printer troubleshooting etc

2026-01-28 16:42:11 -08:00
parent e1f9417684
commit cafd4b6084
26 changed files with 408 additions and 132 deletions
--- a/kiosk/screens/completion.py
+++ b/kiosk/screens/completion.py
@ -43,6 +43,12 @@ class Screen10(tk.Frame):
            self.running = True
            self._update_frame()

+        # Sticker tip - only show when a sticker was printed
+        if GlobalVars.print_type == "sticker":
+            RoundedLabel(container,
+                         text="You might like to add some packing tape on top\nof your sticker to make it more permanent",
+                         bg='white', font=('Georgia', 16)).pack(pady=(10, 0))
+
        # Button container for side-by-side layout
        button_frame = tk.Frame(container, bg=BG_COLOR)
        button_frame.pack(pady=10)
--- a/kiosk/screens/drawing.py
+++ b/kiosk/screens/drawing.py
@ -51,7 +51,7 @@ class Screen4(tk.Frame, DrawingMixin):

        # Initialize drawing via mixin (grid_size=1 for stickers)
        self.init_drawing(597, 360, grid_size=1)
-        self.draw_size = 3  # Override default size for stickers
+        self.draw_size = 4  # Override default size for stickers
        self.imported_img = None

        # QR size positions and defaults
@ -217,6 +217,7 @@ class Screen8(tk.Frame, DrawingMixin):

        # Initialize drawing via mixin
        self.init_drawing(width, height, grid_size=scale_factor)
+        self.draw_size = 4  # Second-from-largest pen size

        # Right panel: Pen tools (grid layout) + action buttons
        right_panel = tk.Frame(main_container, bg=BG_COLOR)
--- a/kiosk/screens/intro.py
+++ b/kiosk/screens/intro.py
@ -77,12 +77,32 @@ It can print stickers and ribbons to affix to an item you care about."""
                             wraplength=500, justify='left', padx=20, pady=20)
        text_label.pack(expand=True)

-        # Bottom: Forward button only
+        # Bottom: Forward button only (delayed)
        nav_frame = tk.Frame(self, bg=BG_COLOR)
        nav_frame.grid(row=1, column=0, columnspan=2, sticky='ew', pady=20)

-        tk.Button(nav_frame, text="Forward →", command=lambda: master.switch_frame(InfoPage2),
-                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(side='right', padx=40)
+        # Dot progress indicator
+        self.dots_label = tk.Label(nav_frame, text="", font=GlobalVars.TEXT_FONT, bg=BG_COLOR)
+        self.dots_label.pack(side='left', expand=True)
+        self.dot_count = 0
+
+        def add_dot():
+            self.dot_count += 1
+            self.dots_label.config(text="." * self.dot_count)
+            if self.dot_count < 8:
+                self.after(1000, add_dot)
+
+        self.after(1000, add_dot)
+
+        self.forward_btn = tk.Button(nav_frame, text="Forward →", command=lambda: master.switch_frame(InfoPage2),
+                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT)
+
+        def show_forward():
+            self.dots_label.pack_forget()
+            self.forward_btn.pack(side='right', padx=40)
+
+        # Show forward button after 8 second delay
+        self.after(8000, show_forward)


 class InfoPage2(tk.Frame):
@ -123,14 +143,35 @@ by tagging an item you are saying to it, 'you matter, I will take care of you'""
                             wraplength=500, justify='left', padx=20, pady=20)
        text_label.pack(expand=True)

-        # Bottom: Back and Forward buttons
+        # Bottom: Back and Forward buttons (forward delayed)
        nav_frame = tk.Frame(self, bg=BG_COLOR)
        nav_frame.grid(row=1, column=0, columnspan=2, sticky='ew', pady=20)

        tk.Button(nav_frame, text="← Back", command=lambda: master.switch_frame(InfoPage1),
                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(side='left', padx=40)
-        tk.Button(nav_frame, text="Forward →", command=lambda: master.switch_frame(InfoPage3),
-                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(side='right', padx=40)
+
+        # Dot progress indicator (centered)
+        self.dots_label = tk.Label(nav_frame, text="", font=GlobalVars.TEXT_FONT, bg=BG_COLOR)
+        self.dots_label.pack(side='left', expand=True)
+        self.dot_count = 0
+
+        def add_dot():
+            self.dot_count += 1
+            self.dots_label.config(text="." * self.dot_count)
+            if self.dot_count < 8:
+                self.after(1000, add_dot)
+
+        self.after(1000, add_dot)
+
+        self.forward_btn = tk.Button(nav_frame, text="Forward →", command=lambda: master.switch_frame(InfoPage3),
+                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT)
+
+        def show_forward():
+            self.dots_label.pack_forget()
+            self.forward_btn.pack(side='right', padx=40)
+
+        # Show forward button after 8 second delay
+        self.after(8000, show_forward)


 class InfoPage3(tk.Frame):
@ -147,14 +188,14 @@ class InfoPage3(tk.Frame):

 All generated items are stored permanently and replicated across the Scuttlebutt network. Once published, it cannot be deleted.

