Series, or ZXP3 models in an environment where moisture is present. This includes medical staff using the HC100 for lab work and warehouse employees using the GK420 or GX420 series for daily shipping tasks. The risk is compounded by the fact that these failures are not always obvious. A worker might continue to use a printer that looks fine on the outside while its internal power supply becomes a fire hazard. Because the recall involves units sold as aftermarket kits or included with the sale of these machines, many users may not realize they possess a recalled component until they check the date codes. The vulnerability lies in the latency between the degradation of the part and the onset of visible failure, leaving workers exposed to danger during that silent window.
How to tell if you have the recalled item
Identifying whether your specific power supply unit is part of this recall requires a close inspection of both the printer model and the physical characteristics of the power brick itself. Because Zebra manufactures these units for a wide variety of thermal industrial printers used in commercial labeling, the first step is to confirm which printer you are using. The recall covers power supplies included with or sold as aftermarket kits for several specific series: the G-Series (including models GK420D/T, GX420D/T, and GX430D/T), the GT Series (GT800, GT810, GT820, and GT830), the ZP455, the HC100, the P1XX Series (P100, P110, P120), and the ZXP3. If your printer falls outside of these specific model numbers, it is not covered by this particular safety notice.
Once you have confirmed your printer model, you must examine the power supply unit attached to it. Look closely at the surface of the brick for printed markings. The recalled units will display either the Zebra logo or the FSP North America logo. Crucially, you need to locate two specific pieces of data printed on the device: the date code and the part number. These are not always in the same spot on every unit, so check the sides and the bottom of the brick carefully. The presence of one of these logos is a strong indicator, but the date code is the definitive filter for this recall.
The specific date codes that trigger this recall are those falling between 1039XX through 1052XX and 1101XX through 1152XX. If your unit’s date code falls within these ranges, it is part of the recall regardless of the printer model it came with, provided the part number matches the corresponding type listed below. To help you verify, here is the breakdown of which part numbers correspond to which power supply types for the affected models:
- Part Number 808099-001 (70W Brick): Used with GK420d, GT800, GT810, GT820, and GT830 models.
- Part Number 808099-002 (70W Brick): Used with the P1XX series of printers.
- Part Number 808099-003 (70W Medical Brick): Specifically used with the HC100 model.
- Part Number 808101-001 (100W Brick): Used with GK420t, GX420d, GX420t, GX430d, GX430t, and ZXP3 models.
If you find a date code within the recalled ranges paired with one of these part numbers, do not attempt to use the unit. Stop using it immediately and contact Zebra for a free replacement. If you cannot read the markings clearly, or if your printer model is not listed above, you may still contact Zebra directly to verify the status of your specific serial number.
What to do — step by step
If you suspect that one of your Zebra thermal printers contains the recalled power supply unit, please take a moment to follow these specific steps carefully. The goal here is simple: to remove the fire hazard from your workspace immediately and get you set up with a safe, functioning replacement at no cost to you.
- Stop using the device immediately. As soon as you identify that your printer matches one of the affected models—such as the GK-Series, GT-Series, ZP455, HC100, P1XX Series, or ZXP3—unplug it from the power source. Do not attempt to continue using the printer for any reason, even if it appears to be working normally. The risk of overheating and potential fire is hidden within the internal components and can occur without warning signs. By disconnecting the power supply now, you eliminate the immediate danger to your office or industrial environment.
- Verify your unit’s details. Before contacting support, take a close look at the power supply brick attached to your printer. You need to confirm that it carries either the Zebra logo or the FSP North America logo. More importantly, check the date code printed on the label. The recall specifically targets units with date codes ranging from 1039XX through 1052XX and 1101XX through 1152XX. If your unit falls outside these ranges or does not have these logos, it is likely not part of this specific recall, but you can still double-check with the company to be sure.