-Please do not create imaginary items or shitpost.
+Please post with care and with positive and constructive intentions.

 The QR codes contain a Scuttlebutt messageID, scanning it works best at www.cust.ooo or any Scuttlebutt client.
 """

        text_label = RoundedLabel(container, text=mindful_text,
-                             font=GlobalVars.TEXT_FONT, bg='white',
-                             wraplength=700, justify='center', padx=30, pady=30)
+                             font=("Helvetica", 20), bg='white',
+                             wraplength=900, justify='center', padx=30, pady=30)
        text_label.pack()

        # Deferred import
@ -162,11 +203,32 @@ The QR codes contain a Scuttlebutt messageID, scanning it works best at www.cust
            from kiosk.screens.ssb_selection import Screen1
            master.switch_frame(Screen1)

-        # Bottom: Back and Forward buttons
+        # Bottom: Back and Forward buttons (forward delayed)
        nav_frame = tk.Frame(self, bg=BG_COLOR)
        nav_frame.place(relx=0.5, rely=0.9, anchor='center')

        tk.Button(nav_frame, text="← Back", command=lambda: master.switch_frame(InfoPage2),
                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(side='left', padx=40)
-        tk.Button(nav_frame, text="Forward →", command=go_to_screen1,
-                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(side='right', padx=40)
+
+        # Dot progress indicator (centered)
+        self.dots_label = tk.Label(nav_frame, text="", font=GlobalVars.TEXT_FONT, bg=BG_COLOR)
+        self.dots_label.pack(side='left', expand=True)
+        self.dot_count = 0
+
+        def add_dot():
+            self.dot_count += 1
+            self.dots_label.config(text="." * self.dot_count)
+            if self.dot_count < 8:
+                self.after(1000, add_dot)
+
+        self.after(1000, add_dot)
+
+        self.forward_btn = tk.Button(nav_frame, text="Forward →", command=go_to_screen1,
+                  height=2, width=15, bg='peach puff', font=GlobalVars.BUTTON_FONT)
+
+        def show_forward():
+            self.dots_label.pack_forget()
+            self.forward_btn.pack(side='right', padx=40)
+
+        # Show forward button after 8 second delay
+        self.after(8000, show_forward)
--- a/kiosk/screens/print_flow.py
+++ b/kiosk/screens/print_flow.py
@ -110,15 +110,20 @@ class Screen13(tk.Frame):

            # Load and rotate scan-tag 90 degrees clockwise
            scan_tag = Image.open("scan-tag.png").convert("L")
-            scan_tag_rotated = scan_tag.rotate(-90, expand=True)  # -90 = clockwise
+            scan_tag_rotated = scan_tag.rotate(-90, expand=True)  # -90 = clockwise, 53×357

-            merged_image = Image.new('L', (675, 375), "white")
+            # 300 DPI printer, 2.25" label = 675 dots
+            # Drawing: 597px, scan-tag rotated: 53px = 650px total (no gap)
+            sticker_width = 650
+            sticker_height = 375
+
+            merged_image = Image.new('L', (sticker_width, sticker_height), "white")
            merged_image.paste(drawing, (0, 8))
            merged_image.paste(qr_img, (QRX, QRY + 8))

            # Paste rotated scan-tag right after drawing, vertically centered
            scan_tag_x = 597  # Right edge of drawing
-            scan_tag_y = (375 - scan_tag_rotated.height) // 2  # Center vertically
+            scan_tag_y = (sticker_height - scan_tag_rotated.height) // 2  # Center vertically
            merged_image.paste(scan_tag_rotated, (scan_tag_x, scan_tag_y))

            merged_image.save("merged_image.png")
@ -161,7 +166,10 @@ class Screen13(tk.Frame):
                                          print_width=ribbon_width,
                                          label_length=total_height)
        else:
-            zpl_code = tozpl.print_to_zpl("merged_image.png")
+            # Sticker: specify dimensions for proper positioning on 2.25" (675 dot @ 300 DPI) label
+            zpl_code = tozpl.print_to_zpl("merged_image.png",
+                                          print_width=sticker_width,
+                                          label_length=sticker_height)

        # save the zpl
        # Open the file in write mode
@ -214,20 +222,21 @@ AND OR
 please email maintenance@cust.ooo

 thanks!"""
-        RoundedLabel(container, text=troubleshoot_text, bg='white', font=('Georgia', 22),
+        RoundedLabel(container, text=troubleshoot_text, bg='white', font=('Georgia', 18),
                     wraplength=900, justify='left').pack(pady=10)

-        # Re-print button
-        tk.Button(container, text="Re-print", command=self._reprint,
-                  height=2, width=30, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(pady=5)
-
-        # Done button
+        # Button container for side-by-side layout
        def go_home():
            from kiosk.screens.home import Screen0
            master.switch_frame(Screen0)

-        tk.Button(container, text="Done", command=go_home,
-                  height=2, width=30, bg='light gray', font=GlobalVars.BUTTON_FONT).pack(pady=5)
+        button_frame = tk.Frame(container, bg=BG_COLOR)
+        button_frame.pack(pady=10)
+
+        tk.Button(button_frame, text="Re-print", command=self._reprint,
+                  height=2, width=20, bg='peach puff', font=GlobalVars.BUTTON_FONT).pack(side='left', padx=10)
+        tk.Button(button_frame, text="Done", command=go_home,
+                  height=2, width=20, bg='light gray', font=GlobalVars.BUTTON_FONT).pack(side='left', padx=10)

    def _reprint(self):
        """Re-send the last print job."""
--- a/kiosk/screens/ssb_selection.py
+++ b/kiosk/screens/ssb_selection.py
@ -54,6 +54,7 @@ class Screen2(tk.Frame):
        tk.Frame.__init__(self, master, bg=BG_COLOR)
        self.selected_label = None
        self.filtered_users = []
+        self._search_after_id = None  # For debouncing search input

        # Create a new frame at the top for the label and text box
        self.top_frame = tk.Frame(self, bg=BG_COLOR)
@ -61,7 +62,7 @@ class Screen2(tk.Frame):

        # Add a label with text wrapping
        self.label = RoundedLabel(self.top_frame,
-                              text="slowly type your public key or alias one letter at a time to find yourself in the list then click on your key to select it.",
+                              text="Type your public key or alias to find yourself in the list, then click on your key to select it.",
                              font=GlobalVars.TEXT_FONT,
                              wraplength=800,
                              bg='white')
@ -69,7 +70,7 @@ class Screen2(tk.Frame):

        # Add text box to the top frame
        self.entry = tk.Entry(self.top_frame, font=GlobalVars.TEXT_FONT)
-        self.entry.bind('<KeyRelease>', lambda e: self.update_users_list())
+        self.entry.bind('<KeyRelease>', self._debounced_search)
        self.entry.pack(side="top", fill="x", padx=20)

        # Focus on the entry box
@ -113,20 +114,51 @@ class Screen2(tk.Frame):
            from kiosk.screens.camera import Screen3
            master.switch_frame(Screen3)

+        def cancel_selection():
+            GlobalVars.selected_user = None
+            go_to_screen3()
+
+        # The 'Cancel' button to skip without selecting a user
+        self.cancel_button = tk.Button(self.button_frame, text="Cancel", command=cancel_selection,
+                                       height=2, width=20, bg='peach puff', font=GlobalVars.BUTTON_FONT)
+        self.cancel_button.pack(side="left", padx=(10, 10))
+
        # The 'Done' button to navigate to next screen
        self.done_button = tk.Button(self.button_frame, text="Done", command=go_to_screen3,
                                     height=2, width=20, bg='peach puff', font=GlobalVars.BUTTON_FONT)
        self.done_button.pack(side="right", padx=(10, 20))

-        # Initialize users list from users.json
-        self.users = self.get_users_from_file()
-        self.update_users_list()
+        # Loading label (shown during initial load)
+        self.loading_label = tk.Label(self.scrollable_frame, text="Loading...",
+                                      font=GlobalVars.TEXT_FONT, bg=BG_COLOR)
+        self.loading_label.pack(pady=20)
+
+        # Defer loading to allow UI to render first
+        self.users = []
+        self.after(10, self._load_users)

        master.add_home_button(self)