- Contact Zebra for a free replacement. Once you have confirmed that your power supply is included in the recall, reach out to Zebra Technologies to initiate the remedy process. You can call their dedicated support line at 800-658-3795. Their team is available any time from Monday through Friday. Alternatively, you may send an email to PSUrecall@zebra.com for assistance. For a more detailed guide on the return process, you can also visit www.zebra.com and click on the "Power Supply Recall" link found on their website.
- Follow the return instructions provided. When you speak with a representative or read the online materials, they will provide you with specific instructions on how to send back the defective power supply unit. Zebra has committed to providing a free replacement power supply for all affected units. Please follow their packaging and shipping guidelines carefully to ensure your replacement arrives promptly and that you are not charged for return shipping.
Taking these steps is straightforward but critical. The recalled power supplies can degrade and corrode when exposed to moisture, leading to overheating. By acting quickly, you protect your equipment and your workplace from the reported incidents where fires have spread from the connector to the printer itself. Zebra’s remedy is designed to be hassle-free, so do not hesitate to reach out for help if you need clarification on any part of this process.
Your refund, repair, or replacement options
If you have determined that your Zebra thermal printer is equipped with one of the recalled power supply units, the good news is that Zebra Technologies has established a clear and straightforward remedy to resolve this safety issue. Because the core problem involves a potential fire hazard due to degradation and corrosion, the company is not asking you to attempt any DIY repairs or to keep the defective unit under any circumstances. Instead, the official remedy provided by the Consumer Product Safety Commission (CPSC) records is a free replacement power supply. This means that Zebra will provide you with a new, safe unit at no cost to you, ensuring that your printing operations can continue without the risk associated with the old hardware.
To initiate this process, you need to contact Zebra directly. The company has set up specific channels for consumers and business owners to reach their recall support team efficiently. You can call them at 800-658-3795. Their customer service representatives are available any time, Monday through Friday, which allows you to schedule a call that fits your work day. If you prefer written communication or need to send documentation regarding your purchase or serial numbers, you can email them directly at PSUrecall@zebra.com. Additionally, Zebra has created a dedicated online portal for this specific recall. You can visit their website at www.zebra.com and look for the "Power Supply Recall" link. This section of their site likely contains forms to fill out, tracking information for your replacement, and further instructions tailored to your specific printer model.
It is important to understand why a free replacement is the chosen remedy rather than a refund or repair. The hazard described involves the internal components of the power supply degrading over time when exposed to moisture. This is not a simple software glitch or a loose wire that can be easily fixed; it is a material failure that compromises safety. Therefore, repairing the old unit would not eliminate the risk, and keeping it is dangerous. A replacement ensures you get a unit that has not undergone the same degradation process. When you contact Zebra, have your printer model number (such as GK420D, GX420T, GT800, etc.) and the part number of your current power supply ready. The recall affects specific date codes between 1039XX through 1052XX and 1101XX through 1152XX, so having these details will help the support team verify that your unit is indeed part of this batch.
While waiting for your replacement power supply to arrive, the most critical step you can take is to immediately stop using the recalled unit. Do not plug it in or attempt to use it with your printer. The recall notice mentions that there have been incidents of overheating and fires, including one case where the fire spread from the connector to the printer itself. By disconnecting the unit now, you are protecting your workspace, your equipment, and potentially your colleagues from harm. Once the new power supply arrives, follow the installation instructions carefully to ensure a safe return to normal operations.
What can happen if you ignore it
When a recall notice lands in your inbox or appears on a safety website, the natural human response is often to pause the inconvenience. You might think, "It’s been working fine for months," or "I only use this printer occasionally." However, with the Zebra Technologies power supply units recalled due to fire hazards, ignoring the notice is not a matter of minor risk; it is an invitation to a serious and potentially dangerous situation. The core issue here is that the degradation and corrosion within these specific power supplies are not static defects. They are progressive. Over time, exposure to moisture—common in many commercial and industrial environments where thermal printers operate—causes internal components to break down. This chemical and physical breakdown leads to increased electrical resistance, which generates excessive heat. If you continue to use a recalled unit, you are essentially letting a slow-burning fuse run unchecked.
The consequences of ignoring this warning move beyond simple equipment failure. According to reports from Zebra Technologies, there have already been three confirmed incidents where these power supply units overheated to the point of catching fire. In one particularly alarming case, the fire did not remain contained within the power brick itself. Instead, it spread from the connector directly into the printer, causing significant damage to the machine and the surrounding workspace. This illustrates a critical reality: electrical fires in commercial settings can quickly escalate, threatening not just your expensive labeling equipment but also nearby documents, packaging materials, and structural elements of your business.
While no injuries have been reported with these specific units so far, the potential for personal harm is real and immediate. A fire originating from a power supply can happen rapidly, often without warning signs like smoke until flames are already visible. In an office or warehouse environment, where employees may be focused on high-volume label printing tasks, a sudden fire could lead to burns, smoke inhalation, or panic-induced accidents during evacuation. Furthermore, the financial and operational fallout is severe. Beyond the cost of replacing the unit (which Zebra will provide for free), you would face the loss of your printer, potential damage to other connected electronics due to electrical surges, and the disruption of critical business operations like shipping and inventory management.
Ultimately, continuing to use a recalled power supply is a gamble with outcomes that are largely out of your control. The corrosion inside the unit is invisible to the naked eye until it is too late. By acting now, you eliminate the risk entirely. By waiting, you allow the hazard to mature, turning a simple product defect into a potential emergency. Do not wait for a spark or a smell to remind you that safety is not optional.
Staying safe: broader tips
Safety is rarely about a single event; it is built through consistent, everyday habits that reduce risk before it becomes a problem. While specific product recalls address immediate threats, adopting a proactive mindset toward the equipment in your home or office can prevent many common hazards. For electronic devices like thermal printers and their associated power supplies, the primary enemies are often heat, moisture, and age. Understanding how these elements interact with electrical components is the first step in maintaining a safe environment.
One of the most effective ways to protect your electronics is to manage their physical environment carefully. Power supply units, like the ones recalled by Zebra Technologies, contain internal components that can degrade over time, especially when exposed to humidity or condensation. To mitigate this risk, always place electronic devices in well-ventilated areas where air can circulate freely. Avoid storing them in enclosed spaces, such as tight cubbies or closed cabinets, which can trap heat and allow moisture to accumulate. If you live in a humid climate or have high indoor humidity levels, consider using a dehumidifier in the room where these devices operate. Keeping the relative humidity between 30% and 50% helps prevent corrosion on internal connectors and circuit boards, extending the life of your equipment and reducing the likelihood of electrical faults.
Another critical aspect of electrical safety is regular visual inspection. Over time, power cords can fray, plugs can loosen, and casings can crack due to normal wear and tear. Make it a habit to check your devices once a month for any signs of damage. Look for discoloration on the power brick, which can indicate overheating, or any unusual smells when the device is first turned on. If you notice any of these warning signs, unplug the device immediately and do not attempt to use it again until it has been professionally evaluated or replaced. This simple practice can catch potential issues long before they escalate into serious hazards.
Finally, staying informed about product safety is an essential part of responsible ownership. Many dangerous defects are identified by manufacturers or government agencies like the Consumer Product Safety Commission (CPSC) after a product has been on the market. To ensure you are not using a recalled item, regularly visit www.cpsc.gov and sign up for email alerts specific to your region. You can also download the free CPSC app to receive immediate notifications about new recalls. By staying connected to these official sources, you empower yourself to act quickly if a product you own is found to be unsafe, ensuring that you and your loved ones remain protected from preventable accidents.
- Ensure adequate airflow around all electronic power supplies to prevent heat buildup.
- Monitor indoor humidity levels and use dehumidifiers if necessary to protect against corrosion.
- Perform monthly visual checks of power cords, plugs, and device casings for wear or damage.
- Subscribe to CPSC recall alerts to stay informed about safety issues affecting your products.