+    def _debounced_search(self, event=None):
+        """Debounce search input - wait 250ms after last keystroke before searching."""
+        if self._search_after_id:
+            self.after_cancel(self._search_after_id)
+        self._search_after_id = self.after(250, self.update_users_list)
+
+    def _load_users(self):
+        """Load users from file and display them."""
+        self.users = self.get_users_from_file()
+        self.loading_label.destroy()
+        self.update_users_list()
+
    def update_users_list(self):
        search_text = self.entry.get().lower()
-        self.filtered_users = [user for user in self.users if search_text in user['id'].lower() or search_text in self.unescape_unicode(user.get('alias', '')).lower()]
+        # Use cached _search_alias and _search_id for fast filtering
+        self.filtered_users = [
+            user for user in self.users
+            if search_text in user.get('_search_id', user['id'].lower())
+            or search_text in user.get('_search_alias', '')
+        ]
        self.display_users()

        # Preserve selection after filtering
@ -148,7 +180,8 @@ class Screen2(tk.Frame):
                frame = tk.Frame(self.scrollable_frame, bg=BG_COLOR)
                frame.pack(fill='x', expand=True, pady=2)

-                alias = self.unescape_unicode(user.get('alias', ''))
+                # Use cached _display_alias if available, otherwise compute it
+                alias = user.get('_display_alias', self.unescape_unicode(user.get('alias', '')))
                id = user.get('id', '')

                alias_label = tk.Label(frame, text=alias, font=('Georgia', 14, 'bold'), width=20, anchor='w', bg='white')
@ -221,14 +254,28 @@ class Screen2(tk.Frame):
            return False

    def refresh_users(self):
+        # Show loading state
+        self.refresh_button.configure(state="disabled", text="Loading...")
+        self.update_idletasks()
+
        try:
-            self.users = self.get_scuttlebutt_users()
+            users = self.get_scuttlebutt_users()
+            # Pre-process aliases for the new users
+            for user in users:
+                display_alias = self.unescape_unicode(user.get('alias', ''))
+                user['_display_alias'] = display_alias
+                user['_search_alias'] = display_alias.lower()
+                user['_search_id'] = user['id'].lower()
+            self.users = users
            self.update_users_list()
-            self.save_users_to_file(self.users)
+            self.save_users_to_file(users)
            messagebox.showinfo("Success", "User list has been refreshed and updated with aliases.")
        except Exception as e:
            print(f"An error occurred while refreshing the user list: {e}")
            messagebox.showerror("Error", "An error occurred while refreshing the user list. Please try again later.")
+        finally:
+            # Restore button state
+            self.refresh_button.configure(state="normal", text="Refresh List")

    def get_scuttlebutt_users(self):
        try:
@ -253,6 +300,12 @@ class Screen2(tk.Frame):
        try:
            with open('users.json') as f:
                users = json.load(f)
+            # Pre-process and cache unescaped aliases for fast search and display
+            for user in users:
+                display_alias = self.unescape_unicode(user.get('alias', ''))
+                user['_display_alias'] = display_alias
+                user['_search_alias'] = display_alias.lower()
+                user['_search_id'] = user['id'].lower()
            return users
        except FileNotFoundError:
            return []
--- a/jumbo/configure_printer.zpl
+++ b/jumbo/configure_printer.zpl
@ -1,8 +0,0 @@
-^XA
-^PW675
-^LL375
-^LH0,0
-^LT0
-^LS0
-^JUS
-^XZ
--- a/jumbo/configure_printer_v2.zpl
+++ b/jumbo/configure_printer_v2.zpl
@ -1,8 +0,0 @@
-^XA
-^PW675
-^LL375
-^LH10,10
-^LT0
-^LS0
-^JUS
-^XZ
--- a/jumbo/configure_printer_v3.zpl
+++ b/jumbo/configure_printer_v3.zpl
@ -1,8 +0,0 @@
-^XA
-^PW675
-^LL375
-^LH5,5
-^LT0
-^LS0
-^JUS
-^XZ
--- a/jumbo/corner_test_v2.zpl
+++ b/jumbo/corner_test_v2.zpl
@ -1,7 +0,0 @@
-^XA
-^FO0,0^GB50,50,50^FS
-^FO605,0^GB50,50,50^FS
-^FO0,305^GB50,50,50^FS
-^FO605,305^GB50,50,50^FS
-^FO280,155^A0N,30,30^FDCENTER^FS
-^XZ
--- a/jumbo/corner_test_v3.zpl
+++ b/jumbo/corner_test_v3.zpl
@ -1,7 +0,0 @@
-^XA
-^FO0,0^GB40,40,40^FS
-^FO625,0^GB40,40,40^FS
-^FO0,325^GB40,40,40^FS
-^FO625,325^GB40,40,40^FS
-^FO290,160^A0N,30,30^FDCENTER^FS
-^XZ
--- a/jumbo/corner_test_v4.zpl
+++ b/jumbo/corner_test_v4.zpl
@ -1,7 +0,0 @@
-^XA
-^FO0,0^GB40,40,40^FS
-^FO605,0^GB40,40,40^FS
-^FO0,305^GB40,40,40^FS
-^FO605,305^GB40,40,40^FS
-^FO285,155^A0N,30,30^FDCENTER^FS
-^XZ
--- a/jumbo/printer_config_query.zpl
+++ b/jumbo/printer_config_query.zpl
@ -1,3 +0,0 @@
-^XA
-~HQ
-^XZ
--- a/jumbo/reset_shifts.zpl
+++ b/jumbo/reset_shifts.zpl
@ -1,6 +0,0 @@
-^XA
-^LT0
-^LS0
-^LH0,0
-^JUS
-^XZ
--- a/jumbo/save_label_home.zpl
+++ b/jumbo/save_label_home.zpl
@ -1,4 +0,0 @@
-^XA
-^LH50,50
-^JUS
-^XZ
--- a/jumbo/save_shifts.zpl
+++ b/jumbo/save_shifts.zpl
@ -1,5 +0,0 @@
-^XA
-^LT50
-^LS50
-^JUS
-^XZ
--- a/jumbo/simple_test.zpl
+++ b/jumbo/simple_test.zpl
@ -1,6 +0,0 @@
-^XA
-^FO10,10
-^GB200,100,3^FS
-^FO30,50
-^A0N,30,30^FDTest^FS
-^XZ
--- a/jumbo/test_center_offset.zpl
+++ b/jumbo/test_center_offset.zpl
@ -1,7 +0,0 @@
-^XA
-^LH50,50
-^FO0,0
-^GB100,100,3^FS
-^FO50,50
-^A0N,30,30^FDCenter Test^FS
-^XZ
--- a/jumbo/test_shifts.zpl
+++ b/jumbo/test_shifts.zpl
@ -1,8 +0,0 @@
-^XA
-^LT50
-^LS50
-^FO0,0
-^GB200,200,3^FS
-^FO20,80
-^A0N,40,40^FDShift Test^FS
-^XZ
--- a/printer-troubleshooting/configure-label-size.zpl
+++ b/printer-troubleshooting/configure-label-size.zpl
--- a/printer-troubleshooting/darkness-troubleshooting.md
+++ b/printer-troubleshooting/darkness-troubleshooting.md
@ -0,0 +1,129 @@
+# Zebra Printer Darkness Troubleshooting
+
+## Understanding Darkness Settings
+
+The Zebra GX430t has **two darkness settings that add together**:
+
+| Command | Type | Range | Persists? |
+|---------|------|-------|-----------|
+| `~SD##` | Absolute base darkness | 0-30 | Yes (with `^JUS`) |
+| `^MD##` | Relative offset | -30 to +30 | Yes (with `^JUS`) |
+
+**Effective darkness = ~SD value + ^MD offset**
+
+### Critical Warning: ^MD Stacks!
+
+The `^MD` command is **relative** - it adds/subtracts from the current saved offset. If you run:
+```bash
+echo "^XA^MD-5^JUS^XZ" | lp -d printer  # offset now -5
+echo "^XA^MD-2^JUS^XZ" | lp -d printer  # offset now -7 (not -2!)
+```
+
+This can quickly result in an extremely low effective darkness, causing blank labels even at high `~SD` values.
+
+### How to Reset
+
+To fix stacked ^MD issues:
+```bash
+# Option 1: Factory reset (WARNING: loses all calibration)
+echo "^XA^JUF^XZ" | lp -d printer
+
+# Option 2: Try setting high ~SD to compensate
+# If prints are blank at ~SD15, try ~SD25 or ~SD30
+echo "^XA~SD25^JUS^XZ" | lp -d printer
+```
+
+## Symptoms and Solutions
+
+### Checkerboard/dithered areas print DARKER than solid black
+**Cause:** Too much heat - solid areas need sustained heat, but you're overheating
+**Solution:** DECREASE darkness (counterintuitive!)
+```bash
+echo "^XA~SD10^JUS^XZ" | lp -d printer  # try lower values
+```
+
+### Ribbon tears or sticks to labels
+**Cause:** Way too much heat
+**Solution:** Significantly decrease darkness
+```bash
+echo "^XA~SD5^JUS^XZ" | lp -d printer
+```
+
+### Text edges dark but centers are gray/muddled
+**Cause:** Slightly too much heat
+**Solution:** Decrease darkness incrementally
+
+### Prints are faint/gray overall
+**Cause:** Not enough heat (or extreme overheat causing poor transfer)
+**Solution:** Increase darkness, but if you've been adjusting ^MD, the offset may be very negative
+
+### Completely blank labels
+**Cause:**
+1. Darkness too low (check for stacked ^MD issue)
+2. Wrong print mode (direct thermal vs thermal transfer)
+3. Ribbon not making contact
+
+**Solution:**
+```bash
+# Ensure thermal transfer mode
+echo "^XA^MTT^JUS^XZ" | lp -d printer
+
+# Try high darkness to rule out ^MD stacking
+echo "^XA~SD25^JUS^XZ" | lp -d printer
+```
+
+## Finding the Right Darkness
+
+Start low and work up - it's easier to recover from too-light than too-dark:
+
+1. Set a known baseline:
+   ```bash
+   echo "^XA~SD5^JUS^XZ" | lp -d printer
+   ```
+
+2. Print test pattern (see test-prints/ directory)
+
+3. If too light, increment by 2-3:
+   ```bash
+   echo "^XA~SD8^JUS^XZ" | lp -d printer
+   ```
+
+4. Stop when black is solid black and gray is distinguishable
+
+**For full resin ribbon on this setup, ~SD25 worked well (after ^MD offset issues).**
+**Originally, ~SD2-6 was optimal before ^MD commands corrupted the offset.**
+
+## Printing ZPL Files
+
+Always use `-o raw` flag:
+```bash
+lp -d printer -o raw /path/to/file.zpl
+```
+
+Without `-o raw`, large ZPL files may not print.
+
+## Quick Reference
+
+```bash
+# Set absolute darkness (0-30)
+echo "^XA~SD15^JUS^XZ" | lp -d printer
+
+# Check thermal transfer mode is enabled
+echo "^XA^MTT^JUS^XZ" | lp -d printer
+
+# Set print speed (1=slowest, higher=faster)
+echo "^XA^PR2^JUS^XZ" | lp -d printer
+
+# Factory reset (last resort - loses calibration!)
+echo "^XA^JUF^XZ" | lp -d printer
+```
+
+## Session Log: 2026-01-28
+
+Started with checkerboard-darker-than-solid symptom. Discovered:
+- Original darkness was way too high
+- Optimal was around ~SD2-6
+- Accidentally used ^MD-5 and ^MD-2 which stacked to create large negative offset
+- Even after power cycle, blank labels persisted (saved to EEPROM)
+- Had to use ~SD25 to compensate for the negative ^MD offset
+- Lesson: Avoid ^MD commands, stick to ~SD for absolute control
--- a/printer-troubleshooting/test-corners.zpl
+++ b/printer-troubleshooting/test-corners.zpl
@ -3,5 +3,5 @@
 ^FO625,0^GB50,50,50^FS
 ^FO0,325^GB50,50,50^FS
 ^FO625,325^GB50,50,50^FS
-^FO300,170^A0N,30,30^FDCENTER^FS
+^FO280,160^A0N,40,40^FDCENTER^FS
 ^XZ
--- a/printer-troubleshooting/test-darkness.zpl
+++ b/printer-troubleshooting/test-darkness.zpl
@ -0,0 +1,12 @@
+^XA
+^FO30,20^A0N,30,30^FDSolid Black:^FS
+^FO30,55^GB120,60,60^FS
+^FO200,20^A0N,30,30^FDCheckerboard:^FS
+^FO200,55^GFA,480,480,8,AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555AAAA5555^FS
+^FO400,20^A0N,30,30^FD50% Gray:^FS
+^FO400,55^GFA,480,480,8,F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0F0^FS
+^FO30,140^A0N,40,40^FDTest Text Here^FS
+^FO30,200^A0N,24,24^FDIf checkerboard is darker than solid = too hot^FS
+^FO30,230^A0N,24,24^FDIf everything is gray = too cold^FS
+^FO30,260^A0N,24,24^FDIdeal: solid=black, checker=medium gray^FS
+^XZ
--- a/printer-troubleshooting/test-simple.zpl
+++ b/printer-troubleshooting/test-simple.zpl
@ -0,0 +1,3 @@
+^XA
+^FO50,50^A0N,50,50^FDTest^FS
+^XZ
--- a/qr.png
+++ b/qr.png
--- a/ssb-troubleshooting-2026-01-27.md
+++ b/ssb-troubleshooting-2026-01-27.md
@ -0,0 +1,63 @@
+# SSB Troubleshooting Notes - January 27, 2026
+
+## Problem
+Kiosk ssb-server posts were not propagating to the pub over the internet.
+
+## Environment
+- Kiosk: `custo-kiosk-2` running ssb-server 15.3.0 as a user systemd service
+- Kiosk key: `@apIwMs+ElLT6h4d9nUqqFSWUXAHII1d+Wz9SopR26Lo=.ed25519`
+- Pub: `69.61.19.149:8807`
+- Pub key: `@jmnz08i4tzykqJ57B3BduqabcYSuDxTukOvihPlLkec=.ed25519`
+
+## Findings
+
+### 1. ekata.social pub is down
+The original pub at `ssb.ekata.social:8008` is not accepting connections:
+```
+Error: connect ECONNREFUSED 64.190.63.222:8008
+```
+- Server pings fine, but port 8008 refuses connections
+- The ssb-server process on that pub is likely not running
+
+### 2. Personal pub at 69.61.19.149:8807 is reachable
+- Port 8807 confirmed open via netcat
+- Friends relationship confirmed (hops=1)
+
+### 3. Manual gossip.connect triggered sync
+Running this command forced a connection and posts synced:
+```bash
+ssb-server gossip.connect 'net:69.61.19.149:8807~shs:jmnz08i4tzykqJ57B3BduqabcYSuDxTukOvihPlLkec='
+```
+
+## Possible Root Causes (not fully diagnosed)
+- Wrong port cached in gossip table (8008 vs 8807)
+- Exponential backoff after failed connection attempts
+- Gossip scheduler not prioritizing the peer
+
+## Useful Diagnostic Commands
+
+```bash
+# Check ssb-server status
+systemctl --user status ssb-server
+
+# View user-level logs
+journalctl --user -u ssb-server --no-pager -n 100
+
+# Check identity
+ssb-server whoami
+
+# List all gossip peers (large output)
+ssb-server gossip.peers
+
+# Check friend relationship
+ssb-server friends.hops '@PUBKEY.ed25519'
+
+# Manually trigger connection to a pub
+ssb-server gossip.connect 'net:HOST:PORT~shs:PUBKEY_WITHOUT_@_AND_.ed25519'
+
+# Test if pub port is reachable
+nc -zv HOST PORT -w 5
+```
+
+## Resolution
+Manually running `gossip.connect` triggered the sync. If this happens again, try forcing a connection with the command above.
--- a/sticker-printer-setup-guide.md
+++ b/sticker-printer-setup-guide.md
@ -85,14 +85,23 @@ echo "^XA^PW675^LL375^JUS^XZ" | lp -d sticker

 ### Step 5: Configure Darkness

-Full resin ribbon needs moderate heat. Start with MD18:
+**Use `~SD` (absolute) instead of `^MD` (relative) to avoid stacking issues.**
+
+Full resin ribbon heat requirements vary. Start LOW and work up:

 ```bash
-echo "^XA^MD18^JUS^XZ" | lp -d sticker
+# Start with low darkness
+echo "^XA~SD5^JUS^XZ" | lp -d sticker
 ```

-If prints are too light/gray, increase to MD20 or MD22.
-If resin sticks to labels when peeling, decrease to MD15.
+Test print and adjust:
+- If too light/gray: increase (`~SD8`, `~SD10`, etc.)
+- If resin sticks or ribbon tears: decrease
+- **If checkerboard prints darker than solid black: DECREASE darkness (counterintuitive!)**
+
+See `printer-troubleshooting/darkness-troubleshooting.md` for detailed guidance.
+
+**WARNING:** Avoid `^MD` commands - they stack and can corrupt saved settings. Stick to `~SD` for absolute control.

 ### Step 6: Physical Calibration

@ -111,13 +120,13 @@ The printer will feed several labels as it calibrates the gap sensor.
 Simple text test:

 ```bash
-echo "^XA^PW675^LL375^MD18^FO50,50^ADN,36,20^FDTest Print^FS^XZ" | lp -d sticker
+echo "^XA^PW675^LL375~SD10^FO50,50^ADN,36,20^FDTest Print^FS^XZ" | lp -d sticker
 ```

 Border alignment test:

 ```bash
-echo "^XA^PW675^LL375^MD18^FO10,10^GB655,355,5^FS^XZ" | lp -d sticker
+echo "^XA^PW675^LL375~SD10^FO10,10^GB655,355,5^FS^XZ" | lp -d sticker
 ```

 This prints a 5-dot border around the label edge. If misaligned, adjust with:
@ -135,26 +144,38 @@ lp -d sticker your_file.zpl

 ### Troubleshooting

+See `printer-troubleshooting/` directory for detailed guides and test prints.
+
 **Problem: Ribbon pools/doesn't wind onto uptake spool**
 - Solution: Make sure you ran `^MNN,Y` (uptake enabled)
 - Factory reset and reconfigure if needed

+**Problem: Checkerboard/dithered areas darker than solid black**
+- Solution: DECREASE darkness (too much heat!)
+- See `printer-troubleshooting/darkness-troubleshooting.md`
+
 **Problem: Prints are fuzzy or gray**
- Solution: Increase darkness (`^MD20` or higher)
+- Solution: Increase darkness with `~SD` command (not `^MD`)
 - Check print head cleanliness (wipe with isopropyl alcohol)

 **Problem: Printing across multiple labels**
 - Solution: Re-run physical calibration (2-blink method)
 - Verify label length matches actual label+gap size

-**Problem: Resin sticks to label when peeling**
- Solution: Decrease darkness (`^MD15` or lower)
+**Problem: Resin sticks to label or ribbon tears**
+- Solution: Decrease darkness significantly
 - Ensure print speed isn't too slow: `echo "^XA^PR4^JUS^XZ" | lp -d sticker`

+**Problem: ZPL file doesn't print (but simple commands work)**
+- Solution: Use `-o raw` flag: `lp -d sticker -o raw file.zpl`
+
 **Problem: ZPL commands print as literal text**
 - Solution: Printer isn't configured as raw queue
 - Reconfigure: `sudo lpadmin -p sticker -m raw`

+**Problem: Blank labels after adjusting darkness**
+- Solution: May have corrupted ^MD offset - see darkness troubleshooting guide
+
 ### Complete Configuration Script

 Save this as a shell script for easy re-setup:
@ -175,12 +196,12 @@ echo "Setting label dimensions (2.25\" x 1.25\")..."
 echo "^XA^PW675^LL375^JUS^XZ" | lp -d $PRINTER_NAME
 sleep 2

-echo "Setting darkness to 18..."
-echo "^XA^MD18^JUS^XZ" | lp -d $PRINTER_NAME
+echo "Setting darkness to 10 (adjust as needed)..."
+echo "^XA~SD10^JUS^XZ" | lp -d $PRINTER_NAME
 sleep 2

 echo "Configuration complete. Run physical calibration (2-blink method) now."
-echo "Test with: echo \"^XA^PW675^LL375^MD18^FO50,50^ADN,36,20^FDTest^FS^XZ\" | lp -d $PRINTER_NAME"
+echo "Test with: echo \"^XA^PW675^LL375~SD10^FO50,50^ADN,36,20^FDTest^FS^XZ\" | lp -d $PRINTER_NAME"
 ```

 ### Quick Reference: Common ZPL Commands
@ -188,7 +209,8 @@ echo "Test with: echo \"^XA^PW675^LL375^MD18^FO50,50^ADN,36,20^FDTest^FS^XZ\" |
 - `^XA` / `^XZ` - Start/end ZPL command block
 - `^PW###` - Print width in dots
 - `^LL###` - Label length in dots
- `^MD##` - Darkness (0-30)
+- `~SD##` - Darkness absolute (0-30) - USE THIS
+- `^MD##` - Darkness relative (-30 to +30) - AVOID (stacks!)
 - `^FO###,###` - Field origin (X,Y position in dots)
 - `^ADN,H,W` - Font: N=default, H=height, W=width
 - `^FD` - Field data (the actual text/content)